AUTOMATIC BREAK FAILURE

INDICATOR
AND ENGINE OVER HEATING ALARM
CONTENTS
 CONTENTS

CHAPTER NO TITLE

SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.1 IR sensor
3.2 Heat sensor
3.3 Brake frailer
3.4 Wheel
3.5
3.6
4 Design and drawing
5 Working principle
6 Merits and demerits
7 Applications
8 List of materials
9 Cost Estimation
10 Conclusion
Bibliography
photography
SYNOPSIS
 SYNOPSIS

The aim is to design and develop a control system based an electronically

controlled automatic break failure indicator by using IR Sensor and engine over
heating alarm by using heat sensor is called “AUTOMATIC BREAK
FAILURE INDICATOR AND ENGINE OVER HEATING ALARM”.

Automatic break failure indicator and engine over heating alarm is

consists of IR sensor circuit, Heat sensor Circuit, Control Unit and frame. The
sensor is used to detect the break wire. There is any disconnection of the break
wire or cutting of any few turns of break wire, the control signal to the alarm
unit. Similarly the heat sensor is fixed to the engine and this heat is measured
and giving the alarm signal when the engine heat exceeds the setted temperature
limit.
 CHAPTER-1
INTRODUCTION

CHAPTER – 1
 INTRODUCTION

Car safety is the avoidance of automobile accidents or the

minimization of harmful effects of accidents, in particular as pertaining to
human life and health. Special safety features have been built into cars for
years, some for the safety of car's occupants only, and some for the safety of
others. We have pleasure in introducing our new project “AUTOMATIC
HEAD LIGHT DIM/BRIGHT CONTROLLER AND ENGINE OVER
HEAT ALARM”, which is fully equipped by sensors circuit, dim/bright light
and engine over heat alarm circuit. It is a genuine project which is fully
equipped and designed for Automobile vehicles.

This forms an integral part of best quality. This product underwent

strenuous test in our Automobile vehicles and it is good. Man has needed and
used energy at an increasing rate for its sustenance and well being ever since he
came on the earth a few million years ago. Primitive man required energy
primarily in the form of food. He derived this by eating plants or animals,
which he hunted.

Subsequently he discovered fire and his energy needs increased as he

started to make use of wood and other bio mass to supply the energy needs for
cooking as well as agriculture. He added a mew dimension to the use of energy
by domesticating and training animals to work for him.

With further demand for energy, man began to use the wind for sailing
ships and for driving windmills, and the force of failing water to turn water
wheels. Till this time, it would not be wrong to say that the sun was supplying
all the energy needs of man either directly or indirectly and that man was using
only renewable sources of energy.

The major components of the project are follows

LDR Sensor and Heat Sensor

Frame
Battery
Dim/Bright Light (Head Light)
Relay
.

CHAPTER-2

LITERATURE SURVAY
 CHAPTER-2

LITERATURE SURVEY

2. LITERATURE SURVEY
2.1. THE MOST COMMON CAUSES OF ENGINE OVERHEATING:
2.1.1 THERMOSTAT STUCK SHUT

The thermostat, which is usually located in a housing where the upper radiator
hose connects to the engine, controls the operating temperature of the engine. It
does this by blocking the flow of coolant from the engine to the radiator until
the engine reaches a certain temperature (usually 190 to 195 degrees F.). When
this temperature is reached, the thermostat opens and allows coolant to circulate
from the engine to the radiator. You can check for this condition by carefully
touching the upper radiator hose when the engine is first started and is warming
up. If the upper radiator hose does not become hot to the touch within several
minutes after starting the engine, it means the thermostat is probably defective
and needs to be replaced.

CAUTION:

The replacement thermostat should always have the same temperature

rating as the original. Do not substitute a colder or hotter thermostat on any
vehicle that has computerized engine controls as engine operating temperature
affects the operation of the fuel, ignition and emissions control systems.
2.1.2 DEFECTIVE FAN CLUTCH

On rear wheel drive vehicles with belt-driven cooling fan, a "fan clutch" is often
used to improve fuel economy. The clutch is a viscous-coupling filled with
silicone oil. The clutch allows the fan to slip at high speed, which reduces the
parasitic horsepower drag on the engine. If the clutch slips too much, however,
the fan may not turn fast enough to keep the engine cool. The silicone fluid
inside the clutch breaks down over time and can leak out due to wear, too. If
you see oily streaks radiating outward on the clutch (and/or the fan can be spun
by hand with little or no resistance when the engine is off), it means the clutch
is bad and needs to be replaced. Any play or wobble in the fan due to wear in
the clutch also signals the need for a new clutch.

2.1.3 INOPERATIVE FAN MOTOR

On most front-wheel drive cars, the fan that cools the radiator is driven by an
electric motor. A temperature switch or coolant sensor on the engine cycles the
fan on and off as additional cooling is needed. If the temperature switch or
coolant sensor (or the relay that routes power to the fan motor is bad), the fan
won't come on when it is needed and the engine will overheat. Likewise, if the
fan motor itself is bad, the fan won't work. The system needs to be diagnosed to
determine where the problem is so the correct component can be replaced.

2.2 EXTERNAL COOLANT LEAKS

Leaks in radiator or heater hoses, the water pump, radiator, heater core or
engine freeze plugs can allow coolant to escape. No engine can tolerate the loss
of coolant for very long, so it usually overheats as soon as a leak develops. A
visual inspection of the cooling system and engine will usually reveal where the
coolant is going. Leaks in hoses can only be fixed by replacing the hose. Leaks
in the water pump also require replacing the pump. But leaks in a radiator,
heater hose or freeze plug may sometimes respond to a sealer added to the
cooling system.

2.3 WEAK OR LEAKY RADIATOR CAP

If no leaks are apparent, the radiator cap should be pressure tested to make sure
it is holding the specified pressure. If the spring inside the cap is weak (or the
cap is the wrong one for the application), the engine will lose coolant out the
overflow tube every time it gets hot.

2.3.1 INTERNAL COOLANT LEAK

If there are no visible coolant leaks, but the engine is using coolant, there
may be a crack in the cylinder head or block, or a leaky head gasket that is
allowing coolant to escape into the combustion chamber or crankcase.

2.3.2 EXHAUST RESTRICTION

In some instances a severe exhaust restriction can produce enough backpressure

to cause an engine to overheat. The most likely cause of the blockage would be
a plugged catalytic converter or a crushed or damaged pipe. Checking intake
vacuum and/or exhaust backpressure can diagnose this kind of problem.

2.4 BAD WATER PUMP

In a high mileage engine, the impeller that pumps the coolant through the
engine inside the water pump may be so badly corroded that the blades are loose
or eaten away. If such is the case, the pump must be replaced. Most pump
failures; however, occur at the pump shaft bearing and seal. After tens of
thousands of miles of operation, the bearing and seal wear out. Coolant starts to
leak out past the shaft seal, which may cause the engine to overheat due to the
loss of coolant. A sealer additive will not stop this kind of leak. Replacing the
water pump is the only cure.

CAUTION:

A leaky water pump should be replaced without delay, not only to reduce
the risk of engine overheating but to prevent catastrophic pump failure. If the
shaft breaks on a rear-wheel drive vehicle, the fan may go forward and chew
into the radiator. One possible reason a car for overheating is that antifreeze is
not circulating through the engine as it should. Antifreeze serves two purposes.
It not only keeps the engine temperature level during the winter (preventing the
engine from freezing) , it also keeps cars from overheating during the warmer
months. It's always a good idea to periodically look under one's car to see if
there are any materials dripping from the car or if your car leaves any puddles
or stains when parked. If so, dealing with the problem at this point may avoid
ever having to deal with an overheating car problem.Antifreeze loss can "sneak
up on a person" though. You can see no leaks or evidence of drips and still be
low on antifreeze. Use, evaporation and time are enough to lessen its supply. If
you forget to replace antifreeze you can be driving along and suddenly notice
that you car is overheating. An ounce of prevention beats a pound of cure. If
you want to avoiding overheating, make checking your antifreeze level a habit.

2.5 REMEDIES AFTER ALARM

What to Do When Begins to Overheat

If the temperature gauge reaches near the "h", here are some courses of action to
prevent your car from actually overheating. These steps are recommended until
you can get yourself to a service station only. First, turn the heat up in the car as
high as possible. Running the heat will temporarily cool the engine and
thetemperature should drop. This will register on the gauge and prevent
overheating. Your engine temperature may actually return to normal, simply by
doing this.

If you know where the antifreeze and its reserve tank are on your car you
can add about a half a cup of water. The antifreeze will be diluted, but with the
added water it should be enough to circulate throughout the engine, and
overheating can be prevented this way as well.

If you appear to have enough antifreeze in the car, the uptake hose may
be the issue. Some hoses become ill-fitting over time and a new replacement
hose may be all that is needed to prevent overheating in the future. The hose
may have dislocated or be blocked. If the hose has detached, look through it to
see if liquid would be able to pass through. It is unusual for a hose to be
completely blocked, but it can happen. Blowing on the tube or running water on
it may clean it out sufficiently for the liquid to be able to flow through it. If it
has detached, simply reattach it. Later, buy a new hose. Overheating has been
temporarily prevented, but without a new hose the problem will re-
emerge.Overheating problems occur for a number of reasons. Lack of antifreeze
or its inability to flow into your engine is just one. However, these simple steps
are one way to determine if this could be the reason and handle the problem so
that you can get to a service station. Those who choose to ignore the
temperature warning and drive until the engine is overheating damage their
engines and usually wind up being towed.

2.5.1 TROUBLESHOOTING AN OVERHEATING ENGINE

The first sign of a vehicle overheating is either when the needle on the
temperature gauge pushes its way into the ominous red zone or the “Check
Engine” or “Temperature” malfunction indicator light on the dashboard casts a
sinister glow. Left alone, the liquid in the radiator eventually boils over, and
steam rolls out from under the hood.If your vehicle overheats often and
constantly loses coolant, the problem may be leaks in your cooling system. If
your vehicle overheats in normal weather and traffic, you may need to add
liquid to the system, replace the thermostat, adjust or replace the accessorybelt,
or check the waterpump.The first thing to check if your vehicle overheats often
is the pressurecap. Sometimes the gasket on the cap deteriorates and lets
pressure escape, which causes the cooling system to malfunction. Most service
stations can test your cap for you and tell you whether it’s in good
condition.Some overheating problems aren’t related to the cooling system at all.
Here are some other circumstances that can cause a vehicle to overheat

1.LATE TIMING:

If your ignition system is malfunctioning, late timing may be causing

your vehicle to overheat because the sparkplugs are firing the fuel/air mixture
after the piston moves back down from the top of its stroke. Late timing alone
doesn’t cause an engine to overheat by more than a few degrees, but when
coupled with other problems, it can bring the engine temperature to a critical
point. Have a service facility place your vehicle on an electronic diagnostic
machine to check your timing and adjust it if necessary.

2.PLUGGED RADIATOR:

Because plugged radiators cut down on the system’s liquid circulation,

the system can’t cool efficiently. The remedy is to have a radiator specialist
remove and inspect the radiator. If you’re lucky, just steam-cleaning the radiator
does the job; if you’re not, the solution may be more expensive.

3.SLIPPING ACCESSORY BELT:

 If you can see and reach the accessory belt that drives the water pump,
check to be sure that there’s no more than about 1⁄2 inch of give. If the belt
seems loose or frayed, you can try to replace it. If you can’t do the job, have a
professional deal with it.

4. COLLAPSING BOTTOM RADIATOR HOSE:

Occasionally, a bottom radiator hose begins to collapse under the vacuum that
the water pump creates, and the impaired circulation causes overheating.Low oil
level: A vehicle that’s low on oil tends to overheat because the oil removes from
75 to 80 percent of the “waste heat” in your engine (in addition to doing its
other job of cushioning the moving engine parts).

2.6 ELECTRICAL TEMPERATURE SENSORS

a) Thermistor- Thermistors are thermally sensitive resistors whose prime

function is to exhibit a large, predictable and precise change in electrical
resistance when subjected to a corresponding change in body
temperature. Negative Temperature Coefficient (NTC) thermistors
exhibit a decrease in electrical resistance when subjected to an increase in
body temperature and Positive Temperature Coefficient (PTC)
thermistors exhibit an increase in electrical resistance when subjected to
an increase in body temperature.
b) Thermocouple
 CHAPTER-3

DESCRIPTION OF EQUIPMENT
 CHAPTER-3

DESCRIPTION OF EQUIPMENT

3.1 SENSORS

A sensor is a transducer used to make a measurement of a physical

variable. Any sensor requires calibration in order to be useful as a measuring

device. Calibration is the procedure by which the relationship between the

measured variable and the converted output signal is established.

Care should be taken in the choice of sensory devices for particular tasks.

The operating characteristics of each device should be closely matched to the

task for which it is being utilized. Different sensors can be used in different

ways to sense same conditions and the same sensors can be used in different

ways to sense different conditions.

TYPES OF SENSOR:

Passive sensors detect the reflected or emitted electro-magnetic radiation

from natural sources, while active sensors detect reflected responses from

objects which are irradiated from artificially generated energy sources, such as

radar. Each is divided further in to non-scanning and scanning systems.

 A sensor classified as a combination of passive, non-scanning and non-

imaging method is a type of profile recorder, for example a microwave

radiometer. A sensor classified as passive, non-scanning and imaging method,

is a camera, such as an aerial survey camera or a space camera, for example on

board the Russian COSMOS satellite.

Sensors classified as a combination of passive, scanning and imaging are

classified further into image plane scanning sensors, such as TV cameras and

solid state scanners, and object plane scanning sensors, such as multi-spectral

scanners (optical-mechanical scanner) and scanning microwave radiometers.

An example of an active, non-scanning and non-imaging sensor is a

profile recorder such as a laser spectrometer and laser altimeter. An active,

scanning and imaging sensor is radar, for example synthetic aperture radar

(SAR), which can produce high resolution, imagery, day or night, even under

cloud cover.

The most popular sensors used in remote sensing are the camera, solid

state scanner, such as the CCD (charge coupled device) images, the multi-

spectral scanner and in the future the passive synthetic aperture radar.

Laser sensors have recently begun to be used more frequently for

monitoring air pollution by laser spectrometers and for measurement of distance

by laser altimeters.
CHARACTERISTICS OF OPTICAL SENSOR:

Optical sensors are characterized specified by spectral, radiometric and

geometric performance. The spectral characteristics are spectral band and

band width, the central wavelength, response sensitivity at the edges of band,

spectral sensitivity at outer wavelengths and sensitivity of polarization.

Sensors using film are characterized by the sensitivity of film and the

transmittance of the filter, and nature of the lens. Scanner type sensors are

specified by the spectral characteristics of the detector and the spectral splitter.

In addition, chromatic aberration is an influential factor. The radiometric

characteristics of optical sensors are specified by the change of electro-

magnetic radiation which passes through an optical system. They are radiometry

of the sensor, sensitivity in noise equivalent power, dynamic range, signal to

noise ratio (S/N ratio) and other noises, including quantification noise.

The geometric characteristics are specified by those geometric factors

such as field of view (FOV), instantaneous field of news (IFOV), band to band

registration, MTF, geometric distortion and alignment of optical elements.

IFOV is defined as the angle contained by the minimum area that can be

detected by a scanner type sensor. For example in the case of an IFOV of 2.5
milli radians, the detected area on the ground will be 2.5 meters x 2.5 meters, if

the altitude of sensor is 1,000 m above ground.

In our project IR transmitter and IR receiver are used to detect the

obstacle. These sensors are fitted at the front side of the vehicle.

IR TRANSMITTER:

The IR transmitting circuit is used in many projects. The IR transmitter

sends 40 kHz (frequency can be adjusted) carrier under 555 timer control. IR
carriers at around 40 kHz carrier frequencies are widely used in TV remote

controlling and ICs for receiving these signals are quite easily available.

IR RECEIVER:

The transmitted signal reflected by the obstacle and the IR receiver circuit

receives the signal and giving control signal to the control unit. The control unit

activates the pneumatic breaking system, so that break was applied.

3.2 HEAT DETECTOR

Mechanical heat detector, both rate of rise and fixed temperature

operation. Aheat detector is a fire alarm device designed to respond when the
convicted thermal energy of a fire increases the temperature of a heat sensitive
element. The thermal mass and conductivity of the element regulate the rate
flow of heat into the element. All heat detectors have this thermal lag. Heat
detectors have two main classifications of operation, "rate-of-rise" and "fixed
temperature."
3.2.2 FIXED TEMPERATURE HEAT DETECTORS

This is the most common type of heat detector. Fixed temperature

detectors operate when the heat sensitive eutectic alloy reaches the eutectic
point changing state from a solid to a liquid. Thermal lag delays the
accumulation of heat at the sensitive element so that a fixed-temperature device
will reach its operating temperature sometime after the surrounding air
temperature exceeds that temperature. The most common fixed temperature
point for electrically connected heat detectors is 136.4°F (58°C). Technological
developments have enabled the perfection of detectors that activate at a
temperature of 117°F (47°C), increasing the available reaction time and margin
of safety. This type of technology has been available for decades without the
use of batteries or electricity as shown in the picture.

3.2.3 RATE-OF-RISE HEAT DETECTORS

Rate-of-Rise (ROR) heat detectors operate on a rapid rise in element

temperature of 12° to 15°F (6.7° to 8.3°C) increase per minute, irrespective of
the starting temperature. This type of heat detector can operate at a lower
temperature fire condition than would be possible if the threshold were fixed. It
has two heat-sensitive thermocouples or thermistors. One thermocouple
monitors heat transferred by convection or radiation. The other responds to
ambient temperature. Detector responds when first’s temperature increases
relative to the other.

Rate of rise detectors may not respond to low energy release rates of slowly
developing fires. To detect slowly developing fires combination detectors add a
fixed temperature element that will ultimately respond when the fixed
temperature element reaches the design threshold.

3.3 BRAKE FAILURE

Though the world is getting modernized, we have to face so many

problems. One of such problems is accidents. One of the thing that everyone
tried to avoid is while traveling is accidents, and sometimes it is inevitable.
Now- a-days we can see accidents in every nook and corner of the world. It
results in the death of thousands of lives. With the population ever climbing
there are more vehicles than ever on road , which means there is a higher
livelihood of the brakes giving out.
In foreign countries they take remedial measures for the prevention of
accidents but our country like India takes less action against the prevention of
accidents. One common cause for accidents is brake failure. Accidents may
occur due to brake failure. In such a situation my project brake failure indicator
plays an important role in controlling accidents.

Brake failure indicator circuit is a circuit that constantly monitors the

condition of brake. The sensor which is attached to the circuit get the chance of
a brake failure by monitoring the brake switch and reminds you of the condition
of brake every time when the brake is applied.
3.4 Wheel:

A wheel is a circular device that is capable of rotating on its axis,

facilitating movement or transportation or performing labour in machines. A

wheel together with an axle overcomes friction by facilitating motion by rolling.

In order for wheels to rotate a moment needs to be applied to the wheel about its

axis, either by way of gravity or by application of another external force.

Common examples are found in transport applications. More generally the term

is also used for other circular objects that rotate or turn, such as a Ship's wheel

and flywheel. The wheel most likely originated in ancient The wheel is a device

that enables efficient movement of an object across a surface where there is a

force pressing the object to the surface. Common examples are a cart drawn by

a horse, and the rollers on an aircraft flap mechanism. The wheel is not a

machine, and should not be confused with the wheel and axle, one of the simple

machines. A driven wheel is a special case that is a wheel and axle. Wheels are

used in conjunction with axles, either the wheel turns on the axle or the axle

turns in the object body. The mechanics are the same in either case. The normal

force at the sliding interface is the same. The sliding distance is reduced for a

given distance of travel. The coefficient of friction at the interface is usually

lower.
 CHAPTER-4

DESIGN AND DRAWING

 CHAPTER-4

DESIGN OF EQUIPMENT AND DRAWING

 CHAPTER -5

WORKING PRINCIPLE
 CHAPTER -5

WORKING PRINCIPLE

In this Project we are using control unit to check the Brake condition
and Engine heat. Here we are sending the signal voltage through the Brake Wire
from one end to other end. At the other end in the wheel the signal conditioning
unit checks that whether the signal voltage in the Brake wire is available or not.

If the Brake Wire is in the good condition the signal and conditioning
unit check that in coming small voltage signal. If any cut in the Brake wire there
is no voltage signal in the braking end so signal and conditioning unit send the
signal to control. Now the control unit activates the alarm through the driver
circuit. The alarm gives the audible Indication to the Rider.
 CHAPTER -6

MERITS AND DEMERITS

 CHAPTER-6

MERITS AND DEMERITS

MERITS

Low cost automation project.

Less power consumption
Operating Principle is very easy.
Installation is simplified very much.
Less time and more profit.

DEMIRTS

1. This circuit is not working on low rain fall.

2. This system applied in the case of water falling on the class period only.
3. Addition cost is required to install this system to four wheeler.
 CHAPTER-7

APPLICATIONS
 CHAPTER-7

APPLICATIONS

 Four wheeler application

 Two Wheeler Application
 CHAPTER-8

LIST OF MATERIALS
 CHAPTER-8

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed
below.
1. PROPERTIES:

The material selected must posses the necessary properties for the

proposed application. The various requirements to be satisfied Can be

weight, surface finish, rigidity, ability to withstand environmental attack

from chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively

affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

 d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,

electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance,

impact resistance, eleastic limit, endurance limit, and modulus of elasticity,

hardness, wear resistance and sliding properties. The various properties

concerned from the manufacturing point of view are,

 Cast ability

 Weld ability

 Bribability

 Forge ability

 Merchantability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. MANUFACTURING CASE:

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may

demand the use of special materials.

3. QUALITY REQUIRED:

This generally affects the manufacturing process and ultimately the

material. For example, it would never be desirable to go casting of a less

number of components which can be fabricated much more economically by

welding or hand forging the steel.

4. AVILABILITY OF MATERIAL:

Some materials may be scarce or in short supply.it then becomes

obligatory for the designer to use some other material which though may not be

a perfect substitute for the material designed.the delivery of materials and the

delivery date of product should also be kept in mind.

5. SPACE CONSIDERATION:

Sometimes high strength materials have to be selected because the forces

involved are high and space limitations are there.

6. COST:

As in any other problem, in selection of material the cost of material

plays an important part and should not be ignored.

 Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of proper

materials.

CHAPTER-9

COST ESTIMATION
 CHAPTER-9

COST ESTIMATION

1. LABOUR COST:

2. OVERGHEAD CHARGES:

The overhead charges are arrived by”manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

Overhead Charges =20%of the manufacturing cost

3.TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

Total cost for this project =

CHAPTER-10

CONCLUSION
 CHAPTER-10

CONCLUSION

The project carried out by us will make an impressing mark in the field of
automobile. It is very usefully for all kind of Automobiles to drive the vehicle
withoutfailure due to heat.
This project has also modern concern. So this system can be easily adopt
with all the existing and upcoming vehicles as the design is based on Global
automobile design. The project has been designed to perform the required task
taking minimum cost.
BIBLIOGRAPHY
 BIBLIOGRAPHY
 Automobile Technology
 Thermodynamics ByP.K.Nag
 Micro processor& Micro Controllers by Rao
 http://en.wikipedia.org/wiki/Heat_detector
PHOTOGRAPHY