PROJECT TITLE : ELECTRO-PNEUMATIC BRAKING SYSTEM WITH COLLISION

WARNING AND ACCIDENT PREVENTION BUMPER

Objectives of Project

A) Design Development of intelligent braking system that is electro-pneumatically

operated.
B) Collision warning indication by flashing lamp and or hooter
C) Simultaneous power regulation to avoid power wastage and brake wear.

Introduction

Accident Avoidance systems in a four wheeler is a cocktail of

several technological marvels.

1. Emergency Brake Assist (EBA)

In an emergency, many people do not depress the brake pedal

hard enough. EBA senses an emergency braking situation and
helps the driver to reduce speed in the shortest distance
possible.

2. Dynamic Stability and traction Control (DSTC)

DSTC makes driving on twisty and slippery road conditions safer,

by using sensors to detect whether any of the wheels is losing
traction. DSTC has the ability to cut power in a flash, helping the
car to regain its grip. If in any case the car shows a tendency to
skid the system automatically slows the particular wheels to help
maintain control.

3. Electronic Brake Distribution (EBD)

EBD makes sure that the braking forces of the car are
distributed between the front and the rear brakes in order to
optimize braking efficiency.

4. Anti-Lock braking system (ABS)

With ABS you can brake as hard as you can and steer yourself to
safety without the fear of wheels locking up and skidding.

5. Blind Spot information system (BSIS)

Using cameras set just below the outer rear view mirrors the
BSDS tell you if there is any vehicle in your blind spot.

6. Night Vision

Driving during the night becomes safe than ever with the night
vision where one can see clearly on the control display even in
pitch black. Thanks to infra red technology.
Problem Definition :

The above systems as applied to automobiles are extremely costly as they compulsorily
need a computer for their implementation More over all these systems are singular problem
oriented, hence there is a need of a cost effective low end technology or device that can
perform the function of over-speed indication –alarm-and brake control with minimal use of
high end technology , suitable for low budget commercial vehicles.

Solution :

The Intelligent collision warning and electro-pneumatic braking system is a answer to

the above problems where in the following features have been incorporated;

a) In advance Collision warning by using photo-electric sensor

b) Collison indication using flashing LED or hooter.

c) Braking –using Disk brake to ensure optimal braking force and minimum braking
distance.

d) Electro Pneumatic actuation using pneumatic actuator ..making the operation

extremely fast thereby safety ensured

e) Braking ( Nature similar to the anti-lock braking) ie, intermittent and gradual braking.

f) Power regulation of the prime mover ( in our case of model ---Single phase variable
speed motor) to avoid power loss and excessive brake wear.

The construction and working is explained in the section below.

Construction :

The system comprises of the following :

a)Chasis or Frame : The chasis or frame is fabricated structure that carries the entire
system , rear wheel shaft is the driver shaft, that carries the reduction pulley driven by motor
using a open belt drive. The end carries the steering mechanism in form of ackerman
steering with the central steering wheel controls the steering angle using the slotted lever
arrangement.

b) Motor : Motor is the prime mover , it is single phase AC motor 50 watt , 0 to 6000 rpm
variable speed. Motor speed is regulated using electronic speed regulator.

c) Collision Sensing mechanism : The over speed sensing mechanism is in the form of an
Photo electric sensor with variable sensing range

Photo-electric sensor
The photo electric sensor is mounted on the sheet metal panel on the base frame by means
of an Z shaped clamp. The photo-sensor as the name suggests senses the proximity of the
obstruction which acts as stops, such that when they come in front of the photo sensor the
Relay is operated to stop the vehicle motion. The photo- sensor is connected to the
electronic relay and the power source.
Sensor type : Photo electric sensor Size : M18

e)Electronic Relay
8 Pin electronic relay MK2PN-5-I-S,230V AC , 10 A. Electronic relay is used for the
sequencing of the actuation mechanism.

f) Electronic Speed Regulator

Motor is an commutator motor ie, the current to motor is supplied to motor by means of
carbon brushes . The power input to motor is varied by changing the current supply to these
brushes by the electronic speed variator, thereby the speed is also is changes
g).Braking Mechanism: The braking mechanism uses a Disk brake and brake caliper
arrangement . The Disk brake is used with the view to maximize the braking and ensure
safety. The brake caliper is actuated electrically using an pneumatic actuator.

i) Collision warning indicator lamp and or Hooter : This is the indication or alarm
system , the lamp is an red LED lamp that flashes when over speed occurs , similarly the
hooter is a horn or buzzer arrangement that goes on after over-speed occurs there by
alarming the driver.

j) The pneumatic bumper acts as a accident prevention mechanism, it operated when

vehicle brake is applied

Working

System starts with motor starting…motor speed controlled by electronic speed

regulator….as vehicle moves forward the resultant gap between obstruction and the
proximity sensor exceeds the permissible limit…which makes the relay to operate and
..consequently the following actions take place…

a) Visual collision warning in the form of indicator lamp lights

b) Audio collision warning in the form of hooter goes ON
c) Braking mechanism is actuated to operate the shoe brake cam Linear actuator
mechanism

ADVANTAGES :

The collision warning and electro-pneumatic braking offers the following

advantages:

1. The system eliminates the possibility of collision within given permissible speed
limits
 2. Ensures safety of the driver and or passengers …as automatically speed is
reduced ,.
3. Reduces brake wear and tear as no need of excessive braking force to keep vehicle
speed in control
4. System components involve simple and cost effective components…hence simple
production .
5. Low system cost as low level electronics is used.
6. No computing / /microprocessor involved…keeps the system cost effective.
7. Can be easily implemented in both commercial LCV/MCV/HCV.
8. Minimal space requirements ..hence modifications in conventional system is reduced
futher increases the adaptability of system
9. Visual indication in the form of indication lamp.
10. Audio indication in the form of hooter…increases operator vigilance and safety.

APPLICATION :
1. Small Cars
2. SUV and commercial cars’
3. Medium to heavy duty transport vehicles
4. Cargo trucks and Public transport vehicles etc.,
 PROJECT ACTION PLAN
PROJECT ACTION PLAN (APPROXIMATE ESTIMATE 4 MONTHS)

PHASE 1 : DATA COLLECTION (DURATION : 1 WEEK)

Data collection phase involves the collection of reference material for project concept, the idea is taken
from book Ingenious mechanisms for designers and inventors

(1 week)

PHASE 2 : SYSTEM DESIGN (DURATION :2 WEEKS)

The system design comprises of development of the mechanism so that the given concept can perform
the desired operation. The system design also determines the system components and their shape and
overall dimensions , the parts are as shown in part list above.

(1 week)

PHASE 3 : MECHANICAL DESIGN( DURATION : ( 3WEEKS)

The parts mentioned above in the part list will be designed for stress and strain under the given system
of forces, and appropriate dimensions will be derived. The standard parts will be selected from the PSG
design data handbook.

(2weeks)

PHASE 4 : PRODUCTION DRAWING PREPARATION ( DURATION :2 WEEKS)

Production drawings of the parts are prepared using Auto Cad ,with appropriate dimensional and
geometric tolerances. Raw material sizes for parts are also determined.
(2 weeks)

PHASE 5 : MATERIAL PROCUREMENT & PROCESS PLANNING ( DURATION :2 WEEKS)

Material is procured as per raw material specification and part quantity. Part process planning is done to
decide the process of manufacture and appropriate machine for the same.

(1 week)

PHASE 6 : MANUFACTURING ( DURATION :2 WEEKS)

Parts are produced as per the part drawings.

(3 weeks)

PHASE 7 : ASSEMBLY –TEST & TRIAL( DURATION : (1 WEEKS)

Assembly of device is done as per assembly drawing ,and test and trial is conducted on device for
evaluating performance.

(1-week)

PHASE 8 : REPORT PREARATION( DURATION :2 WEEKS)

Report preparation of the activities carried out during the above phases is done .

(2 weeks)

 BILL OF MATERIALS:-
SR PART DESCRIPTION QTY MATERIAL
NO. CODE

1. IBS -1 MOTOR 01 STD

2. IBS -2 BELT 01 STD

3. IBS -3 REDUCTION PULLEY 01 MS

4. IBS -4 WHEEL SHAFT 01 EN24

5. IBS -5 DISK BRAKE 01 STD

6. IBS -6 BRAKE CALLIPER 01 STD

7. IBS -7 DISK BRAKE HUB 01 EN24

8. IBS –8 FRONT WHEEL SHAFT 02 EN9

9. IBS –9 STEERING 01 EN9

MECHANISM

10. IBS –10 INDICATOR 01 STD

11. IBS –11 GEAR BOX SUPPORT 02 EN9

PINS

12. IBS –12 ELECTRONIC SPEED 01 STD

VARIATOR

13. IBS –13 ELECTRONIC RELAY 01 STD

14. IBS –14 PROXIMITY SENSOR 01 STD

15. IBS –15 CONTROL PANEL 01 STD

16. IBS –16 FRAME 01 MS

17. IBS –17 INCHING SWITCH 01 STD

18. IBS –18 MOTOR PLATE 01 MS

19. IBS –19 PNEUMATIC 01 STD

CYLINDER

20. IBS -20 5/2 WAY VALVE 02 STD

21. IBS -21 BEARING 6201ZZ 01 STD

MATERIAL PROCUREMENT

Material is procured as per raw material specification and part

quantity. Part process planning is done to decide the process of
manufacture and appropriate machine for the same.
GENERAL MATERIAL USED

EN24- ALLOY STEEL

EN9- PLAIN CARBON STEEL

MS-MILD STEEL

STD- STANDARD PARTS SELECTED FROM PSG DESIGN

DATA/MANUFACTURER CATALOGUE

INFRASTRUCTURE AND MACHINERY REQUIRED

1.Lathe

2.Milling

3.Drilling

4.Electrical arc welding

5.DRO milling machine

MAN POWER REQUIRED

1.Turner

2.Miller

3.Machinist

4. Welder.