Future improvements

The version 2 of the BBTM is just the first step towards a number of possible
improvements that would lead to a complete Brake Testing Equipment Stand. A
crude approximation can be made tagging the old Brake Band Machine to be of the
1950s while the version 2 of the machine to be of the 90s. The current Brake
Testing equipment is highly advanced than the current state of the machine. An
international standard Brake Testing equipment of Today has the capability to
measure and record numerous parameters the majority of i include Brake Torque,
Temperature and Heat Transfer values, Noise, Vibrations and Wear. The following are
some step by step possible improvements that can be made with the modified
version to be on par with the modern international testing equipment.

1. Perform Inspection stage with automated control than by human judgment.

This can be accomplished by use of optical and mechanical sensors that can
measure the gaps and pinpoint the location where hammering is required.
This can be interpreted as a command or a visual output for the user to
observe.
2. Invent a new way to tighten and roll the band perfectly around the drum. If
the output from the sensor can be interpreted as a command this can be
used by an automated robot to hammer the band onto the drum wherever
required. The robot can function on pneumatics on programmed commands.
3. Upgrade the Hydraulic circuit. The control valve can be replaced with a
solenoid valve that uses buttons and can be modified to provide exact
amount of pressures from the hydraulic system. Pressure gauges and filters
can be used to further enhance the durability of the machine.
4. Enhance the machine to perform Dynamic Testing. Rotate the brake drum at
variable angular velocities as of those provided by the Tanks engine through
a gear and engine mechanism and perform testing during the Dynamic
operation.
5. Measure other parameters that are regularly checked for the modern brakes.
Noise and vibration can be sensed by special sensors and so can be the
temperature of the brake during the braking operation other variables such
as heat transferred, work done, torque and brake force can be interpreted
with the use of formulas.
6. Record and Analyze measured data. All measurements of the sensors can be
fed to a computer which has a software installed in it. The software would
have installed programs in it to store individual sensor data and record it
accordingly. The programs can be computed with formulas to calculate the
dependent variables such as Heat Transfer from temperature measurements.
Indigenously devolved programs can be utilized to analyze and interpret the
measured or recorded data.

Conclusion

The project is to be considered as a major upgrade to the existing Brake Band

Testing Machine. Flaws of the existing machine were observed recorded and
analyzed thoroughly. These included the large amount of pull force required,
medical issues for the worker, locking issue and the large amount of time consumed
in order to operate the machine. Ideas generated to solve the current issue involved
a system that would work as a substitute to the original one, meaning that even
though the machine was upgraded it would function with old version as well as the
new one. The ideas, namely hydraulic pneumatic and electrical actuated units that
moved the existing lever of the machine were evaluated on a design criteria
personal priority basis and hydraulic was selected as the best possible option. The
hydraulic unit designed to achieve the required amount of force and distance
parameters. The designed components which involved a cylinder, pump, motor,
reservoir, control valve and pipes were purchased and then installed on the
machine. Testing performed of the hydraulic unit proved that the unit failed to
achieve the desired velocity of levers movement and also that the connecting rod
between the cylinders end bearing and the lever had some undesirable stresses
that were to be removed. Solutions to this problem were two ideas, The Rack and
Pinion and The Connecting rod mechanism. Careful analysis on personally set
design criterion proved that Rack and Pinion was the better option. The mechanism
was designed using ATLANTA and Boston Gear Catalogues and were theoretically
proved to function with machine. All of the fabricated and theoretical part of the
project have been modelled and simulated on CAD software which animatedly
proves the fully functional Brake Band Testing Machine with its added
improvements.