Braking System Using Double Acting

Pneumatic Cylinders
Maganti Tarun - 19BME0212
Chilukuri Eshwar - 19BME0428
Vemula Naga vedadri Naveen -19BME0067

B.Tech. Mechanical Engineering -SMEC

MEE 1904 Capstone Project Presentation-Review- I

School of Mechanical Engineering

Project Guide : Prof. Jambeswar Sahu External Guide:

External Gude:
Date of Presentation : 27th Jan 2023
Organization: Vellore Institute of Technology
Contents

 Abstract/Executive Summary
 Introduction
 Literature Review
 Gaps in the Literature
 Problem Definition
 Objectives
 Methodology
 Work carried out so far
 Work to be done
 Gant Chart (Work plan)
 Milestones in the project phase
 References.

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 2
 Executive Summary

• The objective and the goal is to design and build a control system based
on the braking system of an automotive wheel braking system that is
controlled safely by air.

• The control valve sends air to the double-acting cylinder, which is used
to control the brakes. The stopping action will be taken place with the
help of pneumatic cylinder’s pressure. For our project, we have to use
the way pneumatic brakes work as a reference model.

• We are using pneumatic pressure as it has more power compared to

hydraulic braking system. Pneumatic brakes can be used in heavy
vehicles, Whereas hydraulic braking supports only for light weight
vehicle categeory.

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 3
Introduction

The braking system is one of the most important parts of a vehicle's controls.
The system has to bring the vehicle to a stop in the shortest distance possible.

They do this by turning the kinetic energy of the wheels into heat energy, which
escapes into the air.

• Mechanical brakes
• Hydraulic brakes
• Electric and electronic brakes
• Vacuum brakes
• Air brakes

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 4
Literature Review
Title of the paper Journal & Year Authors Description/Remarks
• This article discusses technical solutions for the
1) Innovative braking system Vestnik of the Railway • V. A. Nikonov creation of an effective design of a brake system
for high-speed 80-foot Research Institute - 2021 • V. F. Zubkov for high-speed longwheelbase platforms intended
platform • M. N. Tsibizov for the transport of containers, as well as for the
• I. V. Nazarov development of a fundamentally new brake
• D. V. Gorskiy equipment for the pneumatic, electro-pneumatic
and mechanical parts of the brake system.

• In this paper, an adaptive unscented Kalman

2) Sensor Fault Diagnosis of Journal of Sensors - • Dianzhu Gao filter- (UKF-) based fault diagnosis strategy is
Locomotive Electro- 2021 • Jun Peng proposed, aimed at detecting bias faults and drift
Pneumatic Brake Using an • Yunyou Lu faults of the equalizing reservoir pressure sensor in
Adaptive Unscented Kalman • Rui Zhang the brake system.
Filter • Yingze Yang

• The main objective of the paper is,to review the

3) A Review On Braking International Journal of PRASANNAVENKATESH.M Braking system in automobiles and to improve
System In Automobiles Scientific & Engineering NAVEEN KUMAR. mechanical and electrical properties in it,The aim
Research - 2021 SARAVANAN. of this paper is to provide people with more
SHARAN.D knowledge about automotive brake systems and
Dr.MANIVEL to look into some simple maintenance techniques.
MURALIDARAN

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 5
Gaps in the Literature
• In the above research papers, It is more focussed on mechanical and electric
brakes.

• In Mechanical brakes, Wear and tear happens at brake surfaces and they
are not as effective than hydraulic or pneumatic brakes

• Heat dissipation is not uniform in Mechanical brakes and they are less
effective compared to hydraulic and pneumatic brake systems.

• Discussing about the electric brakes, They only work while vehicle is moving.
It means if we have to park vehicle on a road which has a slope then we
have to use mechanical brake.

• Otherwise the vehicle will move downwards due to gravity.

• They have high initial cost and are not suitable for high temperatures.

• So, We are focusing on pneumatic braking system and trying to improve

disadvantages in it.

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 6
Problem Definition
• Increased kinetic energy produce excessive heat in mechanical breaks which leads to
failure of brakes and wear and tear of other parts in vehicles and heat dissipation is
very difficult due to the design of the mechanical braking systems.

• Leaking hydraulic lines causing braking failure, leading to loss of all braking power and
be unable to stop or slow down the vehicle.

• Hydraulic braking system doesn’t need electric power or recharging of the pneumatic
tanks but are only suitable for light weight vehicle category.

• Brakes can become “mushy,” giving you partial braking power but failing to slow or
stop the vehicle quickly enough to avoid an accident. Brakes can grab, causing the
vehicle to suddenly jerk to a stop unexpectedly.

• An improperly installed hydraulic line can function just fine, providing good braking
until it suddenly comes loose and all pressure is lost. Often the driver has no idea that
the brakes are compromised until he or she tries to use them at high speeds. Whereas
in pneumatic braking systems the driver can be notified about the pneumatic
pressure using an analog or digital meter and the pneumatic tanks can be refilled
while the vehicle is moving.
B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 7
Objectives
• The main objective of this project is to develop and improve a safe pneumatic braking
system using double acting brake shoes and double acting pneumatic pistons to support
the axle and prevent sliding.

• To improve the defects of the pneumatic braking systems using double pneumatic
pistons.

• To include both pneumatic and hydraulic systems to avoid braking failures and wear and
tear of the braking disc.

• In this project, The main working will be based on pneumatic pressured braking system
while hydraulic pressured system will be used as backup in cases of failure of pneumatic
braking system to avoid losing of braking power.

• Hydraulic pressured braking system is being used as backup to avoid structural

complications as both hydraulic and pneumatic are similar in both working and assembly,
Whereas mechanical braking system assembly is completely different when compared to
hydraulic and pneumatic systems.

• Using Mechanical braking system increases kinetic energy in turn increases heat and the
heat dissipation is difficult due to the structure and assembly of the mechanical system. 8
B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva
Methodology

• Step 1: - Intially a mild steel metallic frame was constructed as a support to the working
components.

• Step 2: -  A wheel was bought and a braking disc was designed according to the
measurements of the frame and the wheel.

• Step 3: -  A DC Motor of 16 volts along with a V-belt is used as a driving force for the wheel.

• Step 4: -  Installed a double acting pneumatic cylinder in place to contact with braking disc,
Then connected to pneumatic brake hose to pneumatic actuator to hold the compression of
the air.

• Step 5: - The pneumatic cylinder is connected to the other end on the pneumatic actuator
to send air pressure to the piston with actuator in between to regulate the air pressure
without leakage or dripping to avoid any failures.

• Step 6: - The air pressure in the pneumatic cylinder is monitored using a

pneumatic pressure gauge.

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 9
Work carried out so
far

• Analyzed the review papers and found gaps in the already existing literature.

• After analyzing the gaps we have defined the problem and improvements to be
done in pneumatic braking systems.

• Experimental setup is completed.

• Literature Review is completed and 75% of the review paper is completed.

• We have finalized pneumatic braking system as core of the project.

• Figured out all material properties of wheel cylinder, double acting pneumatic piston,
brake pads and other components of the project.

• Constructed metallic frame to support the assembly of the components.

• Assembled wheel and braking disc to the wheel.

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 10
Work to be done

• Assembly of pneumatic piston.

• Assembly of pneumatic actuator in between the piton and pneumatic cylinder.

• Assembly of pneumatic cylinder.

• Completing the fabrication using all the necessary components.

• Testing and experimental investigation of the fabrication.

• Improving the fabrication by altering if anything is required

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 11
Results and
Discussions

• By doing this mega super duper 100CR project we were able to

understand the importance of Coordination between the various
departments in an manufacturing unit.

• This brake system offers ample scope for improvement by providing

intermittent force at the brake plate.

• One of the major aims to achieve is that when the operator sees a
brake force , that he needs to know immediately strike him, implying
that the designs simple and easily understandable.

• Such was the case with AIR brake system. AIR Brake system are hailed
as the greatest mechanical contrivance.

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 12
References

• Henry Hartmann, Mat1in Shautt, Antonio Pascucci, Bernd Gombert. "eBrake® - the
mechatronic wedge brake", SAE Technical Paper Series, paper No. 2002-01-2582, 6pp, 2002.

• “Automotive Braking System” , by Thomas W. birch.

• “Automotive Engineering Fundamentals” by Richard Stone, Jeffrey K. Ball

• Siigmar Micke, Richard E. Thompson, Bernd-Holger Roehling (1990). The introduction of Air
Disc Brakes for Trucks end Buses in Europe, SAE Technical Paper series, paper No. 902203.

• Richard Roberts, Bernd Gombert, Hemy Hartmann, Dittmar Lange, & Martin Schautt."Testing
the Mechatronic Wedge Brake", SAE Technical Paper Series, paper No.2004-0 1-2766, 9 pp,
2004.

• The investigation of disc brake mechanisms. - Minsk Automotive Plant, 1999. -lIp

B.Tech. Mechanical Engineering/Production and Industrial Engineering/ Mechanical with Specialization in Automotive Engineering Review-I/II/Final viva 13