Intelligent Reverse Braking System Mech Proj

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CONTENTS
ABSTRACT -IV
LIST OF FIGURES -V
1. INTRODUCTION -5
1.1. TYPES OF BRAKES -8
1.1.1. MECHANICAL BRAKES -11
1.1.2. HYDRAULIC BRAKES -12
1.1.3. AIR BRAKES -13
1.1.4. ELECTRICAL BRAKES -13
1.1.5. VACCUM BRAKES -14
1.1.6. REGENERATIVE BRAKES -14
1.2. IR SENSOR -16
1.2.1. SENSORS -16
1.2.2. TYPES OF SENSORS -16
1.2.3. IR TRANSMITTER -18
1.2.4. IR RECIEVER -18
2. LITERATURE SURVEY -19
3. COMPONENTS AND DESCRIPTION -21
3.1. SELECTION OF PNEUMATICS -21
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32 PNEUMATIC COMPONENTS AND
ITS DESCRIPTION -21
3.2.1. PNEUMATIC SINGLE ACTING CYLINDER -22
3.2.2. SOLENOID VALVE -26
3.2.3. FLO! CONTROL VALVE -28
3.2.4. IR SENSOR UNIT -29
3.2.4.1. IR TRANSMITTER CIRCUIT -3"
3.2.4.2. IR RECIEVER CIRCUIT -31
3.2.5. !HEEL AND BRAKE ARRANGEMENT -32
3.2.6. CONNECTOR# REDUCER# HOSE COLLAR -33
3.2.7. STAND -33
3.2.8. SINGLE PHASE ACTING INDUCTION MOTOR -33
3.3. BLOCK DIAGRAM OF IBS -3$
3.4. CIRCUIT DIAGRAM OF IBS -38
3.5. LAYOUT OF THE IBS -39
3.6. !ORKING OPERATION -42
4. APPLICATIONS AND ADVANTAGES -44
5. COST ESTIMATION -45
6. CONCLUSION -46
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7. REFERENCES -4$
ABSTRACT
Braking is nothing but bringing a moving vehicle or moving body to a stop.
Noadays sa!ety is an important !eature in the automotive industry. "he intelligent
braking system is the ne#t step to automation. $resently cars have the alarm system
here hen the car gets too close to an ob%ect an alarm is triggered hich arns
the driver about an ob%ect close by. But this !eature has produced lot o! problems
and are prone to human error. &e have enhanced the !acility by using the same
system but e have altered it so that the car brakes automatically hen an obstacle
is close by.
"he aim is to design and develop a control system based on intelligent
electronically controlled automotive braking system is called 'INTELLIGENT
REVERSE BRAKING SYSTEM%. (ensor )perated $neumatic Brake consists o!
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*+ transmitter and +eceiver circuit, -ontrol .nit, $neumatic breaking system. "he
*+ sensor is used to detect the obstacle. "here is any obstacle in the path, the *+
sensor senses the obstacle and giving the control signal to the breaking system. "he
pneumatic breaking system is used to brake the system. (o basically here the car
brakes on its on by determining the distance !rom the ob%ect.
LIST OF FIGURES
-hapter Name )! "he /igure $age Number
3.2.4.1 *+ "ransmitter circuit 30
3.2.4.2 *+ +eceiver circuit 31
3.2.1 -apacitor start motors 34
3.2.1 (plit $hase motor 36
3.2.1 $ermanent (plit -apacitor 2otor 36
3.3 Block 3iagram 37
3.4 -ircuit 3iagram 31
3.5 4ayout )! *B( 35
3.5 6#perimental (etup71 40
3.5 6#perimental (etup72 41
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INTRODUCTION
&e have pleasure in introducing our ne pro%ect 'INTELLIGENT
BRAKING SYSTEM%# hich is !ully e8uipped by *+ sensors circuit and
$neumatic breaking circuit. *t is a genuine pro%ect hich is !ully e8uipped and
designed !or 9utomobile vehicles. "his !orms an integral part o! best 8uality.
"he 'PNEUMATIC BRAKING CIRCUIT: can stop the vehicle ithin 2
to 3 seconds running at a speed o! 50 ;2. "he intelligent braking system is a !ully
automated.
"his is an era o! automation here it is broadly de!ined as replacement o!
manual e!!ort by mechanical poer in all degrees o! automation. "he operation
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remains an essential part o! the system although ith changing demands on
physical input as the degree o! mechani<ation is increased.
3egrees o! automation are o! to types, vi<.
/ull automation.
(emi automation.
*n semi automation a combination o! manual e!!ort and mechanical
poer is re8uired hereas in !ull automation human participation is very
negligible.
NEED FOR AUTOMATION&
9utomation can be achieved through computers, hydraulics, pneumatics,
robotics, etc., o! these sources, pneumatics !orm an attractive medium !or lo cost
automation. "he main advantages o! all pneumatic systems are economy and
simplicity. 9utomation plays an important role in mass production.
/or mass production o! the product, the machining operations decide the
se8uence o! machining. "he machines designed !or producing a particular product
are called trans!er machines. "he components must be moved automatically !rom
the bins to various machines se8uentially and the !inal component can be placed
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separately !or packaging. 2aterials can also be repeatedly trans!erred !rom the
moving conveyors to the ork place and vice versa.
Noadays almost all the manu!acturing process is being atomi<ed in order to
deliver the products at a !aster rate. "he manu!acturing operation is being
atomi<ed !or the !olloing reasons.
"o achieve mass production
to reduce man poer
"o increase the e!!iciency o! the plant
"o reduce the ork load
"o reduce the production cost
"o reduce the production time
"o reduce the material handling
"o reduce the !atigue o! orkers
"o achieve good product 8uality
4ess 2aintenance
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TYPES OF BRAKING
"he brakes !or automotive use may be classi!ied according the !olloing
considerations.
1. $.+$)(6
2. 4)-9"*)N
3. -)N("+.-"*)N
4. 26"=)3 )/ 9-".9"*)N
5. 6>"+9 B+9;*N? 6//)+"
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Based on the above considerations, brakes are classi!ied ith respect to
!olloing !actors.
1. &ith respect to application,
a. /oot brake
b. =and brake
2. &ith respect to the number o! heels,
a. "o heel brakes
b. /our heel brakes
3. &ith respect to the method o! braking contact
a. *nternal e#panding brakes
b. 6#ternal contracting brakes
4. &ith respect to the method o! applying the braking !orce.
a. (ingle acting brake
b. 3ouble acting brakes.
5. &ith respect to the brake gear,
a. 2echanical brake
b. $oer brakes
6. &ith respect to the nature o! poer employed
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a. @acuum brake
b. 9ir brake
c. =ydraulic brake
d. =ydrostatic brake
e. 6lectric brake
7. &ith respect to poer transmission,
a. 3irect acting brakes
b. ?eared brakes
1. &ith respect to poer unit,
a. -ylinder brakes
b. 3iaphragm brake
"he !oot brake or service brake is alays applied by a pedal, hile the
parking brake is applied by a hand lever. "he parking brake is intended chie!ly to
hold the car in position. "he parking brake can be set in the ')N: position by
means o! a latch hile the service brake remains on only as long as the driver
presses don on the pedal.
"he hand brake is normally used only a!ter the driver has stopped the car by
using the !oot brake. *ts other use is as an emergency brake to stop the car i! the
!oot braked system should !ail. "he hand or parking brakes operates on a pair o!
heels, !re8uently the rear heels. &hen drum type rear brakes are used, the same
shoes can be used !or both hand and !oot control.
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"he drum type o! brake may either be a band brake or a shoe brake. Both
band brakes and shoe brakes may be either e#ternal or internal. "he band brakes
generally are e#ternal and shoe brakes internal. *n drum brakes the drum is
attached to the heel and revolves ith it. /riction to slo the drum is applied
!rom inside by the shoes hich do not rotate but are mounted on a stationary metal
back plate. "here are di!!erent types o! drum brakes such as a to leading shoe
arrangement A hich gives an augmented response to pedal e!!ort because o! its
sel! applying arrangement. 9 leading7trailing shoe is a cheaper and better
alternative as it is e8ually e!!ective hether the car is going !orard or backards.
2anu!acturers design drum brakes so that rain, sho or ice or grit cannot
get inside and decrease braking e!!iciency !or moisture greatly reduces the !riction
beteen the linings and the drum.
"he dissipate 8uickly the considerable amount o! heat generated hen
braking a !ast moving heavy car large brake drums ould be re8uired. 3isc brakes
do the %ob more e!!iciently, !or the cooling air can get to the rubbing beteen each
piston and the disc, there is a !riction pad held in position by retaining pins, spring
plates etc. $assages are drilled in the caliper !or the !luid to enter or leave the each
housing. "hese passages are also connected to another one !or bleeding. 6ach
cylinder contains a rubber selling ring beteen the cylinder and the piston.
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"he brakes are applied, hydraulically actuated piston move the !riction pads
into contact ith the disc, applying e8ual and opposite !orces on the later. )n
releasing the brakes, the rubber sealing rings act as return springs and retract the
pistons and the !riction pads aay !rom the disc.
MECHANICAL BRAKE&
*n a motor vehicle, the heel is attached to an au#iliary heel called
drum. "he brake shoes are made to contact this drum. *n most designs, to shoes
are used ith each drum to !orm a complete brake mechanism at each heel. "he
brake shoes have bake linings on their outer sur!aces. 6ach brake shoe is hinged at
one end by on anchor pinB the other end is operated by some means so that the
brake shoe e#pands outards. "he brake linings come into contact ith the drum.
+etracting spring keeps the brake shoe into position hen the brakes are not
applied. "he drum encloses the entire mechanism to keep out dust and moisture.
"he heel attaching bolts on the drum are used to contact heel and drum. "he
braking plate completes the brake enclosure, holds the assembly to car a#le, and
acts the base !or !astening the brake shoes and operating mechanism.
HYDRAULIC BRAKES&
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"he hydraulic brakes are applied by the li8uid pressure. "he pedal !orce is
transmitted to the brake shoe by means o! a con!ined li8uid through a system o!
!orce transmission.
"he !orce applied to the pedal is multiplied and transmitted to brake shoes
by a !orce transmission system. "his system is based upon $ascalCs principle,
hich states that '"he con!ined li8uids transmit pressure ithout loss e8ually in all
directions:.
*t essentially consists o! to main components A master cylinder and heel
cylinder the master cylinder is connected by the heel cylinders at each o! the !our
heels. "he system is !illed ith the li8uid under light pressure hen the brakes
are not in operation. "he li8uid is knon as brake !luid, and is usually a mi#ture o!
glycerin and alcohol or caster7oil, denatured alcohol and some additives (pring
pressure, and thus the !luid pressure in the entire system drops to its original lo
valve, hich allos retracting spring on heel brakes to pull the brake shoes out o!
contact ith the brake drums into their original positions. "his causes the heel
cylinder piston also to come back to its original inard position. "hus, the brakes
are released.
AIR BRAKE&
9ir brakes are idely used in heavy vehicle like buses and trucks hich
re8uire a heavier braking e!!ort that can be applied by the driverCs !oot. 9ir brakes
are applied by the pressure o! compressed air, instead o! !oot pressure, acting
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against !le#ible diaphragms in brake chamber. "he diaphragms are connected to
the heel brakes. "hese diaphragms are controlled through a hand or !oot
operated valve. "he brake valve controls brake operation by directing the !lo o!
air !rom a reservoir against diaphragms in the brake chamber hen the brakes are
applied and !rom brake chambers to tube atmosphere hen the brakes are released.
"he air compressor, driven by the engine !urnishes compressed air to the reservoir
!all belo a set valve.
ELECTRIC BRAKE&
6lectric Brakes are also used in some motor vehicles, although these are not
very popular. &arner electric brake is one o! the e#amples o! such brakes. 9n
electric brake essentially consists o! an electromagnet ithin the brake drum. "he
current !rom the battery is utili<ed to energi<e the electromagnet, hich actuates
the mechanism to e#pand the brake shoe against the brake drum, thus applying the
brakes. "he severity o! braking is controlled by means o! a rheostat, hich is
operated by the driver through the !oot pedal.
6lectric brakes are simpler. "hese brakes do not re8uire complicated
operating linkage. )nly cable is re8uired to take current !rom the battery to the
electromagnet. 9lso, these are very 8uick in action as compared to other types o!
brakes.
VACUUM BRAKES ' SERVO BRAKES&
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9 serve mechanism !itted to the braking system reduces the physical e!!ort
the driver has to use on the brake pedal most servo mechanisms are o! the vacuum
assistance type. 9 pressure di!!erential can be established by sub%ecting one side
o! the piston to atmospheric pressure and the other side to a pressure belo
atmospheric pressure by e#hausting air !rom the corresponding end o! the servo
cylinder.
REGENERATIVE BRAKING&
6lectricity poered vehicles use regenerative braking !or stopping the
vehicle. &ith regenerative braking pressing the brake pedal does not necessarily
activate a conventional !riction brake. "he motor controller controlling the vehicle
is treated as a generator hich slos the vehicle and simultaneously provides an
output !or charging the battery. "he e!!ectiveness o! regenerative braking !alls o!
ith vehicle speed. 6lectric vehicles ill have to be !itted ith conventional
hydraulic !riction brakes as ell as ith regenerative systems.
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IR SENSOR
SENSORS
9 sensor is a transducer used to make a measurement o! a physical
variable. 9ny sensor re8uires calibration in order to be use!ul as a measuring
device. -alibration is the procedure by hich the relationship beteen the
measured variable and the converted output signal is established.
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-are should be taken in the choice o! sensory devices !or particular
tasks. "he operating characteristics o! each device should be closely matched to
the task !or hich it is being utili<ed. 3i!!erent sensors can be used in di!!erent
ays to sense same conditions and the same sensors can be used in di!!erent ays
to sense di!!erent conditions.
TYPES OF SENSOR&
P())*+, ),-)./) detect the re!lected or emitted electro7magnetic radiation
!rom natural sources, hile (01*+, ),-)./) detect re!lected responses !rom ob%ects
hich are irradiated !rom arti!icially generated energy sources, such as radar. 6ach
is divided !urther in to -.--)0(--*-2 and )0(--*-2 )3)1,4).
9 sensor classi!ied as a combination o! passive, non7scanning and -.--
*4(2*-2 4,15.6 is a type o! pro!ile recorder, !or e#ample a microave
radiometer. 9 sensor classi!ied as passive, non7scanning and *4(2*-2 4,15.6, is a
camera, such as an aerial survey camera or a space camera, !or e#ample on board
the +ussian -)(2)( satellite.
(ensors classi!ied as a combination o! passive, scanning and imaging are
classi!ied !urther into *4(2, 78(-, )0(--*-2 ),-)./), such as "@ cameras and
solid state scanners, and .9:,01 78(-, )0(--*-2 ),-)./), such as multi7spectral
scanners Doptical7mechanical scannerE and scanning microave radiometers.
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9n e#ample o! an active, non7scanning and non7imaging sensor is a pro!ile
recorder such as a laser spectrometer and laser altimeter. 9n active, scanning and
imaging sensor is radar, !or e#ample synthetic aperture radar D(9+E, hich can
produce high resolution, imagery, day or night, even under cloud cover.
"he most popular sensors used in remote sensing are the camera, solid state
scanner, such as the --3 Dcharge coupled deviceE images, the multi7spectral
scanner and in the !uture the passive synthetic aperture radar.
4aser sensors have recently begun to be used more !re8uently !or monitoring
air pollution by laser spectrometers and !or measurement o! distance by laser
altimeters.
*n our pro%ect *+ transmitter and *+ receiver are used to detect the obstacle. "hese
sensors are !itted at the !ront side o! the vehicle.
IR TRANSMITTER&
"he *+ transmitting circuit is used in many pro%ects. "he *+ transmitter
sends 40 k=< D!re8uency can be ad%ustedE carrier under 555 timer control. *+
carriers at around 40 k=< carrier !re8uencies are idely used in "@ remote
controlling and *-s !or receiving these signals are 8uite easily available.
IR RECEIVER&
"he transmitted signal re!lected by the obstacle and the *+ receiver
circuit receives the signal and giving control signal to the control unit. "he control
unit activates the pneumatic breaking system, so that break as applied.
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LITERATURE SURVEY
P-,;4(1*0)
"he ord FpneumaC comes !rom ?reek and means breather ind. the
ord pneumatics is the study o! air movement and its phenomena is derived !rom
the ord pneuma. "oday pneumatics is mainly understood to means the
application o! air as a orking medium in industry especially the driving and
controlling o! machines and e8uipment.
$neumatics has !or some considerable time beteen used !or carrying
out the simplest mechanical tasks in more recent times has played a more
important role in the development o! pneumatic technology !or automation.
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$neumatic systems operate on a supply o! compressed air hich must
be made available in su!!icient 8uantity and at a pressure to suit the capacity o! the
system. &hen the pneumatic system is being adopted !or the !irst time, hoever it
ills indeed the necessary to deal ith the 8uestion o! compressed air supply.
"he key part o! any !acility !or supply o! compressed air is by means
using reciprocating compressor. 9 compressor is a machine that takes in air, gas at
a certain pressure and delivered the air at a high pressure.
-ompressor capacity is the actual 8uantity o! air compressed and
delivered and the volume e#pressed is that o! the air at intake conditions namely at
atmosphere pressure and normal ambient temperature.
T5, 0.47/,))*9*8*13 .< 15, (*/ =() <*/)1 *-+,)1*2(1,6 93 R.9,/1
B.38, *- 1962 (-6 15(1 <.;-6 15(1 15, 7/.6;01 .< 7/,));/, (-6 +.8;4, .< (
7(/1*0;8(/ >;(-1*13 .< 2()
"he usual ritten as
pv G c DorE pivi G p2v2
*n this e8uation the pressure is the absolute pressured hich !or !ree is
about 14.7 psi and is o! courage capable o! maintaining a column o! mercury,
nearly 30 inches high in an ordinary barometer. 9ny gas can be used in pneumatic
system but air is the mostly used system no a days.
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COMPONENTS AND DESCRIPTION
SELECTION OF PNEUMATICS&
2echani<ation is broadly de!ined as the replacement o! manual e!!ort by
mechanical poer. $neumatics is an attractive medium !or lo cost mechani<ation
particularly !or se8uential or repetitive operations. 2any !actories and plants
already have a compressed air system, hich is capable o! providing both the
poer or energy re8uirements and the control system Dalthough e8ually pneumatic
control systems may be economic and can be advantageously applied to other
!orms o! poerE.
22
T5, 4(*- (6+(-1(2,) .< (- (88-7-,;4(1*0 )3)1,4 (/, ;);(883 ,0.-.43
(-6 )*478*0*13# 15, 8(11,/ /,6;0*-2 4(*-1,-(-0, 1. ( 8.= 8,+,8 I1 0(- (8). 5(+,
.;1 )1(-6*-2 (6+(-1(2,) *- 1,/4) .< )(<,13
PNEUMATIC COMPONENTS AND ITS DESCRIPTION
"he pneumatic bearing press consists o! the !olloing components to !ul!ill
the re8uirements o! complete operation o! the machine.
1E $N6.29"*- (*N?46 9-"*N? -H-4*N36+
2E ()46N)*3 @94@6
3E /4)& -)N"+)4 @94@6
4E *+ (6N()+ .N*"
5E &=664 9N3 B+9;6 9++9N?626N"
6E $. -)NN6-")+, +63.-6+, =)(6 -)449+
7E ("9N3
1E (*N?46 $=9(6 *N3.-"*)N 2)")+
1) PNEUMATIC SINGLE ACTING CYLINDERI
$neumatic cylinder consist o!
9E $*(")N BE -H4*N36+
"he cylinder is a (ingle acting cylinder one, hich means that the air
pressure operates !orard and spring returns backard. "he air !rom the
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compressor is passed through the regulator hich controls the pressure to re8uired
amount by ad%usting its knob.
9 pressure gauge is attached to the regulator !or shoing the line pressure.
"hen the compressed air is passed through the single acting 3J2 solenoid valve !or
supplying the air to one side o! the cylinder.
)ne hose take the output o! the directional -ontrol D(olenoidE valve and
they are attached to one end o! the cylinder by means o! connectors. )ne o! the
outputs !rom the directional control valve is taken to the !lo control valve !rom
taken to the cylinder. "he hose is attached to each component o! pneumatic system
only by connectors.
CYLINDER TECHNICAL DATA&
P*)1.- R.6&
2.(. hard -hrome plated
S,(8)&
Nitrile DBuna A NE 6lastomer
E-6 C.+,/)&
-ast iron graded !ine grained !rom 25mm to 300mm
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P*)1.-&
-9luminium.
M,6*(&
-9ir.
T,47,/(1;/, R(-2,&
0Kc to 15Kc
P(/1) .< P-,;4(1*0 C38*-6,/
P*)1.-&
"he piston is a cylindrical member o! certain length hich reciprocates
inside the cylinder. "he diameter o! the piston is slightly less than that o! the
cylinder bore diameter and it is !itted to the top o! the piston rod. *t is one o! the
important parts hich convert the pressure energy into mechanical poer.
"he piston is e8uipped ith a ring suitably proportioned and it is relatively
so!t rubber hich is capable o! providing good sealing ith lo !riction at the
operating pressure. "he purpose o! piston is to provide means o! conveying the
pressure o! air inside the cylinder to the piston o! the oil cylinder.
?enerally piston is made up o!
9luminium alloy7light and medium ork.
Brass or bron<e or -*7=eavy duty.
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"he piston is single acting spring returned type. "he piston moves !orard
hen the high7pressure air is turned !rom the right side o! cylinder.
"he piston moves backard hen the solenoid valve is in )// condition.
"he piston should be as strong and rigid as possible. "he e!!iciency and economy
o! the machine primarily depends on the orking o! the piston. *t must operate in
the cylinder ith a minimum o! !riction and should be able to ithstand the high
compressor !orce developed in the cylinder and also the shock load during
operation.
"he piston should posses the !olloing 8ualities.
a. "he movement o! the piston not creates much noise.
b. *t should be !rictionless.
c. *t should ithstand high pressure.
P*)1.- R.6
"he piston rod is circular in cross section. *t connects piston ith piston o!
other cylinder. "he piston rod is made o! mild steel ground and polished. 9 high
!inish is essential on the outer rod sur!ace to minimi<e ear on the rod seals. "he
piston rod is connected to the piston by mechanical !astening. "he piston and the
piston rod can be separated i! necessary.
)ne end o! the piston rod is connected to the bottom o! the piston. "he
other end o! the piston rod is connected to the other piston rod by means o!
coupling. "he piston transmits the orking !orce to the oil cylinder through the
piston rod. "he piston rod is designed to ithstand the high compressive !orce. *t
26
should avoid bending and ithstand shock loads caused by the cutting !orce. "he
piston moves inside the rod seal !i#ed in the bottom cover plate o! the cylinder.
"he sealing arrangements prevent the leakage o! air !rom the bottom o! the
cylinder hile the rod reciprocates through it.
C38*-6,/ C.+,/ P8(1,)
"he cylinder should be enclosed to get the applied pressure !rom the
compressor and act on the pinion. "he cylinder is thus closed by the cover plates
on both the ends such that there is no leakage o! air. 9n inlet port is provided on
the top cover plate and an outlet ports on the bottom cover plate. "here is also a
hole drilled !or the movement o! the piston.
"he cylinder cover plate protects the cylinder !rom dust and other particle
and maintains the same pressure that is taken !rom the compressor. "he !lange has
to hold the piston in both o! its e#treme positions. "he piston hits the top plat
during the return stroke and hits the bottom plate during end o! !orard stroke. (o
the cover plates must be strong enough to ithstand the load.
C38*-6,/ M.;-1*-2 P8(1,)&
*t is attached to the cylinder cover plates and also to the carriage ith the
help o! F4C bends and bolts.
2 SOLENOID VALVE !ITH CONTROL UNIT&
"he directional valve is one o! the important parts o! a pneumatic system.
-ommonly knon as 3-@, this valve is used to control the direction o! air !lo in
the pneumatic system. "he directional valve does this by changing the position o!
its internal movable parts.
27
"his valve as selected !or speedy operation and to reduce the manual
e!!ort and also !or the modi!ication o! the machine into automatic machine by
means o! using a solenoid valve. 9 solenoid is an electrical device that converts
electrical energy into straight line motion and !orce. "hese are also used to operate
a mechanical operation hich in turn operates the valve mechanism. (olenoids
may be push type or pull type. "he push type solenoid is one in hich the plunger
is pushed hen the solenoid is energi<ed electrically. "he pull type solenoid is one
is hich the plunger is pulled hen the solenoid is energi<ed.
"he name o! the parts o! the solenoid should be learned so that they can be
recogni<ed hen called upon to make repairs, to do service ork or to install them.
P(/1) .< ( S.8,-.*6 V(8+,
1 C.*8
"he solenoid coil is made o! copper ire. "he layers o! ire are separated
by insulating layer. "he entire solenoid coil is covered ith an varnish that is not
a!!ected by solvents, moisture, cutting oil or o!ten !luids. -oils are rated in various
voltages such as 115 volts 9-, 230 volts 9-, 460 volts 9-, 575 @olts 9-, 6 @olts
3-, 12 @olts 3-, 24 @olts 3-, 115 @olts 3- L 230 @olts 3-. "hey are
designed !or such !re8uencies as 50 =< to 60 =<.
2 F/(4,
"he solenoid !rame serves several purposes. (ince it is made o! laminated
sheets, it is magneti<ed hen the current passes through the coil. "he magneti<ed
coil attracts the metal plunger to move. "he !rame has provisions !or attaching the
mounting. "hey are usually bolted or elded to the !rame. "he !rame has
provisions !or receivers, the plunger. "he ear strips are mounted to the solenoid
!rame, and are made o! materials such as metal or impregnated less !iber cloth.
28
3 S.8,-.*6 P8;-2,/
"he (olenoid plunger is the mover mechanism o! the solenoid. "he plunger
is made o! steel laminations hich are riveted together under high pressure, so that
there ill be no movement o! the lamination ith respect to one another. 9t the
top o! the plunger a pin hole is placed !or making a connection to some device.
"he solenoid plunger is moved by a magnetic !orce in one direction and is usually
returned by spring action.(olenoid operated valves are usually provided ith cover
over either the solenoid or the entire valve. "his protects the solenoid !rom dirt
and other !oreign matter, and protects the actuator. *n many applications it is
necessary to use e#plosion proo! solenoids.
!ORKING OF 3'2 SINGLE ACTING SOLENOID ?OR@ CUT OFF VALVE&
"he control valve is used to control the !lo direction is called cut o!!
valve or solenoid valve. "his solenoid cut o!! valve is controlled by the emergency
push button. "he 3J2 (ingle acting solenoid valve is having one inlet port, one
outlet port and one e#haust port. "he solenoid valve consists o! electromagnetic
coil, stem and spring. "he air enters to the pneumatic single acting solenoid valve
hen the push button is in )N position.
T,05-*0(8 D(1(&
(i<e I M:
$ressure I 0 to 7 kg J cm2
2edia I 9ir
"ype I 3J2
29
9pplied @oltage I 230@ 9.-
/re8uency I 50 =<
3 FLO! CONTROL VALVE&
1 T,05-*0(8 D(1(&
(i<e I M:
$ressure I 0 to 10 kg J cm2
2edia I 9ir
?9@ P;/7.),&
"his valve is used to speed up the piston movement and also it acts as an one
A ay restriction valve hich means that the air can pass through only one ay
and it canCt return back. By using this valve the time consumption is reduced
because o! the !aster movement o! the piston.
4 IR SENSOR UNIT&-
30
"he *+ transmitter and *+ receiver circuit is used to sense the obstacle. *t is
!i#ed to the back side o! the !rame stand ith a suitable arrangement. "he
pneumatic cylinder is controlled by the !lo control valve, single acting solenoid
valve and control unit.
AT NORMAL CONDITION&
"he *+ transmitter sensor is transmitting the in!rared rays ith the
help o! 555 *- timer circuit. "hese in!rared rays are received by the *+ receiver
sensor. "he "ransistor "1, "2 and "3 are used as an ampli!ier section. 9t normal
condition "ransistor "5 is )// condition. 9t that time relay is )//, so that the
vehicle running continuously.
31
32
33
AT OBSTACLE CONDITION&
9t )bstacle conditions the *+ transmitter and *+ receiver, the
resistance across the "ransmitter and receiver is high due to the non7conductivity
o! the *+ aves. (o the output o! transistor "5 goes !rom )// condition to )N
stage. *n that time the relay is )N position. *n that time, the solenoid valve is on so
that the vehicle stops.
5 !HEEL AND BRAKING ARRANGEMENT&
"he simple heel and braking arrangement is !i#ed to the !rame stand. Near
the brake drum, the pneumatic cylinder piston is !i#ed.
6 CONNECTORS# REDUCER AND HOSECOLLAR&
*n our pneumatic system there are to types o! connectors usedB one is the
hose connector and the other is the reducer. =ose connectors normally comprise
an adapter DconnectorE hose nipple and cap nut. "hese types o! connectors are
made up o! brass or 9luminium or hardened steel. +educers are used to provide
inter connection beteen to pipes or hoses o! di!!erent si<es. "hey may be !itted
straight, tee, '@: or other con!igurations. "hese reducers are made up o! gunmetal
or other materials like hardened steel etc.
34
$ STAND&
"his is a supporting !rame and made up o! mild steel.
SINGLE PHASE INDUCTION MOTOR&-
*t is !ound to drive the roller sha!t hich !i#ed on the end o! the !rame
structure. "he !ree end o! the sha!t in the motor a large pulley is !ound around
hich the belt runs. "he other speci!ication about the motor is discussed in design
part o! the machine.
S*-28,-P5(), T5,./3
Because it has but a single alternating current source, a single7phase motor
can only produce an alternating !ieldI one that pulls !irst in one direction, then in
the opposite as the polarity o! the !ield sitches. 9 s8uirrel7cage rotor placed in
this !ield ould merely titch, since there ould be no moment upon it. *! pushed
in one direction, hoever, it ould spin.
"he ma%or distinction beteen the di!!erent types o! single7phase 9- motors
is ho they go about starting the rotor in a particular direction such that the
alternating !ield ill produce rotary motion in the desired direction. "his is usually
done by some device that introduces a phase7shi!ted magnetic !ield on one side o!
the rotor.
"he !igure the per!ormance curves o! the !our ma%or types o! single7phase
9- motors. "hey are described belo.
35
S78*1-P5(), M.1./)&
"he split phase motor achieves its starting capability by having to separate
indings ound in the stator. "he to indings are separated !rom each other.
)ne inding is used only !or starting and it is ound ith a smaller ire si<e
having higher electrical resistance than the main indings. /rom the rotorNs point
o! vie, this time delay coupled ith the physical location o! the starting inding
produces a !ield that appears to rotate. "he apparent rotation causes the motor to
start.
9 centri!ugal sitch is used to disconnect the starting inding hen the
motor reaches appro#imately 75O o! rated speed. "he motor then continues to run
on the basis o! normal induction motor principles.
36
C(7(0*1./-S1(/1 M.1./)
-apacitor start motors !orm the largest single grouping o! general purpose
single phase motors. "hese motors are available in a range o! si<es !rom !ractional
through 3=$.
"he inding and centri!ugal sitch arrangement is very similar to that used
in a split phase motor. "he main di!!erence being that the starting inding does not
have to have high resistance. *n the case o! a capacitor start motor, a speciali<ed
capacitor is utili<ed in a series ith the starting inding.
"he addition o! this capacitor produces a slight time delay beteen the
magneti<ation o! starting poles and the running poles. "hus the appearance o! a
rotating !ield e#ists. &hen the motor approaches running speed, the starting sitch
opens and the motor continues to run in the normal induction motor mode.
"his moderately priced motor produces relatively high starting tor8ue, 225
to 400O o! !ull load tor8ue. "he capacitor start motor is ideally suited !or hard to
start loads such as conveyors, air compressors and re!rigeration compressors. 3ue
to its general overall desirable characteristics, it also is used !or many applications
here high starting tor8ue may not be re8uired. "he capacitor start motor can
usually be recogni<ed by the bulbous protrusion on the !rame here the starting
capacitor is located.

37
P,/4(-,-1-S78*1 C(7(0*1./ M.1./)
"he capacitor o! this motor is le!t in series ith the starting inding during
normal operation. "he starting tor8ue is 8uite lo, roughly 40O o! !ull7load, so
lo7inertia loads such as !ans and bloers make common applications.

+unning per!ormance and speed regulation can be tailored by selecting an
appropriate capacitor value. No centri!ugal sitch is re8uired.
38
BLOCK DIAGRAM
POWER
SUPPLY
CONTROL UNIT
PNEUMATIC
CYLINDER
SOLINOID
VALVE
BREAK
ARRANEME
IR RECEIVER
FLOW
CONTROL
VANVE
AIR TANK
IR
TRANSMITTER
39
CIRCUIT DIAGRAM
40
LAYOUT OF THE INTELLIGENT BRAKING SYSTEM
41
EAPERIMENTAL SETUP-I
42
EAPERIMENTAL SETUP-II
43
!ORKING OPERATION
"he important components o! our pro%ect are,
*+ transmitter
*+ receiver
-ontrol .nit ith $oer supply
(olenoid @alve
/lo control @alve
9ir "ank D-ompressorE
"he IR TRANSMITTER circuit is to transmit the *n!ra7+ed rays. *! any
obstacle is there in a path, the *n!ra7+ed rays re!lected. "his re!lected *n!ra7+ed
rays are received by the receiver circuit is called 'IR RECEIVER%
"he *+ receiver circuit receives the re!lected *+ rays and giving the control
signal to the control circuit. "he control circuit is used to activate the solenoid
valve.
*! the solenoid valve is activated, the compressed air passes to the (ingle
9cting $neumatic -ylinder. "he compressed air activate the pneumatic cylinder
and moves the piston rod.
*! the piston moves !orard, then the breaking arrangement activated. "he
breaking arrangement is used to break the heel gradually or suddenly due to the
piston movement. "he breaking speed is varied by ad%usting the valve is called
BFLO! CONTROL VALVE%
44
*n our pro%ect, e have to apply this breaking arrangement in one heel as a
model. "he compressed air dran !rom the compressor in our pro%ect. "he
compressed air !lo through the $olyurethene tube to the !lo control valve. "he
!lo control valve is connected to the solenoid valve.
45
APPLICATIONS AND ADVANTAGES
APPLICATION&
/or automobile application
*ndustrial application
ADVANTAGES
Brake cost ill be less.
/ree !rom ear ad%ustment.
4ess poer consumption
4ess skill drivers is su!!icient to operate.
*t gives very simpli!ied operation.
*nstallation is simpli!ied.
"o avoid other burnable interactions vi<.P D3iaphragmE is
not used.
46
COST ESTIMATION
MATERIAL COST&
S8 N.
PARTS
C13 A4.;-1 ?R)@
i. (ingle 9cting $neumatic -ylinder 1 1200
ii. /lo -ontrol @alve 1 600
iii. &heel 1 500
iv. (olenoid @alve 1 600
v. (ingle $hase induction motor 1 2000
vi. (ensor .nit 1 100
vii. $ulley 1 10
viii. $olyethylene "ube 7 60
i#. =ose -ollar and +educer 7 150
> (tand D/rameE 1 250
TOTAL COST DR) 624"ER) 26" ?4*)0,88(-,.;) 0.)1@
DR) 65""
CONCLUSION
47
"his pro%ect ork has provided us an e#cellent opportunity and e#perience,
to use our limited knoledge. &e gained a lot o! practical knoledge regarding,
planning, purchasing, assembling and machining hile doing this pro%ect ork.
&e !eel that the pro%ect ork is a good solution to bridge the gap beteen
institution and industries.
&e are proud that e have completed the ork ith the limited time
success!ully. "he INTELLIGENT PNEUMATIC BRAKE is orking ith
satis!actory conditions. &e are able to understand the di!!iculties in maintaining
the tolerances and also 8uality. &e have done to our ability and skill making
ma#imum use o! available !acilities.
*n conclusion remarks o! our pro%ect ork, let us add a !e more lines about
our impression pro%ect ork. "hus e have developed an BINTELLIGENT
BRAKING SYSTEM hich helps to kno ho to achieve lo cost automation.
"he application o! pneumatics produces smooth operation. By enhancing this
techni8ue, the system can be modi!ied and developed according to the applications.
+6/6+6N-6(
48
1. ?.B.(. Narang, 'A;1.4.9*8, E-2*-,,/*-2:, ;hanna $ublishers, 3elhi,
pp 671.
2. &illiam =. -rose, 'A;1.4.9*8, E-2*-,,/*-2:.
3. 3onald. 4. 9nglin, 'A;1.4.9*8, E-2*-,,/*-2:.
4. P-,;4(1*0 C.-1/.8 S3)1,47777(troll L Bernaud, "ata 2c ?ra =ill
$ublications.
5. P-,;4(1*0 S3)1,477772a%umdhar, Ne 9ge *ndia *nternational D$E 4td
6. A;1.4.1*+, ,8,01/.-*0) *- passenger cars A9.Numa<aa
&eb sitesI
. $ro!c.udec.clJQgabrielJtutorials.com
.carsdirect.comJ!eaturesJsa!ety!latures
.hysa!ety.org
.&ikipedia.com
.-ra<yengineers.com
.hostu!!orks.com

Intelligent Reverse Braking System Mech Proj

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