AUTOMATIC BRAKE FAILURE INDICATOR

CHAPTER 1: INTRODUCTION
A brake is a mechanical device that inhibits motion by slowing down a body
or by slowing it. Brakes retard the motion of a body creating friction between two
working surfaces and convert the kinetic energy of the moving body into heat.
Sometimes brake failure may occur when the brake lining is cut-off. Most brakes
commonly use friction between two surfaces pressed together to convert the kinetic
energy of the moving object into heat, though other methods of energy conversion
may be employed.

For example, regenerative braking converts much of the energy to electrical

energy, which may be stored for later use. Other methods convert kinetic energy
into potential energy in such stored forms as pressurized air or pressurized oil.
Eddy current brakes use magnetic fields to convert kinetic energy into electric
current in the brake disc, fin, or rail, which is converted into heat.

Still other braking methods even transform kinetic energy into different
forms, for example by transferring the energy to a rotating flywheel. Brakes are
generally applied to rotating axles or wheels, but also take other forms such as the
surface of a moving fluid (flaps deployed into water or air). Some vehicles use a
combination of braking mechanisms, such as drag racing cars with both wheel
brakes and a parachute, or airplanes with both wheel brakes and drag flaps raised
into the air during landing. The aim of this work is to design a braking system with
indicator. Brake failure occurs only because of worn out of brake shoe and cut in
liner. This system provides audio and visual alert when the brake fails.

DEPT OF EEE, BNMIT Page 1

AUTOMATIC BRAKE FAILURE INDICATOR

CHAPTER 2: PROBLEM STATEMENT

Automatic brake failure is designed for avoiding accidents due to brake
failure. It is the most effective and the simplest methodology used to reduce the
rate of accidents due to brake failure. Almost 40% of the accidents occur because
of brake failure issue. With early identification of this condition, we can reduce
accident rate.With the passage of time, today’s generation is growing up with the
dreams of high speed vehicles.

The problem is that as the birth ratio is increasing, the accidents are getting
in number which is one of the major problems faced in this era and it would be
rapidly increasing in the coming period. So, everyone tries to avoid accidents while
travelling but sometimes it is unavoidable. Accidents are happening at each nook
of the streets around the world. Lakhs of life result in death as an aspect of these
accidents.

As the population is increasing, the number of vehicles is increasing in the same

proportion. Which suggests there needs a lively hood of the brakes giving out. The
condition of brakes is regularly monitored by the brake failure indicator circuit.
The brake failure condition is sensed by the sensors attached to the circuit through
monitoring the brake switch. So, when the brake is applied it shows the condition
of brake everytime.

DEPT OF EEE, BNMIT Page 2

AUTOMATIC BRAKE FAILURE INDICATOR

CHAPTER 3. ARCHITECTURE OF AUTOMATIC

BRAKE FAILURE INDICATOR
The main purpose of the model is to efficiently recognize the fault in the
system and activate alarm system followed by emergency braking system. The
brake wire system is connected to the wire of the detection circuit which is
powered by a DC voltage source. it can be powered by solar charger. Whenever
there is a fault or break in the brake wire of the system this creates the condition of
circuit to work.

Figure.3.1: Block diagram of Brake Failure Indicator

The main components of EBS are the NE555 timer and the BC557 transistor
followed by braking mechanism to wheel.

The pnp junction transistor which is bs, 557 model is used to control the
light emitting diodes and the 5V buzzer. Whenever the wire which is managed to
connect in concurrence with the automobile braking wire. the transistor will get a
supply voltage of maximum voltage. This helps the circuit to work such that the
green diode itself glows, leaving the red led and the buzzer in turn off condition.

When there is circuit damage like abnormality in the brake wire condition
the transistor will be in off condition, then the green led will be turned off. Which
in turn activates the red led and the buzzer will be connected to the ground. The
timer used will be in Astable condition. This gives the blinking of led or the beep
sound.

DEPT OF EEE, BNMIT Page 3

AUTOMATIC BRAKE FAILURE INDICATOR

Figure 3.2: Circuit Diagram of Brake Failure Indicator

The detailed diagram of circuit and EBS are depicted above. can observe that
the failure in brake system alerts the timer which periodically checks for voltage
provided across the terminals and gives the audio and visual output to the driver as
red light and buzzer sound. This activates the emergency braking system. The
motor rotates the wheel at an angle of 90° .then the hydraulic system lowers the
emergency wheels to reach the ground to make in synchronization with the vehicle
velocity. Now at this movement driver can activate the emergency brakes attached
to these wheels in addition to pressing the clutch so that engine won’t be powering
the vehicle. The whole process will take less time if it use efficient spares and
standard mechanisms. This will slow down the vehicle and stops at certain point.
To avoid the major accidents which are caused by brake failures can be reduced
using this mechanism.

DEPT OF EEE, BNMIT Page 4

AUTOMATIC BRAKE FAILURE INDICATOR

CHAPTER 4: SOFTWARE AND HARDWARE REQUIREMENTS

4.1. SOFTWARE

Fig.4.1:Logo of software

TINKERCAD

Autodesk Tinker cad is a free browser-based CAD program. It is made with

makers in mind, supporting file export for 3D-printing and laser cutting. It is
amazingly powerful easy to use tool for creating digital designs that are ready to be
3D printed into physical objects. Tinker cad Circuits allows anyone to virtually
create and program Arduino projects without the need for physical hardware. In the
user’s dashboard, we can find a whole section devoted to circuit projects. It is
organized similarly to the CAD project gallery, making it easy to navigate. It
allows users to have hands on experience which is a must require facet for the
students to retain their knowledge. It helps learners to gather problem solving,
action oriented and human centered skills with the ability to create various kinds of
3D – printable models. Tool – Free browser Based Modeling software.
Compatibility – Runs on window, MAC and Linux operating system. Works best
with chrome

DEPT OF EEE, BNMIT Page 5

AUTOMATIC BRAKE FAILURE INDICATOR

4.2. HARDWARE REQUIREMENT

1.555 TIMER IC

Fig.4.2.1 555Timer

The 555 timer IC is an integrated circuit (chip) used in a variety of timer,

delay, pulse generation, and oscillator applications. Derivatives provide two (556)
or four (558) timing circuits in one package.

Depending on the manufacturer, the standard 555 package includes

25 transistors, 2 diodes and 15 resistors on a silicon chip installed in an 8-pin dual
in-line package (DIP-8). Variants available include the 556 (a DIP-14 combining
two complete 555s on one chip), and 558 / 559 (both a DIP-16 combining four
reduced-functionality timers on one chip).

The NE555 parts were commercial temperature range, 0 °C to +70 °C, and

the SE555 part number designated the military temperature range, −55 °C to +125
°C. These were available in both high-reliability metal can (T package) and
inexpensive epoxy plastic (V package) packages. Thus the full part numbers were
NE555V, NE555T, SE555V, and SE555T.
Low-power CMOS versions of the 555 are also available, such as the
ICM7555 and Texas Instruments LMC555, TLC555, TLC551. CMOS timers use
significantly less power than bipolar timers; CMOS timers also cause less supply
noise than bipolar version when the output switches states.

DEPT OF EEE, BNMIT Page 6

AUTOMATIC BRAKE FAILURE INDICATOR

2. RESISTORS

Fig.4.2.2 Resistor(440kΩ)

A resistor is passive two terminal components that implements electrical

resistance as a circuit element. In electronic circuits, resistors are used to reduce
current flow, adjust signal levels, to divide voltages, bias active elements, and
terminate transmission lines, among other uses
. High-power resistors that can dissipate many watts of electrical power as
heat, may be used as part of motor controls, in power distribution systems, or as
test loads for generators. Fixed resistors have resistances that only change slightly
with temperature, time or operating voltage. Variable resistors can be used to
adjust circuit elements (such as a volume control or a lamp dimmer), or as sensing
devices for heat, light, humidity, force, or chemical activity.
Resistors are common elements of electrical networks and electronic
circuits and are ubiquitous in electronic equipment. Practical resistors as discrete
components can be composed of various compounds and forms. Resistors are also
implemented within integrated circuits.
The electrical function of a resistor is specified by its resistance: common
commercial resistors are manufactured over a range of more than nine orders of
magnitude. The nominal value of the resistance falls within the manufacturing
tolerance, indicated on the component.

DEPT OF EEE, BNMIT Page 7

AUTOMATIC BRAKE FAILURE INDICATOR

3. CAPACITORS

Fig.4.2.3: Capacitor(1µF)

A capacitor is a device that stores electrical energy in an electric field. It is

a passive electronic component with two terminals. The effect of a capacitor is
known as capacitance. While some capacitance exists between any two electrical
conductors in proximity in a circuit, a capacitor is a component designed to add
capacitance to a circuit. The capacitor was originally known as a condenser this
name and its cognates are still widely used in many languages, but rarely in
English, one notable exception being condenser microphones, also called capacitor
microphones. The physical form and construction of practical capacitors vary
widely and many types of capacitor are in common use. Most capacitors contain at
least two electrical conductors often in the form of metallic plates or surfaces
separated by a dielectric medium. A conductor may be a foil, thin film, sintered
bead of metal, or an electrolyte. The no conducting dielectric acts to increase the
capacitor's charge capacity. Materials commonly used as dielectrics
include glass, ceramic, plastic film, paper, mica, air, and oxide layers. Capacitors
are widely used as parts of electrical circuits in many common electrical devices.
Unlike a resistor, an ideal capacitor does not dissipate energy, although real-
life capacitors do dissipate a small amount (see Non-ideal behavior). When
an electric potential difference (a voltage) is applied across the terminals of a
capacitor, for example when a capacitor is connected across a battery, an electric
field develops across the dielectric, causing a net positive charge to collect on one
plate and net negative charge to collect on the other plate. No current actually
flows through the dielectric.

DEPT OF EEE, BNMIT Page 8

AUTOMATIC BRAKE FAILURE INDICATOR

4. LED LIGHTS

Fig.4.2.4:LED LIGHTS

A light-emitting diode (LED) is a semiconductor light source that emits

light when current flows through it. Electrons in the semiconductor recombine
with electron holes, releasing energy in the form of photons. The color of the light
(corresponding to the energy of the photons) is determined by the energy required
for electrons to cross the band gap of the semiconductor. Appearing as practical
electronic components in 1962, the earliest LED emitted low-
intensity infrared (IR) light. Infrared LEDs are used in remote-control circuits,
such as those used with a wide variety of consumer electronics. The first visible-
light LEDs were of low intensity and limited to red. Modern LEDs are available
in visible, ultraviolet (UV), and infrared wavelengths, with high, low, or
intermediate light output. Early LEDs were often used as indicator lamps,
replacing small incandescent bulbs, and in seven-segment displays. Recent
developments have produced high-output white light LEDs suitable for room and
outdoor area lighting. LEDs have given rise to new type of displays and sensors,
while their high switching rates are useful in advanced communications
technology.

DEPT OF EEE, BNMIT Page 9

AUTOMATIC BRAKE FAILURE INDICATOR

5. TRANSISTOR

Fig.4.2.4: Transistor(PNP)

A transistor is a semiconductor device used to amplify or switch electronic

signals and electrical power. Transistors are one of the basic building blocks of
modern electronics.
 It is composed of semiconductor material usually with at least
three terminals for connection to an external circuit.
A voltage or current applied to one pair of the transistor's terminals controls
the current through another pair of terminals. Because the controlled (output)
power can be higher than the controlling (input) power, a transistor can amplify a
signal. Today, some transistors are packaged individually, but many more are
found embedded in integrated circuits.
Austro-Hungarian physicist Julius Edgar Lilienfeld proposed the concept of
a field-effect transistor in 1926, but it was not possible to actually construct a
working device at that time. 
Most transistors are made from very pure silicon, and some
from germanium, but certain other semiconductor materials are sometimes used. A
transistor may have only one kind of charge carrier, in a field-effect transistor, or
may have two kinds of charge carriers in bipolar junction transistor devices.
Compared with the vacuum tube, transistors are generally smaller and require less
power to operate.

6. BUZZER

DEPT OF EEE, BNMIT Page 10

AUTOMATIC BRAKE FAILURE INDICATOR

Fig.4.2.6:Buzzer

A buzzer or beeper is an audio signaling device, which may

be mechanical, electromechanical, or piezoelectric (piezo for short). Typical uses
of buzzers and beepers include alarm devices, timers, and confirmation of user
input such as a mouse click or keystroke.

7. BREAD BOARD

Fig.4.2.7: Bread Board

A breadboard is a construction base for prototyping of electronics.

The solder less breadboard does not require soldering, it is reusable. This makes it
easy to use for creating temporary prototypes and experimenting with circuit
design. For this reason, solderless breadboards are also popular with students and
in technological education.

DEPT OF EEE, BNMIT Page 11

AUTOMATIC BRAKE FAILURE INDICATOR

8. BATTERY

Fig.4.2.8:Battery(9V)

A battery is a source of electric power consisting of one or

more electrochemical cells with external connections for powering electrical
devices such as flashlights, mobile phones, and electric cars.
When a battery is supplying electric power, its positive terminal is
the cathode and its negative terminal is the anode. The terminal marked negative is
the source of electrons that will flow through an external electric circuit to the
positive terminal. When a battery is connected to an external electric load,
a redox reaction converts high-energy reactants to lower-energy products, and
the free-energy difference is delivered to the external circuit as electrical
energy. Historically the term "battery" specifically referred to a device composed
of multiple cells, however the usage has evolved to include devices composed of a
single cell.
Primary (single-use or "disposable") batteries are used once and discarded,
as the electrode materials are irreversibly changed during discharge; a common
example is the alkaline battery used for flashlights and a multitude of portable
electronic devices
CHAPTER 5: SYSTEM IMPLEMENTATION
5.1. System Implementation

DEPT OF EEE, BNMIT Page 12

AUTOMATIC BRAKE FAILURE INDICATOR

Fig.5.1: Simulated circuit

The proposed circuit can be easily engineered on any board like in this case
bread board is used, pcb board makes the circuit even more simpler to make it
rigid whenever the copper wire which is termed as brake wire is cut the timer
operates in astable mode it makes the transistor off so it turns off the green led the
red led and the buzzer will be in ON condition.

A 555 Timers in Astable Mode

This mode helps in timer to be precisely used for the control of turning on
and off of the led’s this mechanism happens in a periodic fashion for certain time
it will be considered as on time, and off time the internal structure of timer has
resistors and a capacitor to calculate the specific on and off times the formulas for
calculation for the astable mode working of the timer is given below.

5.2. Calculations

Time1 =0.693*(R1+R2)*C1=0.693(1K+440K)*(1mF)=0.305ms

DEPT OF EEE, BNMIT Page 13

AUTOMATIC BRAKE FAILURE INDICATOR

Time2 = 0.693*R2*C1=0.693*440K*1mF=0.304ms

T = (T1+T2) =0.609ms

Frequency (F) = 1/T=1.6379

D duty cycle = Time1/(Time1+Time2)=0.5005675

R1 Ω R2 Ω C1 (F) T1 T2 T F
1000 44000 0.000001 0.305613 0.30492 0.610533 1.63

Table 5.2.1 Operation of 555 timer in astable mode

R1, R2 - Resistors, C1, C2 – Capacitors, T1&T2 are ON and OFF times for timer -
Time Period - Frequency.

Fig.5.2.2: Waveforms of 555Timer

5.3. WORKING

i. It is a device used for avoiding accidents. This circuit is continuously

monitor the conditions of brake and gives audio visual indication.

DEPT OF EEE, BNMIT Page 14

AUTOMATIC BRAKE FAILURE INDICATOR

ii. If the brake system is intact then green LED blinks and for around one
second and when the brake fails the buzzer beeps and also only red will LED
glows.

iii. Then emergency breaking mechanism is also powered the motor rotates the
wheel to angle of 90° angle so that it aligns under the vehicle.

iv. The hydraulic system works (or a hydraulic drive system) is a transmission
system that uses pressurized hydraulic fluid to power hydraulic machinery.

v. This will lower the wheel slowly to certain height and makes the wheels to
lift 1cm above ground balances the system and runs with its own speed

vi. Now they can apply the hand brake to stop it completely and vehicle stops
eventually

vii. Instead of applying hand brake suddenly (which leads to accident) one can
stop the vehicle through this method safely.

Condition of wire attached Circuit output Emergency

to brake wire Braking system

Good Green LED ON OFF State

DEPT OF EEE, BNMIT Page 15

AUTOMATIC BRAKE FAILURE INDICATOR

Slightly damaged Green LED with slight OFF State

Red LED output

Wire disconnection or cut Red LED with Buzzer ON State(Fully

Sound Activated)

Table.5.3.1:Mechanism of how EBS works

CHAPTER 6: RESULTS AND DISCUSSION

6.1: WORKING
Under normal condition

DEPT OF EEE, BNMIT Page 16

AUTOMATIC BRAKE FAILURE INDICATOR

Fig.6.1.1: Working under normal condition

Under brake fault condition

Fig.6.1.2:Working when fault occurs

The main purpose of this project is to supply such a tool to vehicles operator
in order that any harmful harm and damages accidents caused by failure of brake
may be simply prevented by the correct indication of operating condition of brake.
This system endlessly monitors the condition of the brake wire and alerts the rider
before it gets cut. The indication to the rider is given within the type of audio sign.
The entire elements area unit placed rigorously, therefore contributory to the most
effective working of the unit. Therefore the project has been with success designed
and tested. The emergency braking system will be a new era of vehicle protection
system if implemented in any motor vehicles to protect them from accidents.
There have been many devices to stop the vehicle at abnormal conditions. But the
proposed model deals with application of brake before any accident could happen
and also ensures the safety of human as well as vehicle.

DEPT OF EEE, BNMIT Page 17

AUTOMATIC BRAKE FAILURE INDICATOR

CHAPTER NO 7: ADVANTAGES AND DISADVANTAGES

7.1 ADVANTAGES

DEPT OF EEE, BNMIT Page 18

AUTOMATIC BRAKE FAILURE INDICATOR

 Economical .
 Circuit is very simple.
 It is not dependent on Fuel level.
 Very less power consumption.
 There is no necessity of an external battery as circuit uses the battery of the
vehicle itself.

7.2 DISADVANTAGES

 The break switch stops functioning if there is any leakage of fluid as it is

fluid operated.
 As battery is used for both car and Brake Failure Indicator circuit, battery
charge may reduce.
 This system can only be used for negatively grounded vehicles.

CHAPTER 8: CONCLUSION

DEPT OF EEE, BNMIT Page 19

AUTOMATIC BRAKE FAILURE INDICATOR

The main purpose of this project is to provide such a device to vehicles

operator so that any harmful damage and accidents caused by failure of brake can
be easily prevented by the proper indication of working condition of brake. This
system continuously monitors the condition of the brake wire and alerts the rider
before it gets cut. The indication to the rider is given in the form of audio visual
signal. All the components are placed carefully, thus contributing to the best
working of the unit. Thus the project has been successfully designed and tested.

CHAPTER 9: REFERENCES

DEPT OF EEE, BNMIT Page 20

AUTOMATIC BRAKE FAILURE INDICATOR

[1] Radhakishan Maske, Satesh Surwase, Balbhim Moharir, Vrushabh Mahajan,

Vijay Kedar, Prof.Amol Adkine “Automatic brake failure indicator and braking
system”in International Journal of Advance Research and Innovative Ideas in
EducationVol-3 Issue-3 2017
http://ijariie.com/AdminUploadPdf/AUTOMATIC_BRAKE_FAILURE_INDICA
TOR_AND_BRAKING_SYSTEM_ija riie5483.pdf

[2] N.Venkatachalapathi, V. Mallikarjuna “Automatic Brake Failure Indicator and

Over Heating Alarm”in International Journal of Engineering Science and
Computing, Volume 6 Issue No. 7 July 2016
http://ijesc.org/upload/99d41a4418e5e416d392fe63ff706e92.Automatic%20Brake
%20Failure%20Indicator%20and%20 Over%20Heating%20Alarm.pdf

[3] Pandit Biradar, Jitendra Baravkar, Komal Bhujbal, Avi Bhapkar “Automatic
Brake Failure Detection with Auxiliary Braking System”in International Journal
for Science and Advance Research in Technology Volume 2 Issue 3 –MARCH
2016

http://ijsart.com/Content/PDFDocuments/IJSARTV2I3845.pdf

[4] K.Mohan, G.Pugazhendhi “Accidents Avoiding System Indicator Due To

Brake Failure”in Asian Journal of Applied Science and Technology, Volume 1,
Issue 6, Pages 03-07, July 2017 http://ajast.net/data/uploads/002.pdf

[5] Vishal Pagar, Pravin Shewale, Harshad Savkar, Bhushan Surale, Vikram
Londhe “Automatic Brake Fluid Leakage Prevention with Safety Bypass Braking
System”in International Journal for Scientific Research & Development|, Vol. 5,
Issue 12, 2018 http://www.ijsrd.com/articles/IJSRDV5I120116.pdf

DEPT OF EEE, BNMIT Page 21