AUTOMATIC HEAD LIGHT

ALLIGNMENT AND
AUTOMATIC HAND
BRAKE RELEASE

CONTENTS
Sr. No

Title

Introduction

Need of project

Objectives

Problem statement

Literature review

Construction and design calculations

ADVANTAGES and APPLICATIONS

References

Introduction
AUTOMATIC HEAD LIGHT ALLIGNMENT:
A headlamp is a lamp attached to the front of a vehicle to
light the road ahead. While it is common for the term
headlight to be used interchangeably in informal discussion,
headlamp is the term for the device itself, while headlight
properly refers to the beam of light produced and distributed
by the device. Headlamp performance has steadily improved
throughout the automobile age, spurred by the great disparity
between daytime and nighttime traffic fatalities:

the US National Highway Traffic Safety Administration states that

nearly half of all traffic-related fatalities occur in the dark, despite only
25% of traffic travelling during darkness. Other vehicles, such as trains
and aircraft, are required to have headlamps.
This is an era of automation where it is broadly defined as replacement
of manual effort by mechanical power in all degrees of automation. The
operation remains an essential part of the system although with changing
demands on physical input as the degree of mechanization is increased.

IMPORTANCE:

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.

AUTOMATIC HAND BRAKE RELEASE:

We have pleasure in introducing our new project AUTOMATIC

HAND BRAKE RELEASE, which is fully equipped by automatic
system. 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.
In cars, the parking brake, also called hand brake, emergency brake, or
e-brake, is a latching brake usually used to keep the vehicle stationary.
It is sometimes also used to prevent a vehicle from rolling when the
operator needs both feet to operate the clutch and throttle pedals.

Automobile hand brakes usually consist of a cable directly

connected to the brake mechanism on one end and to a lever or
foot pedal at the driver's position. The mechanism is often a handoperated lever (hence the hand brake name), on the floor on either
side of the driver, or a pull handle located below and near the
steering wheel column, or a (foot-operated) pedal located far apart
from the other pedals.

IMPORTANCE:
Conventional parking brake actuation involves the human
interference. Without pulling or pushing the lever, the parking
brake will not work. Also, sometimes due to negligence or in
emergency conditions, we humans often forget to apply parking
brakes. This may lead to rolling of vehicle in case of slopes and
collision with other vehicles in parking area. Constant enhancements
in active safety and improvements with respect to the reliability and
comfort of operation mean that mechanical handbrakes are
increasingly being replaced by electromechanical systems.

NEED OF PROJECT
To provide smooth and safety ride.
To provide safe and automatic braking
of vehicles on slopes.
To provide the nation with an accident
free roads. With Low Cost Automation
Project
The head lamp aligns in two directions
(Left, right).
10/20/16

OBJECTIVE
To design and develop the model of showing
both the systems.
The fabricate the model which will work on
these two systems for the vehicle safety
conditions.

PROBLEM STATEMENT

DESIGN and DEVELOP the model of

vehicle which will have the vehicle safety
system of combining two systems of
automatic head lamp alignment system for
directional head lights and second the
automatic hand brake release which helps
for automatic parking brake activation and
release on slopes.
Also to fabricate the model of the same
which would able to show the characteristics
of both the systems and their individual;
working according to need.

Literature review
DESIGN OF AN ADAPTIVE HEADLIGHTS SYSTEM FOR AUTOMOBILES
Rare CRIAN*, Olimpiu TTAR**, Vistrian MTIE***, Dan
MNDRU****

Nowadays, the automobile industry is more and more

dynamic. The major issue in the design of the automobiles
represents the safety of the transportation. In this idea, this
paper presents the issues related to the safety of driving in
night or fog conditions, the comparison between classical
lights and adaptive systems, as well as one solution,
developed at our Department which deals with fully integrated
solution for positioning of the spot lights which is used as
didactical stand. We presented the principles for command and
control of adaptive headlights, in two variants, one which
serves as demonstrative approach commanded from P.C. via
Lab View software and one as principle, for implementation
with micro controller.

construction
AUTOMATIC HEAD LIGHT ALLIGNMENT:
The whole parts are mounted on bace frame structure with the
suitable arrangement. Boring of bearing sizes and open bores
done in one setting so as to align the bearings properly while
assembling. Provisions are made to cover the bearings with
grease.
Movable frame which is mounted at the front portion of the
vehicle setup and connected to the rack and pinion
arrangement which is connected with the steering system.
When the steering is turned left or right, this frame along with
the steering turns in the steering direction. The headlights are
mounted upon this frame such that when the frame turns, the
headlight also turns with it.
A headlamp is a lamp attached to the front of a vehicle to light
the road ahead. While it is common for the term headlight to
be used interchangeably in informal discussion, headlamp is
the term for the device itself, while headlight properly refers to
the beam of light produced and distributed by the device.

AUTOMATIC HAND BREAK RELEASE:

The parking brakes or the hand brakes must be locked every
time when the vehicle is parked. While travelling in hilly areas,
these brakes are highly useful. Hence our project incorporates
the feature of the automatic hand brake release system. That is
every time, the key is inserted in its slot for ignition, the control
unit senses and sends signals to activate the motor, the motor
releases the hand brake through a cable. On the other hand,
when the key is released after parking, the motor is controlled by
the control unit and is rotated in the reverse direction such that
the hand brakes are locked automatically. AUTOMATIC HAND
BRAKE RELEASE is nothing but one of the braking systems in
automobile at the time of vehicle switches off condition. In this
braking system motorized operated one. In this project, the
control unit is received the signal from the key switch. The key
switch is ON at the time of vehicle start condition. The first time
clutch is applied so that the motor is rotating in forward direction
for 2 sec to release the brake (Already wheel is on braking
condition). The key switch is OFF the motor is rotating in reward
direction for 2 sec to applying the brakes.

It consists of the following main

parts:
Frame,
Rack and pinion,
Movable links,
Headlights.
Motor,
Control unit,
Wheel arrangement,
Frame,
Key inserting slot.
Braking system.

Project
schematic

WORKING PRINCIPLE
Our project is to the turn the right light bracket to the right,
when the vehicle turns to right leaving the left bracket to
remain in standstill position, and vice versa. When the
steering steers to the right, a sprocket attached to the
steering rod rotates which in turn connected to the other
sprocket through a chain. The sizes of the sprockets were
designed in such a way that, if the smaller sprocket rotates
four full complete rotations the larger sprocket will rotate
once. Also the small gear, which is attached to the same
shaft as of the larger sprocket, also rotates along with the
sprocket. A larger gear of the former is chosen, which is
twice its diameter, is meshed to transmit the motion. After
this, the rotation of cam is achieved by fixing the cam in
the same shaft of the larger gear. The spherical edged
follower is attached to the cam is used to convert the
rotary motion of cam into reciprocating motion. So the
right light bracket moves according to the movement of
the follower.

At the same time, the cam at the other end remains in the
dwell period, which results in the stand still position of the
light brackets. The light bracket will returns back to its
original position, using the spring mechanism attached to
it. When the vehicle turns to left, the left bracket alone
turns to the left leaving the right light bracket in standstill
position.

AUTOMATIC HAND BREAK RELEASE is nothing but

one of the breaking systems in automobile at the time of
vehicle switches off condition. In this breaking system
motorized operated one.
In this project, the control unit is received the signal
from the key switch. The key switch is ON at the time of
vehicle start condition. The first time clutch is applied so
that the motor is rotating in forward direction for 2 sec to
release the break (Already wheel is on braking condition).
The key switch is OFF the motor is rotating in reward
direction for 2 sec to applying the break.

1.Base frame
WE design a basic frame for a prototype by mild steel channel (L beam),
L Channel- MS Angles are L-shaped structural steel represented by dimension
of sides & thickness. For e.g. 25x25x3 means, both the sides of angles are
25mm & thickness is of 3mm.
DESIGN OF FRAME SAFETY:
Frame design for safety FOR 25*25*3 L angle mild
steel channel
b = 25 mm, d= 25 mm, t = 3 mm.
Consider the maximum load on the frame to be 50 kg.
Max. Bending moment = force*perpendicular distance
= 50*9.81*150
M = 73575 Nmm
We know,
M / I = b / y
I = bd3 /12
= 25*253 / 12
I = 32552.08 mm4

b = My / I
= 73575*12.5 / 32552.08
b = 28.25 N /mm2
The allowable shear stress for material is
allow = Syt / fos
Where Syt = yield stress = 210 MPa = 210
N/mm2
And fos is factor of safety = 2
So allow= 210/2 = 105 MPa = 105 N/mm2
Comparing above we get,
b < allow i.e. 28.25 < 105 N/mm 2
So design is safe.

Fig.frame with dimensions in mm.

RACK AND PINION:

A rack and pinion is a type of linear actuator that comprises a pair of gears
which convert rotational motion into linear motion. A circular gear called "the
pinion" engages teeth on a linear "gear" bar called "the rack"; rotational motion
applied to the pinion causes the rack to move relative to the pinion, thereby
translating the rotational motion of the pinion into linear motion.

D = Pitch Diameter (mm)

T = Number of Teeth
M = Module

Minimum Number of Teeth to avoid Interference

Where, Aw = Fraction by which the standard addendum for the wheel should
be multiplied =1
G = Gear ratio or velocity ratio = TR / TP = 1.3
TR = Number of teeth on rack = 70
TP = Number of teeth on pinion =32
= Pressure angle = 20
Thus, substituting these values in the above equation
Tpf = 14
Minimum number of teeth to avoid interference is 14.
Taken no of teeth = 32.

Linear Displacement of Rack for 1 rotation of pinion (LD1P)

LD1P= mZp .
m= module = d/z =1.05.
LD1P = 118.69mm.
Tangential tooth load = (Wt) Wt = P/V x Cs P = 2nt/60 Radius of wheel =
200 mm Therefore, 2.5 kg force applied by hand, T = 2.5 x 9.81 = 24.525 N.
Torque = F x r = 24.525 x 100 = 2452.5 Nmm
P =2 x 5 x 2452.5/60 = 1283.475 w
WT = 1283.475/0.0942 X1 = 13625 N

WT = b x b x x m x Yp
504823/730.5 = b/12.5
b = 86.44 N/mm2.
Yield strength of Al 20.7 mpa If we take Fs = 2,
Max. allowable bending stress, = 210/2 = 105 N/mm2
Calculated stress < Allowable atress Hence design is safe.
Rack and pinion design specifications
No. of teeth of rack=70.
No. of teeth on pinion=32.
Length of rack= 380mm.
Pinion PCD=60 mm.
Pinion module =1.875
Rack module = 1.25

DC MOTOR
Type 12 volt geared DC motor
A DC motor is any of a class of electrical machines that converts direct
current electrical power into mechanical power. The most common types rely
on the forces produced by magnetic fields. Nearly all types of DC motors
have some internal mechanism, either electromechanical or electronic, to
periodically change the direction of current flow in part of the motor. Most
types produce rotary motion; a linear motor directly produces force and
motion in a straight line.
Specifications

Standard nominal voltage = 12 V and No load current = 2A

Nominal speed = 100 rpm

Nominal torque = 70 Nm.

Nominal power = 8 watt

Max. efficiency = 80 %

ADVANTAGES
1] Free from wear adjustment.
2] Reduce the manual work
3] Less skill technicians is sufficient to
operate.
4]Installation is simplified very much.

APPLICATION
Four wheeler application
It is also implemented in two
wheeler.
This system can be used in heavy
moving vehicles such as buses
and trucks etc.

CONCLUSION
The topic of this project is steering controlled (or directional) headlights,
that are usually a separate set of headlights fitted to road vehicles beside the
usual low beam/high beam headlights and their feature is that they turn with
the steering, so that the driver of the vehicle can see the bend, what he is
actually turning into.
The electromechanical parking brake help with automatic parking brake
application based on Engine ignition condition. Safe braking is assured in
slopes and hill starts with the help of HOLD function. This system also
gets some advanced options like hold function in head to head traffic and
inclined roads, which would promise the drivers and vehicle owners with a
safe pleasure drive and stops.

References
[1] Chien-Tai. Huang, Chien-Tzu Chen, Shou-Yi Cheng, Bo-Ruei Chen and Ming-Hu Huang,
Design and Testing of a headlight Actuator, Paper #:2008-01-2555, Published on 2008-10-12,
SAE Int. J. Passenger Cars- Mechanical system in Automotive Research & Testing Center
(ARTC), Taiwan.
[2] William H Crouse and Donald L Anglin, Automotive mechanics, SIE 10th edition 2008,
McGraw hill education(India) private limited, ISBN 978-0-07-063435-0.
[3] Tatsuya Yamasaki, Masaaki Eguchi, Yusuke Makino, NTN technical review No.75(2007),
Need of an Electromechanical headlights .
[4] Chih Feng Lee, A thesis on head light, Brake force control and judder compensation of an
automotive brake by wire, 2013, Department of Mechanical Engineering, The University of
Melbourne, Victoria, Australia, Link- dtl.unimelb.edu. au/ researchfile 304026.pdf
[5] Chien-Tai. Huang, Chien-Tzu Chen, Shou-Yi Cheng, Bo-Ruei Chen and Ming-Hu Huang,
Design and Testing of a New Electric Parking Brake Actuator, Paper #:2008-01-2555,
Published on 2008-10-12, SAE Int. J. Passenger Cars- Mechanical system in Automotive
Research & Testing Center (ARTC), Taiwan. Link- http://papers.sae.org/2008- 01-2555/

Thank you