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Design and fabrication of antilock braking system test rig

Conference Paper · December 2016

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 Proceedings of Innovative Research and Industrial Dialogue’16, pp. 141-142 (May 2017)

Design and fabrication of antilock braking system test rig

M.A. Abdullah1,2,*, M.S. Musthafa1, M.H. Harun1,2, F. Ahmad1,2, M.Z. Hassan3

1)
Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal,
Melaka, Malaysia

2)
Centre for Advanced Research on Energy, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian
Tunggal, Melaka, Malaysia

3)
Faculty of Engineering Technology, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100, Durian Tunggal,
Melaka, Malaysia
*
Corresponding e-mail: mohdazman@utem.edu.my

Keywords: ABS test rig; design for manufacture; fabrication

ABSTRACT – In this research, a new design of a the control parameters [5].

quarter car antilock braking system (ABS) test rig is In this paper, an ABS test rig is designed and
fabricated. The test rig is designed due to the problems fabricated. A simple stress analysis is performed to
arise during analysis of the behavior of an ABS in a determine the safety of the test rig [6]. The selected
vehicle. Commercial computer aided design (CAD) design is fabricated using available materials and
software is used to design and analysis the test rig components. The design for manufacture approach is
formation in modeling 3-dimensional (3D). The material practised [7].
selected for the main parts of the test rig is mild steel.
The material is selected through the commercial 2. METHODOLOGY
material selection software. Further analysis of the
All of the test rigs that had been set up in the
project is carried out with two methods of computation
previous studies were considered in designing the ABS
to obtain the load at each point on both wheels and
test rig for this project. All the parts, components and
roller shaft. The CAD software is used to generate
layout of the components, were taken into consideration
structural analysis workbench to analyze the
in producing the best design. Therefore, the main parts
components of the rig and roller body. Cutting process
in setting up a test rig in this project were; wheel, motor,
for the rig and roller body materials are performed using
brake system, sensor roller and rig body. Wheel is the
metal cutter saw, hand drill and grinder. The joining
main component for this test rig. An actual scale wheel
methods applied throughout the fabrication are the
was used. The actual scale of the wheel provides better
metal inert gas (MIG) welding, and bolt and nuts. The
precision for the test rather than smaller scale of weight
assembly processes of the components are then carried
that acted as a car wheel. The electric motor used in this
out according to the design that has been finalized. The
project supplied the rotational torque to the wheel.
ABS test rig was successfully tested and performed as
Figure 1 shows the CAD assembly of the test rig.
predicted.
Shaft
1. INTRODUCTION Wheel Electric motor
Power control
Braking system in a vehicle, especially a four
wheel vehicle, is very important due to the safety of the panel
passengers and the vehicles itself. It is quite critical in
term of analysing the behavior of a car braking system
[1]. A road test using an actual car is very difficult and
requires much hard work, although it is possible to be Roller
done [2,3]. The invention of the antilock braking system
(ABS) has changed the automotive industry a lot. Risks
of accidents to occur have been reduced due to the
invention of the ABS. By having a well-functioning
braking system, risk of accident will be reduced to its
minimum. The study on the braking behavior, and the
invention of several test rig or test bench actually ease
the process of researching and development of the ABS
Support frames
system [4]. In past years, various outdoor tests have
been set up for validating the antilock braking system
behavior. The outdoor road tests are still the best Figure 1 CAD assembly of the ABS test rig
approach for functions validating of the ABS and tuning

© Advanced Manufacturing Centre

 Abdullah et al., 2017

3. RESULTS AND DISCUSSION ACKNOWLEDGEMENT

The chosen material, for the analysis on the part as The authors gratefully acknowledge the Advanced
shown in Figure 2, is low carbon steel. The yield Vehicle Technology (AcTiVe) research group of Centre
strength of the low carbon steel ranges from 250 MPa to for Advanced Research on Energy (CARe), the financial
395 MPa. The lowest value of the yield strength was support from Universiti Teknikal Malaysia Melaka,
considered to ensure that all the parts would be in the PTPTN and The ministry of Education, Malaysia under
safest condition. The factor of safety calculated with Short Term Research Grant, Grant no.
maximum pressure force of 1000 N was 1.5. Figure 3 PJP/2014/FKM(10A)/S01330 and Fundamental
shows the final prototype of the ABS test rig. Research Grant Scheme (FRGS), grant no.:
FRGS/2013/FKM/TK06/02/2/F00165.

REFERENCES
[1] N.K. Arzumanyan, M.A. Smirnova, and M.N.
Smirnov, “Synthesis and modeling of anti-lock
braking system”, International Conference on
Stability and Control Processes in Memory of VI
Zubov (SCP), 5-9 October, IEEE, pp. 552-554,
2015.
[2] M.A. Abdullah, M.A. Salim, M.Z. Mohammad
Nasir, M.N. Sudin, and F.R. Ramli, “Dynamics
performances of Malaysian passenger vehicle,”
ARPN Journal of Engineering and Applied
Sciences, ISSN 1819-6608, vol. 10, no. 17, pp.
7759-7763, 2015.
[3] S. Luo, H.Y. Shu, and X.B. Chen, “Human vehicle
Figure 2 Stress analysis dynamics coupling effect of miniature vehicle roll
characteristic,” International Journal of Electric
Wheel and Hybrid Vehicles, vol. 8, no. 2, pp. 97-108,
Shaft 2016.
[4] H. Ru-ru, Z. Xiang-mo, and X. Zhi-gang, “Auto
anti-lock braking system bench test results
classification model based on neural network”,
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[5] Z. Wie, D. Nenggen, C. Moran, Y. Guizhen, and
Roller
X. Xiangyang, “Development of a low-cost
hardware-in-the-loop simulation system as a test
bench for anti-locked braking system”, Chinese
Electric motor Journal of Mechanical Engineering. vol. 24, no. 1,
pp. 1-8, 2011.
[6] M.A. Abdullah, N. Tamaldin, F.R. Ramli, M.N.
Sudin, and A.M. Mohamed Muslim, “Analysis of
Support frames the chassis and components of all terrain vehicle
(ATV)”, Applied Mechanics and Materials, Trans
Figure 3 Final ABS test rig prototype Tech Publications, vol. 660, pp. 753-757, 2014.
[7] M.A. Abdullah, M.R. Mansor, M.Mohd Tahir, S.I.
4. CONCLUSION Abdul Kudus, M.Z. Hassan and M.N. Ngadiman,
“Design, analysis and fabrication of chassis frame
In conclusion, the antilock braking system test rig for UTeM Formula VarsityTM race car”,
was successfully designed and fabricated after International Journal of Mining, Metallurgy &
considering all the available components and the Mechanical Engineering (IJMMME), vol. 1, no. 1,
requirements in designing the ABS test rig. The material pp. 75-77, 2013.
selection processes did not only consider the strength of
the material, but also its availability in the market, with
its standard sizes and dimensions. The functionality test
were run successfully, and the data obtained were valid
to prove that the ABS test rig was considerably
approved to run test and experiments on the behavior of
standard passenger antilock braking system vehicles.

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