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Intelligent Braking System - Project Report
Intelligent Braking System - Project Report
SYSTEM
PROJECT REPORT
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INTELLIGENT BRAKING SYSTEM
of
Bachelor of Technology
in
Mechanical Engineering
Submitted by
Head of Department
Of
Mechanical Engineering
2015-2016
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TABLE OF CONTENTS
S.NO. TOPIC PAGE NO.
1 CANDIDATE’S DECLARTION 4
2 CERTIFICATE 5
3 ACKNOWLEDGEMENT 6
4 ROLE AND RESPONSIBILITIES 7
5 PERSONAL ENGINEERING 8
ACTIVITY
6 ABSTRACT 9
7 INTRODUCTION 10
8 RELATED WORK 12
9 MAIN COMPONENTS 14
10 DESCRIPTION OF EQUIPMENT 15
11 DESIGN 39
12 WORKING PRINCIPLE 42
13 BLOCK DIAGRAM 43
14 APPLICATIONS 44
15 ADVANTAGES & 44
DISADVANTAGES
16 CONCLUSION 45
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CANDIDATE’S DECLARTION
I hereby certify that the work which is being presented by Amit Jaiswal, Ajay
Singh Chauhan, Rajeev Kumar, Raman Kumar, Vijay Kumar in partial fulfillment
of requirement for the award of degree of B.Tech. in MECHANICAL ENGINEERING
submitted at KALPI INSTITUTE OF TECHNOLOGY under KURUKSHETRA
UNIVERSITY, KURUKSHETRA is an authentic record of my own work carried out
under the supervision of Er. Harish Kumar Sharma (HOD) and Er. Vikas Kunnar.
Project Member:
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CERTIFICATE
Mr.........................
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ACKNOWLEDGEMENT
First of all we would like to thank our project guide Mr. ......................
Assistant Professor, Mechanical engineering Department, Kurukshetra
University who has given valuable support during the course of our
project by clarifying our doubts and guiding us with her novel ideas.
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Role and Responsibilities
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PERSONAL ENGINEERING ACTIVITY
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ABSTRACT
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INTRODUCTION
The “PNEUMATIC BRAKEING CIRCUIT” can stop the vehicle within 2 to 3 seconds
running at a speed of 50 KM. The intelligent breaking system is a fully automation
project. 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.
Degrees of automation are of two types, viz.
Full automation.
Semi automation.
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There is any obstacle in the path, the IR sensor senses the obstacle and giving the
control signal to the breaking system. The pneumatic breaking system is used to
brake the system. So basically here the car brakes on its own by determining the
distance from the object.
If the solenoid valve is activated, the compressed air passes to the Single Acting
Pneumatic Cylinder. The compressed air activate the pneumatic cylinder and
moves the piston rod. If the piston moves forward, then the breakng arrangement
activated. The breaking arrangement is used to break the wheel gradually or
suddenly due to the piston movement.
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The breaking speed is varied by adjusting the valve is called“FLOW CONTROL
VALVE”.The compressed air flow through the Polyurethene tube to the flow
control valve. The flow control valve is connected to the solenoid valve.
RELATED WORK
Accidents are considered as non-avertable. Accidents occur due technical
problems within the vehicle or due the mistakes of the drivers. Sometimes the
drivers may become fatigue and they lose the control over the vehicle and
sometimes the accidents occur due to drunken drivers and sometimes due to rash
driving. In all these cases the accidents occur because the brakes are not applied
at right time. When the drivers come to know that the vehicle is going to collide
they become nervous and they don’t apply the brakes. Majority of the accidents
occur only this way.
The system designed will prevent such accidents. It keeps track of any vehicles in
front. It will continuously keep track of the distance between the two vehicles.
When two come dangerously close the microprocessor in the system will activate
the brakes and it will slow down the vehicle or bring it to a stop if needed.
NEED FOR THIS SYSTEM
ACCIDENTS
Accidents are resulting in loss of invaluable lives, materials and money. So far the
accident preventing systems are not very efficient and the loss of lives is
continuing. There are many systems like air bags, GPS, robot driven cars, tracked
cars etc which can avert accidents to some extent.
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CAUSES OF ACCIDENTS:
There are many causes of accidents. Some of them are
In all these cases the basic reason cited is failure to apply the brakes at the right
time. In all the above cases if the brakes are applied at the right time the
accidents can be averted. If a system is developed, which applies the brakes at the
time of accidents automatically will avert accidents, which are caused by all the
above reasons. This project aims to overcome the mistake made by the drivers
and at the time of accidents the system takes control of the vehicle and brings the
vehicle to stop before colliding.
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MAIN COMPONENTS
FRAME
WHEELS
PNEUMATIC CYLINDERS
AIR COMPRESSOR
SOLENOID VALVE
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DESCRIPTION OF EQUIPMENT
The key part of any pneumatic system for supply of compressed air is by means
using reciprocating compressor. A compressor is a machine that takes in air, gas
at a certain pressure and delivers it at a higher pressure. Compressor capacity is
the actual quantity of air compressed and delivered. And the volume expressed is
that of the air at intake conditions namely at atmosphere pressure and normal
ambient temperature.
Clean condition of the suction air is one of the factors, which decides the life of a
compressor. Warm and moist suction air will result in increased precipitation of
condense from the compressed air.
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Turbo compressors are employed where large capacity of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
application unless built in multistage designs and are seldom encountered in
pneumatic service.
RECIPROCATING COMPRESSORS:
Built for either stationary (or) portable service the reciprocating compressor is by
far the most common type. Reciprocating compressors deliver more than 500
m³/min. In single stage compressor, even if the air pressure is of 6 bar, the
machines can discharge pressure of 15 bars. Discharge pressure in the range of
250 bars can be obtained with high pressure reciprocating compressors that of
three & four stages. Single stage and 1200 stage models are particularly suitable
for pneumatic applications , with preferences going to the two stage design as
soon as the discharge pressure exceeds 6 bar, because it in capable of matching
the performance of single stage machine at lower costs per driving powers in the
range.
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Air Compressor
2. Turbo compressor
Positive displacement:-
• Piston-type air compressors use this principle by pumping air into an air
chamber through the use of the constant motion of pistons. They use one-way
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valves to guide air into a cylinder chamber, where the air is compressed. Rotary
screw compressors use positive-displacement compression by matching two
helical screws that, when turned, guide air into a chamber, whose volume is
decreased as the screws turn.
• Vane compressors use a slotted rotor with varied blade placement to guide
air into a chamber and compress the volume. A type of compressor that delivers a
fixed volume of air at high pressures.
Negative displacement:-
Cooling:-
Applications:-
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• To supply moderate-pressure clean air for driving some office and school
building pneumatic HVAC control system valves.
Most air compressors either are reciprocating piston type, rotary vane or rotary
screw. Centrifugal compressors are common in very large applications. There are
two main types of air compressor's pumps: oil-lubed and oil-less. The oil-less
system has more technical development, but is more expensive, louder and lasts
for less time than oil-lubed pumps. The oil-less system also delivers air of better
quality.
Repair leaks
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PNEUMATIC CONTROL COMPONENT:
PNEUMATIC CYLINDER
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Key points:-
• Custom designs can perform better and save money when standard
cylinders don’t fit the job.
Resources:-
Pneumatic cylinders are widely used to generate force and motion on a vast range
of OEM equipment. They can move products directly or indirectly by pushing,
pulling, lifting, lowering, or rotating, and can keep them from moving by clamping
them in place.
Wide acceptance comes in large part because cylinders are simple, economical,
durable, and easy to install. They can produce thousands of pounds of force over
a broad range of velocities; cycle at high speeds without overheating; and stall
without internal damage. And they readily tolerate tough conditions such as high
humidity, dusty environments, and repetitive high-pressure wash downs.
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Cylinder design:-
The basic, rod-style industrial cylinder consists of a tube sealed by end caps. A rod
attached to an internal piston extends through a sealed opening in one of the
ends. The cylinder mounts to a machine and the piston rod acts upon the load.
A port at one end of the cylinder supplies compressed air to one side of the
piston, causing it (and the piston rod) to move. The port at the other end lets air
on the opposite side of the piston escape — usually to atmosphere. Reversing the
roles of the two ports makes the piston and rod stroke in the opposite direction.
Rod-style cylinders function in two ways:
Double-acting cylinders use compressed air to power both the extend and retract
strokes, moving the rod back and forth. This arrangement makes them ideal for
pushing and pulling loads. Controlling the rate at which air exhausts determines
rod speed.
Single-acting cylinders have compressed air supplied to only one side of the
piston; the other side vents to atmosphere. Depending on whether air is routed
to the cap or rod end determines whether the rod extends or retracts.
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Rod-style cylinders come in various designs:-
Compact:-
Cylinders fit into smaller spaces where only a short stroke is required. They are
used in lighter-duty applications due to the small bearing surface on which the
rod slides. They mainly come in single-acting versions, but double-acting styles
also are available.
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Guided :-
Cylinders have guide rods and guide blocks mounted parallel to the piston rod, or
dual piston rods. They prevent the piston from rotating and provide precise,
controlled linear motion — especially when the unit is subject to high side loads.
In such cases, the guides reduce rod and piston bending and uneven seal wear.
They are recommended in applications with sizeable offset loads or require that
the load be guided, for example, down a conveyor.
A double acting cylinder is employed in control systems with the full pneumatic
cushioning and it is essential when the cylinder itself is required to retard heavy
loads. This can only be done at the end positions of the piston stock. In all
intermediate positions a separate externally mounted cushioning device must be
provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the end of the
stock is required. As a result the sit in the cushioning chamber is again
compressed since it cannot escape but slowly according to the setting made on
reverses.
The air freely enters the cylinder and the piston stokes in the other direction at
full force and velocity.
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Double Acting Cylinder
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SINGLE ACTING CYLINDER:
VALVES:
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SOLENOID VALVE: (Direction Control Valve:-)
Directional control valves are one of the most fundamental parts in hydraulic
machinery as well and pneumatic machinery. They allow fluid flow into different
paths from one or more sources. They usually consist of a spool inside a cylinder
which is mechanically or electrically controlled. The movement of the spool
restricts or permits the flow, thus it controls the fluid flow.
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The directional valve is one of the important parts of a pneumatic system.
Commonly known as DCV, this valve is used to control the direction of air flow in
the pneumatic system. The directional valve does this by changing the position of
its internal movable parts.
This valve was selected for speedy operation and to reduce the manual effort and
also for the modification of the machine into automatic machine by means of
using a solenoid valve.
A solenoid is an electrical device that converts electrical energy into straight line
motion and force. These are also used to operate a mechanical operation which in
turn operates the valve mechanism. Solenoids may be push type or pull type.
The push type solenoid is one which the plunger is pushed when the solenoid is
energized electrically. The pull type solenoid is one is which the plunger is pulled
when the solenoid is energized.
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PARTS OF A SOLENOID VALVE:
A. COIL:
The solenoid coil is made of copper wire. The layers of wire are separated by
insulating layer. The entire solenoid coil is covered with a varnish that is not
affected by solvents, moisture, cutting oil or often fluids. Coils are rated in various
voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts DC,
12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC. They are designed for such
frequencies as 50 Hz to 60 Hz.
B. FRAME:
The solenoid frame serves several purposes. Since it is made of laminated sheets,
it is magnetized when the current passes through the coil. The magnetized coil
attracts the metal plunger to move. The frame has provisions for attaching the
mounting. They are usually bolted or welded to the frame. The frame has
provisions for receivers, the plunger. The wear strips are mounted to the solenoid
frame, and are made of materials such as metal or impregnated less fiber cloth.
C. SOLENOID PLUNGER
The Solenoid plunger is the mover mechanism of the solenoid. The plunger is
made of steel laminations which are riveted together under high pressure, so that
there will be no movement of the lamination with respect to one another. At the
top of the plunger a pin hole is placed for making a connection to some device.
The solenoid plunger is moved by a magnetic force in one direction and is usually
returned by spring action.
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Solenoid operated valves are usually provided with cover over either the solenoid
or the entire valve. This protects the solenoid from dirt and other foreign matter,
and protects the actuator. In many applications it is necessary to use explosion
proof solenoids.
The solenoid valve has 5 openings. This ensures easy exhausting of 5/2 valve. The
spool of the 5/2 valve slide inside the main bore according to spool position; the
ports get connected and disconnected. The working principle is as follows
POSITION-1
When the spool is actuated towards outer direction port ‘P’ gets connected to ‘B’
and ‘S’ remains closed while ‘A’ gets connected to ‘R’
POISITION-2
When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets connected to
each other and ‘B’ to ‘S’ while port ‘R’ remains close
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5/2 Way Solenoid Valve Sectional View
The control valve is used to control the flow direction is called cut off valve or
solenoid valve. This solenoid cut off valve is controlled by the electronic control
unit.
In our project separate solenoid valve is used for flow direction of vice cylinder. It
is used to flow the air from compressor to the single acting cylinder.
In any fluid power circuit, flow control valve is used to control the speed of the
actuator. The flow control can be achieved by varying the area of flow through
which the air in passing.
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When area is increased, more quantity of air will be sent to actuator as a result its
speed will increase. If the quantity of air entering into the actuator is reduced, the
speed of the actuator is reduced.
Flow control valves facilitate high precision adjustment of flow volumes and are
used to precisely control the piston speed of a drive.
For adjustable speed via exhaust air flow control. The piston moves between air
cushions created through freely flowing supply air and restricted exhaust air. The
benefit is improved operating behaviour, even in the event of load changes
For adjustable speed via supply air flow control. The piston is moved via an air
cushion at one end, created by freely flowing exhaust air and restricted supply air.
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In contrast with exhaust air restriction, there is a tendency towards a stick-slip
effect.
HOSES
Hoses used in this pneumatic system are made up of polyurethane. These hose
can with stand at a maximum pressure level of 10 N/m². Polyurethane combines
the best properties of both plastic and rubber. It offers abrasion and tear
resistance, high tensile and elongation values, and low compression set.
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Polyurethane is naturally flexible and exhibits virtually unlimited flexural abilities.
Combining good chemical resistance with excellent weathering characteristics
sets polyurethane apart from most other thermoplastics. It has exceptional
resistance to most gasolines, oils, kerosene, and other petroleum based
chemicals, making it an ideal choice for fuel lines (although additives in today’s
gasoline and petroleum products warrant field testing).
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APPLICATIONS OF PU TUBE:
• Any time condensation can occur with small actuators, air grippers and air
operated valves. Condensation in a pneumatic system will cause operating failure
and affect the life of pneumatic equipment.
• When you need to eliminate water condensation but you cannot use a
membrane or desiccant dryer (as you cannot use a fast exhaust).
BENEFITS OF PU TUBE:
• Prevents operational failure of small actuators, air grippers and pilot operated
valves due to condensation.
• Easy mounting.
CONNECTORS:
In our system hose connectors are used . Hose connectors normally comprise an
adoptee hose nipple. These types of connectors are made up of brass (or)
Aluminum (or) hardened pneumatic steel. For these type hose connectors no
need of hose clamp these are self-locking hose connectors. a Multi way four way
hose connecter.
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The universal combination at an attractive price. Can be widely used thanks to
resistant materials. Easy to install thanks to optimised bending radii. Limited reset
effect. Attractively priced: the universal solution for metal fittings. Perfect for
standard pneumatic applications – in many different fields. Wide range of variants
Over 1000 types for maximum flexibility in standard applications. Hydrolysis
resistant For applications in damp environments or in contact with water at up to
60 °C. Resistant to pressure Secure connection when used with pressure ranges of
up to 14 bar. Economical for pneumatic installations in the high pressure ranges.
Hose Connector
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fitting Approved for the food Industry Food and Drug Administration certification
for use in the food industry:
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applications in direct proximity to welding splatter Double-sheathed tube and
special fitting.
CONTROL UNIT
The nozzles welded to the fan can be rotated in either direction. The rpm and
torque of the shaft depends upon the pressure of the air admitted so by varying
the pressure, the RPM and torque can be varied. Thick tubes interconnect the
parts. The Clamps are used at the connecting parts to prevent leakage. In thread
parts seals are used to prevent leakage.
The compressed air from the compressor first enters the control unit. In the
control unit the pressure of the air is controlled and sent to the barrel to rotate
the fan in the required direction. The gate valve controls the pressure and volume
of air. Then the pressure is read by a pressure gauge. Later the air is admitted to
the barrel, a shaft is placed and it carries the fan.
The shaft is supported by bearing. The bearings are placed in the couplings, which
covers the end of barrel.
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DESIGN
FRAME
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WHEELS
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PNEUMATIC CYLINDER
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WORKING OPERATION
The IR receiver circuit receives the reflected IR rays and giving the control signal
to the control circuit. The control circuit is used to activate the solenoid valve. The
operating principle of solenoid valve is already explained in the above chapter.
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BLOCK DIAGRAM
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APPLICATION
ADVANTAGES
DISADVANTAGES
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CONCLUSION
The Intelligent Braking system, if implemented can avert lots of accidents
and can save invaluable human lives and property. Implementation of such
an advanced system can be made compulsory similar to wearing of seat belts so
that accidents can be averted to some extent. Our Intelligent braking system
provides a glimpse into the future of automotive safety, and how much more
advanced these individual systems can be for avoiding accidents and protecting
vehicle occupants when they are integrated into one system.
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