FABRICATION OF PNEUMATIC BRAKING SYSTEM

Submitted in the partial fulfillment of the requirement for the award of

“DIPLOMA IN MECHANICAL ENGINEERING”

SUBMITTED BY:

1. G.K. MANIGANDAN 4. J. DHANAJEYAN

2. B. KARTHIKEYAN 5. D. DURAIVEL
3.P.BALASUBRAMANI 6.L.PRABHU

Under guidance of

Mr. V.K. RAJENDRAN,M.E.

MA!" #$%&'

DEPARTMENT OF MECHANICAL ENGINEERING

 BONAFIDE CERTIFICATE

Thi( i( to certif) that thi( *ro+ect wor, on

- FABRICATION OF PNEUMATIC BRAKING SYSTEM "

(ubmitted b) ........ .....' eg' /o' .....

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING

Thi( i( the bonafide record of wor, carried out b) him under

our (uper0i(ion during the )ear #$%&

Submitted for the 1i0a20oce e3am held on ......................''

"EAD 45 T"E DE*ATME/T *46E!T 7UIDE

I/TE/A8E9AMI/E E9TE/A8E9AMI/E
 ACKNOWLEDGEMENT

At the out(et we would li,e to empha(i;e our (incere than,( to the *rincipal Mr.

R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement and 0aluable ad0ice'

we than, our E(quired "ead of Department Mr R. RAJKUMAR, A.M.I.E,

M.E., for pre(enting hi( felicitation( on u('

<e are grateful on our Entourage( Mr. V.K.RAJENDRAN, M.E.,for

guiding in 0ariou( a(pect( of the pro+ect ma,ing it a grand (ucce(('

<e al(o owe our (incere than,( to all (taff member( of the Mechanical

Engineering =MTM> Department'

Ultimatel) we e3tend our than,( to all who had rendered their co2operation

for the (ucce(( of the pro+ect'

 CONTENTS

!hapter/o' TIT8E

%' I/T4DU!TI4/

#' SY/4*SIS

?' <4@I/7
' DES!I*TI4/ 45 BA@E SYSTEM

' BA@E DETAI8S

&' AI BA@E DIA7AM

C' ME!"A/I!A8 S*AE *ATS

DETAI8S
' */EUMATI! *ATS DETAI8S

' 5I/IS"I/7 A/D *AI/TI/7

%$' !4ST ESTIMATI4/

%%' !4/!8USI4/

%#' BIBI847A*"Y
 Thi( i( a (elf F a((e((ment te(t on the part of the (tudent( to a((e(( hi(

competenc) in creati0it)'

During the cour(e of (tud) the (tudent i( put on a (ound theoretical foundation of

0ariou( mechanical engineering (ub+ect( and of cour(e to a (ati(factor)

e3tent' 4pportunitie( are made a0ailable to him to wor, on different ,ind( of machine(

(o that he i( e3po(ed to 0ariou( ,ind( of manufacturing proce(('

A( a (tudent( learn more and more hi( hold on production technolog) become(

(tronger' "e attain( a (tage of perfection when he him(elf i( able to de(ig n

and fabricate a de0ice'

Thi( i( the pro+ect wor,' That i( the te(timo n) for the (trenuou( training which

the (tudent had in the in(titute' Thi( a((ure( that he i( no more a (tudent he i(

an engineer'

Thi( report di(cu(e( the nece((it) of the pro+ect and 0ariou( a(pect( of planning 

de(ign (election of material( fabrication erection e(timation and te(ting'

 ABSTRAC

The aim i( to de(ign and de0elop a control ()(tem ba(ed on brea,ing ()(tem of an
AI controlled (afel) automoti0e wheel bra,ing ()(tem'

'

The control 0al0e which direct( the air to the double acti ng c)linder for
brea,ing control' Thi( bra,ing action( i( implemented In our pro+ect we ha0e to appl)
thi( bra,ing ()(tem in one wheel a( a model'
CHAPTER– 1
 DESCRIPTION OF
BRAKE
SYSTEM

CHAPTER – 1

DESCRIPTION OF BRAKE SSTEM

1.1 INTRODUCTION

1.1 INTRODUCTION
 Bra,e( are one of the mo(t important control component( of the 0ehicle' The) are
required to (top the 0ehicle within the (malle(t po((ible di(tance and thi( i( done b)
con0erting the ,inetic energ) of the wheel( into the heat energ) which i( di((ipated into
the atmo(phere'

T!"#$ %& 'r()#$ '($#* %+ #-h%* %& (-/(-0%+

%' Mechanical bra,e(
#' ")draulic bra,e(
?' Electric and electronic bra,e(
' 1acuum bra,e(
' Air bra,e(

T!"#$ %& 'r()#$ '($#* %+ (""20(-0%+

%' Drum bra,e(
#' Di(c bra,e(
?' *ar,ing Bra,e(

1.3 DRUM BRAKES

The modern automobile drum bra,e wa( in0ented in %$# b) 8oui( enault

though a le(( 2 (ophi(ticated drum bra,e had been u(ed b) Ma)bach a )ear earlier' In the
fir(t drum bra,e( the (hoe( were mechanicall) operated with le0er( and rod( or cable('
5rom the mid2%?$( the (hoe( were operated with oil pre((ure in a (mall wheel c)linder
and pi(ton( though (ome 0ehicle( continued with purel)2mechanical ()(tem(
for decade(' Some de(ign( ha0e two wheel c)linder('
The (hoe( in drum bra,e( are (ub+ect to wear and the bra,e( needed to be ad+u(ted
regularl) until the introduction of (elf ad+u(ting drum bra,e( in the %$(' In the %&$
( and %C$( bra,e drum( on the front wheel of car( were graduall) replaced with di(c
bra,e( and now practicall) all car( u(e di(c bra,e( on the front wheel( with
man) offering di(c bra,e( on all wheel(' "owe0er drum bra,e( are (till often
u(ed for

handbra,e( a( it ha( pro0ed 0er) difficult to de(ign a di(c bra,e (uitable for holding a
car when it i( not in u(e' Moreo0er it i( 0er) ea() to fit a drum handbra,e in(ide a di(c
bra,e (o that one unit (er0e( for both footbra,e and handbra,e'

Earl) t)pe bra,e (hoe( contained a(be(to(' <hen wor,ing on bra,e ()(tem( of
older car( care mu(t be ta,en not to inhale an) du(t pre(ent in the bra,e a((embl)' The
United State( 5ederal 7o0ernment began to regulate a(be(to( production and bra,e
manufacture( had to (witch to non2a(be(to( lining(' 4wner( initiall) complained of
poor

bra,ing with the replacement(G howe0er technolog) e0entuall) ad0anced to

compen(ate' A ma+orit) of dail)2dri0en older 0ehicle( ha0e been fitted with a(be(to(2
free lining(' Man) other countrie( al(o limit the u(e of a(be(to( in bra,e('

Drum bra,e( con(i(t of a bac,ing plate bra,e (hoe( bra,e drum wheel c)linder
return (pring( and an automatic or (elf2ad+u(ting ()(tem' <hen )ou appl) the bra,e(
bra,e fluid i( forced under pre((ure into the wheel c)linder which in turn pu(he(
the bra,e (hoe( into contact with the machined (urface on the in(ide of the drum' <hen
the pre((ure i( relea(ed return (pring( pull the (hoe( bac, to their re(t po(ition' A( the
bra,e lining( wear the (hoe( mu(t tra0el a greater di(tance to reach the drum' <hen
the di(tance reache( a certain point a (elf2ad+u(ting mechani(m automaticall) react(
b) ad+u(ting the re(t po(ition of the (hoe( (o that the) are clo(er to the drum'

1.3.1 BRAKE SHOES

 8i,e the di(c pad( bra,e (hoe( con(i(t of a (teel (hoe with the friction material or
lining ri0eted or bonded to it' Al(o li,e di(c pad( the lining( e0entuall) wear out and
mu(t be replaced' If the lining( are allowed to wear through to the bare metal (hoe the)
will cau(e (e0ere damage to the bra,e drum'

1.3.3 BACKING PLATE

The bac,ing plate i( what hold( e0er)thing together' It attache( to the a3le and
form( a (olid (urface for the wheel c)linder bra,e (hoe( and a((orted hardware' It rarel)
cau(e( an) problem('

1.3.4 BRAKE DRUM

Bra,e drum( are made of iron and ha0e a machined (urface on the in(ide where
the (hoe( ma,e contact' 6u(t a( with di(c rotor( bra,e drum( will (how (ign( of wear a(
the bra,e lining( (eat them(el0e( again(t the machined (urface of the drum' <hen new
(hoe( are in(talled the bra,e drum (hould be machined (mooth' Bra,e drum( ha0e a
ma3imum diameter (pecification that i( (tamped on the out(ide of the drum' <hen a
drum i( machined it mu(t ne0er e3ceed that mea(urement' If the (urface cannot be
machined within that limit the drum mu(t be replaced'

1.3.5 WHEEL CLINDER

The wheel c)linder con(i(t( of a c)linder that ha( two pi(ton( one on each (ide'
Each pi(ton ha( a rubber (eal and a (haft that connect( the pi(ton with a bra,e (hoe'
<hen bra,e pre((ure i( applied the pi(ton( are forced out pu(hing the (hoe( into contact
with the drum' <heel c)linder( mu(t be rebuilt or replaced if the) (how (ign( of
lea,ing'

The ma+or component( of the drum bra,e a((embl) i( (hown in the following
figure the detailed e3ploded 0iew of drum bra,e component('

1.3.6 RETURN SPRINGS

eturn (pring( pull the bra,e (hoe( bac, to their re(t po(ition after the pre((ure i(
relea(ed from the wheel c)linder' If the (pring are wea, and do not return the (hoe( all
the wa) it will cau(e premature lining wear becau(e the lining( will remain in contact
with the drum' A good technician will e3amine the (pring( during a bra,e +ob and
recommend their replacement if the) (how (ign( of fatigue' 4n certain 0ehicle( the

technician ma) recommend replacing them e0en if the) loo, good a( ine3pen(i0e
in(urance'

1.3.7 SELF ADJUSTING SSTEM

The part( of a (elf ad+u(ting ()(tem (hould be clean and mo0e freel) to in(ure that
the bra,e( maintain their ad+u(tment o0er the life of the lining(' If the (elf ad+u(ter( (top
wor,ing )ou will notice that )ou will ha0e to (tep down further and further on the bra,e
pedal before )ou feel the bra,e( begin to engage' Di(c bra,e( are (elf ad+u(ting
b) nature and do not require an) t)pe of mechani(m' <hen a technician perform( a
bra,e
+ob a(ide from chec,ing the return (pring( he will al(o clean and lubricate( the
(elf ad+u(ting part( where nece((ar)'

1.4 PARKING BREAKS

 The par,ing bra,e =a','a' emergenc) bra,e> ()(tem control( the rear bra,e(
through a (erie( of (teel cable( that are connected to either a hand le0er or a foot
pedal' The idea i( that the ()(tem i( full) mechanical and completel) b) pa((e( the
h)draulic ()(tem (o that the 0ehicle can be brought to a (top e0en if there i( a total bra,e
failure'

In drum bra,e( the cable pull( on a le0er mounted in the rear bra,e and i( directl)
connected to the bra,e (hoe(' Thi( ha( the effect of b) pa((ing the wheel c)linder and
controlling the bra,e( directl)'

%' Support plate

#' *ar, bra,e (hoe(
?' Equali;er
' Spring(

' "old down clip(

&' Ad+u(ter

Di(c bra,e( on the rear wheel( add additional complication for par,ing bra,e ()(tem('
There are two main de(ign( for adding a mechanical par,ing bra,e to rear di(c bra,e('
The fir(t t)pe u(e( the e3i(ting rear wheel caliper and add( a le0er attached to a
mechanical cor,(crew de0ice in(ide the caliper pi(ton' <hen the par,ing bra,e cable
pull( on the le0er thi( cor,(crew de0ice pu(he( the pi(ton again(t the pad(
thereb) b)pa((ing the h)draulic ()(tem to (top the 0ehicle' Thi( t)pe of ()(tem i(
primaril) u(ed with (ingle pi(ton floating caliper( if the caliper i( of the four pi(ton
fi3ed t)pethen that t)pe of ()(tem canHt be u(ed' The other ()(tem u(e( a complete
mechanical drum bra,e unit mounted in(ide the rear rotor' The bra,e (hoe( on thi( ()
(tem are connected to a le0er that i( pulled b) the par,ing bra,e cable to acti0ate the
bra,e(' The bra,e -drum i( actuall) the in(ide part of the rear bra,e rotor'
 4n car( with automatic tran(mi((ion( the par,ing bra,e i( rarel) u(ed' Thi( can cau(e
a couple of problem(' The bigge(t problem i( that the bra,e cable( tend to get corroded
and e0entuall) (i;e up cau(ing the par,ing bra,e to become inoperati0e' B) u(ing the
par,ing bra,e from time to time the cable( (ta) clean and functional' Another
problem come( from the fact that the (elf ad+u(ting mechani(m on certain bra,e ()(tem(
u(e( the

par,ing bra,e actuation to ad+u(t the bra,e(' If the par,ing bra,e i( ne0er u(ed then the
bra,e( ne0er get ad+u(ted'

1.5 DISC BRAKES

1.5.1 INTRODUCTION

Di(c bra,e( con(i(t of a metal di(c attached to the wheel hub that rotate( with the

wheel' !aliper( are attached to the frame or for, along with pad( that (quee;e together
on the di(c' Such bra,e( ha0e been (ucce((full) u(ed on motorc)cle( for decade( and
been the principal choice there' The di(c bra,e i( a lot li,e the bra,e( on bic)cle' Bic)cle
bra,e( ha0e a caliper which (quee;e( the bra,e pad( again(t the wheel' In a di(c bra,e
the bra,e pad( (quee;e the rotor in(tead of the wheel and the force i( tran(mitted
h)draulicall) in(tead of through a cable' 5riction between the pad( and the di(c
(low( the di(c down'

1.5.3 CONSTRUCTION

THEOR OF CONVENTIONAL HDRAULIC DISC BRAKE

A Di(c bra,e u(e( a flat round di(c or rotor attached to the wheel hub
in(tead of a drum' Bra,e pad( are po(itioned on the oppo(ite (ide( of the rotor and are
mounted in the bra,e caliper' The caliper contain( the h)draulic pi(ton u(ed to appl) the
(hoe( and to tran(mit the bra,ing force( from the (hoe( to the (u(pen(ion member('

All di(c bra,e( are non energi;ed non (er0o bra,e(G lining pre((ure i( directl)
proportional to bra,e pedal pre((ure'

!entrifugal force will throw the contaminant( off the rotor' A di(c bra,e will ha0e much
cooler operation than drum bra,e( becau(e of increa(ed area that i( e3po(ed to the air
flowing pa(t it'

All modern automoti0e bra,e ()(tem u(e( a h)draulic ()(tem to tran(mit the
application force( from the bra,e pedal to the bra,e (hoe('
The bra,eH( h)draulic ()(tem begin( at the ma(ter c)linder' The ma(ter c)linder i(
ba(icall) a pi(ton t)pe h)draulic pump operated b) the bra,e pedal' A( bra,e pedal
i(

pu(hed bra,e fluid i( pumped to the caliper or wheel c)linder pi(ton' Thi( fluid pu(he(
on the pi(ton( which pu(h the bra,e (hoe( again(t the rotor'

%.5.4 ADVANTAGES OF DISC BRAKES OVER DRUM BRAKES

 In ca(e of di(c bra,e( the friction( (urface i( directl) e3po(ed to the cooling air (o

the heat di((ipation i( much ea(ier in di(c bra,e than drum bra,e('

 The frictional (urface in ca(e of di(c bra,e( are flat when compared to cur0ed

(urface of drum bra,e( thi( mean in di(c bra,e( there i( uniform wear'

 5rictional pad material i( not (ub+ected to an) bending thereb) increa(ing

the range of material( from which to choo(e the (uitable one'

  The de(ign of di(c bra,e( i( (uch that there i( no lo(( efficienc) due to e3pan(ion
a( the ()(tem become( hot e3pan(ion of drum of internall) e3panded (hoe t)pe(
if bra,e tend( to mo0e the friction (urface apart cau(ing a lo(( of effecti0e pedal
tra0el on the friction (urface( (lightl) without tending to increa(e the clearance'

 Di(c bra,e weigh le(( than their con0entional drum t)pe counterpart a
(a0ing appro3imatel) #$J being po((ible'

 Di(c bra,e ha( a better anti fade characteri(tic( than drum bra,e('

1.5. DISADVANTAGES

 An) lea,age( of h)draulic fluid lead( to bra,e failure

 Air bubble( if an) got trapped in the h)draulic circuit will re(ult i( bra,e failure'

 Sufficient le0el of bra,e fluid (hould alwa)( be maintained all the time

 ")draulic di(c bra,e( u(uall) require relati0el) (peciali;ed tool( to bleed

the bra,e ()(tem('

 epair( on the trail are difficult to perform wherea( mechanical di(c bra,e( rarel)

fail completel)'
 !on(idering the abo0e mentioned ad0antage( and (uperior nature of di(c bra,e( we
decided to choo(e modification( in di(c bra,e( to ma,e it much (impler and more
effecti0e and cheaper de(ign'

1.6 HDRAULIC VS MECHANICAL

Two main di(c bra,e ()(tem( e3i(t: h)draulic and mechanical =cable2actuated>'
Mechanical di(c bra,e( =which are almo(t alwa)( le(( e3pen(i0e than h)draulic> ha0e
le(( modulation than h)draulic di(c bra,e ()(tem( and (ince the cable i( u(uall) open to
the out(ide mechanical di(c bra,e tend to pic, up (mall bit( of dirt and grit in the cable
line( when ridden in har(h terrain' ")draulic di(c ra,e( u(e fluid from a re(er0oir
pu(hed through a ho(e to actuate the pi(ton( in the di(c caliper that then actuate
the pad(' ")draulic di(c bra,e ()(tem( generall) ,eep contaminant( out better'
"owe0er

(ince h)draulic di(c bra,e( u(uall) require relati0el) (peciali;ed tool( to bleed the bra,e
()(tem( repair( on the trail are difficult to perform wherea( mechanical di(c bra,e(
rarel) fail completel)' ")draulic di(c bra,e( occa(ionall) require bleeding of the bra,e
line( to remo0e air bubble(' There are two t)pe( of bra,e fluid u(ed in di(c bra,e( toda):
mineral oil and D4T fluid' Mineral oil i( generall) inert and while D4T ha( a higher
boiling point it i( ,nown to be corro(i0e to frame paint' The two are generall)
not interchangeable a( the different fluid( ma) cau(e (eal( to (well or be corroded' Al(o
the h)draulic fluid ma) boil on (teep continuou( down hill(' Thi( i( due to heat building
up in the di(c and pad( and can cau(e the bra,e to lo(e it( abilit) to tran(mit force
through incompre((ible fluid( (ince (ome of it ha( become a ga( which i(
compre((ible' To a0oid thi( problem #$? mm = inch> diameter di(c rotor( ha0e
become common on downhill bi,e(' 8arge( rotor( di((ipate heat more quic,l) and ha0e
a larger amount of ma(( to ab(orb heat' 5or the(e rea(on( one mu(t weigh the
ad0antage( and di(ad0antage( of u(ing a h)draulic ()(tem 0er(u( a mechanical ()(tem'
 4ur de(ign i( mainl) focu(ed to a0oid the abo0e mentioned di(ad0antage( b)
entirel) new and inno0ati0e ()(tem for di(c bra,e(' The main concept of our pro+ect i(
deri0ed from electronic wedge bar,ing ()(tem' and few important outline of the E<B i(
gi0en below'
 CHAPTER -

2 AIR BRAKING

SYSTEM
 FABRICATION
OF
THE
PROJECT

FABRICATION OF THE PROJECT

Thisprojectconsistsof

1) DCV system
 2) Pneumaitc

acutaotrunit

3)Towwh eler (TVS

MOPED)

2P.NEUMATCI ACTUATOR UNIT;

The brake leveris connected to the double acting

cylinderwhich is

cotnroled by the 5/2 way soelnodi opearetd

direciotnalcotnrolvavle.

Thiscylinderhas12mm diaand25mm strokelength.

3T)wo wheler (TVS MOPED)

Tofabricatethisbrakesetup aTVS

CHAMP twowhelermoped is arranged.

WORKING PRINCIPLE
WORKING PRINCIPLE

Thisprojectconsistsof

1) AIR cotnrolsyesmt

2) Pneumaitc

acutaotrunit

3)Towwh eler (TVS

MOPED)
2.5.1.ADVANTAGES
 25.1.1..ADVANTAGES

%' Bra,e co(t will be le((

#' 5ree from wear ad+u(tment(
?' 8e(( power con(umption
' 8e(( (,ill technician( i( (ufficient to operate
' In(tallation i( (implified 0er) much
 Incerasedsaefyt:improvemnt in

maneuvearbility and satbility ofthe

vehicle

 Mo oromand less ewgiht: erslut in sanvgis

er fewercopmonents nitemrs

ofspace danwegiht

 Flexbility and ease omfaintenance

DISADVANTAGES

%' /eed (eparate air tan,

#' Thi( bra,e ()(tem i( co(tlier one'

?' Addition co(t i( required to in(tall thi( ()(tem to four wheeler

APPLICATIONS
 APPLICATIONS

%' 5our wheeler application

#' It i( al(o implemented in two wheeler
 DESCRIPTION OF
PNEUMATIC COMPONENTS
 DESCRIPTION OF PNEUMATIC COMPONENTS

%' Double acting air c)linder with pi(ton arrangement'

#' Spool 0al0e =# po(ition  port( 0al0e>

?' *neumatic fitting(

a' Bul, head

union b' 5le3ible

ho(e( c' Air

compre((or(

DOUBLE ACTING AIR CLINDER WITH PISTON ARRANGEMENT

It con(i(t( of a pi(ton in(ide a c)lindrical hou(ing called a barrel' Attached to

one end of the pi(ton i( a rod which the rod end ha( one port' Thi( rod end port i( u(ed

for

entrance of air and e3tend( out(ide one end of the c)linder' At another end i( a port for
e3it of air'

Double acting c)linder can be e3tended and retracted pneumaticall)' The (malle(t

bore (i;e of a double acting c)linder i( % %K inch' The pi(ton which i( made of ductile

Iron contain( u2cup pac,ing to (eal again(t lea,age

between the pi(ton and barrel' The port( are located in the end cap( which are (ecured

to the barrel b) bolt( and nut('

SPOOL VALVE

The (pool i( rod in K# 0alue( (o that K# 0al0e i( called -(pool

0al0e' It u(ed to change the path of flow of air'

DIRECTING CONTROL VALVES

A direction control 0al0e i( u(ed to change the direction of airflow a( and when

required b) the ()(tem for re0er(ing the machine tool de0ice(' A direction control 0al0e

ma) be cla((ified according to the con(truction of the internal mo0ing part( a(

%' otar) (pool T)pe'

#' Sliding Spool T)pe'

?' Solenoid operated 0al0e(

SOLENOID OPERATED VALVES

Solenoid 0al0e( are electromechanical de0ice( li,e rela)( and contra ctor(' A

(olenoid 0al0e i( u(ed to obtain mechanical mo0ement in machiner) b) utili;ing fluid or

air pre((ure' The fluid or air pre((ure i( applie d to the c)linder pi(ton through a 0al0e

operated b) a c)lindrical electrical coil' The electrical coil along with it( frame and

plunger i( ,nown a( the (olenoid and the a((embl) of (olenoid and mechanical 0al0e i(

,nown a( (olenoid 0al0e' The (olenoid 0al0e i( thu( another important

electromechanical de0ice u(ed in control of machine(' Solenoid 0al0e( are of two t)pe(

%' Single (olenoid (pring return operating 0al0e=K#>

#' Double (olenoid operating 0al0e'

In fig % i( (hown a (ingle (olenoid (pring return 0al0e in it( de2energi;ed condition' The

()mbol for the (olenoid and the return are al(o (ho wn' The (olenoid 0al0e i( (hown

connected to the c)linder to help reader( under(tand

the (olenoid 0al0e action' In the de energi;ed condition the plunger and the 0al0e (pool

po(ition a( (hown in figure %'

 K# <AY 1A81E

In thi( po(ition of (pool port * i( connected to port A and port B i( connected to tan, or

e3hau(t =i'e' atmo(phere> if air i( u(ed' Spring pre((ure =S> ,eep( the (pool in

thi(

cothilea( condition

loan(g

i( de

energi;ed' 5luid pre((ure from port * through port A i( applied to the left (ide of the

c)linder pi(ton' Thu( the c)linder pi(ton mo0e( in the right direction' /ow

when the (olenoid coil i( energi;ed plunger i( attracted and it pu(he( the (pool again(t

(pring pre((ure'

The new po(ition of plunger and (pool are (hown in fig #'
In thi( po(ition of (pool port A get( connected to tan, and port * get( connected to port

B' Thu( pre((ure i( applied to the c)linder pi(ton from right and mo0e( the pi(ton

rod to the left' At the (ame time fluid in the other (ide i( drained out to the tan,'

<hen the (olenoid coil i( again de energi;ed the (pring =S> will mo0e the (pool to it(

srcinal po(ition a( (hown in figure %' Thu( normall) when the (olenoid coil i( de

energi;ed the pi(ton rod remain( e3tended'

PNEUMATIC FITTINGS

There are no nut( to tighten the tube to the fitting( a( in the con0entional t)pe of

metallic fitting(' The tube i( connected to the fitting b) a (imple pu(h en(uring lea ,

proof connection and can be relea(ed b) pre((ing the cap and doe( not require an)

(pecial tooling li,e (panner to connect =or> di(connect the tube from the fitting'

SPECIFICATION OF THE FITTING

Bod)Material 2*la(tic

!ollectKThread /ipple 2 Bra((

Seal /2 itrateubber

5luidU(ed A2 ir

Ma3' 4perating *re((ure 2 C Bar

Tolerance on 4D of the tube( 2 ± %

mm Min' <all thic,ne(( of tube( 2%

mm'
FLE8IBLE HOSES

The *neumatic ho(e( which i( u(ed when pneumatic component( (uch

a( actuator( are (ub+ected to mo0ement' "o(e i( fabricated in la)er of

Ela(tomer or ()nthetic rubber which permit( operation at high pre((ure' The

(tandard out(ide diameter of tubing i( %K%& inch' If the ho(e i( (ub+ected to rubbing it

(hould be enca(ed in a protecti0e (lee0e'

 CONCLUSOIN

Bydo htis mini alb undesrat miporatnc

nig proejctwe weer e ot nd the e of

Coodrinaitonbewteenthe vaiorus deaprmtents ni

anmanufacutring unit

This brake system offers ample scope

forimprovementBy providing

interimtent forcet tahe brake ma ot achieves

plate.One of the maojr si ihtat

when
theoperatorsesabrakeforce,thathenedstoknow
immediately

srtike him, implynig htatthe desgins smiple adn

ealsyiundersatndable.Such

was the casewith AIR brakesystem.AIR Brake system

arehailed as the greastmecahnical cotnrviance.

 REFERENCE

 Henry Hartma n, Ma1tni Shaut, Antonio Pasuci,

Bernd Gombet.r

"eBrake® - the mechartonic wedgerabke," SAE

TehcnicalPaper Siesr, paperNo.2002-01-

2582,6 p,2002.

 “AutomoitveBraking hTom .Wbirch.

System” , by as

 “Automoitve Engnieering Fundamenatsl”by

RichadrStone,Jerffey .K

Bal

 Sigmar Mick,eRichadrE. Thompso,nBenrd-Hogler

Roehingl (1 90).

TheintroductionofAirDiscBrakesorfTrucks
enBduses ni EuropeS,AE

TechnicalPaperseries,paperNo.902 03.

 Richard Robrets, Bernd Gombet,r Hemy Hartma n,

Ditmar Lan,g&e

Martin Schuat."Tetisng the Mechartonic

WedgeBrake," SAE Technical

PaperSeires,paperNo2.0 4-0 1-276 , 9 p , 20 4.

 Theinvestigation ofdiscbrakemechanisms.-
MinskAutomotivePlant,

19 9. -lIp.

COST ESTIMATION
COST ESTIMATION

%' BA@E SYSTEM 22222222222222222 #$$$'$$

#' AI!Y8I/DE %%$$'$$

?' K# <AY 8E1E 4*EATED D!12222222 $$'$$

' 5abrication wor, 22222222222222222 %#$$'$$

' 1A81E!4//E!T4S2222222/4S22 ?$$'$$

&' &K *48YUET"A/E TUBE 222222#METE2222222222 #$$'$$

C' Tran(port co(t 22222222222222222222222222222222 ?$$'$$

LLLLLLLLLLLLLLL

Total &$$$'$$
 LLLLLLLLLLLLLLL

PHOTO VIEW
PHOTO VIEW