1

CONTENTS ABSTRACT LIST OF FIGURES

1.

-IV -V -5 -8

INTRODUCTION
1.1.

TYPES OF BRAKES
1.1.1. 1.1.2. 1.1.3. 1.1.4. 1.1.5. 1.1.6.

MECHANICAL BRAKES -11 HYDRAULIC BRAKES -12 AIR BRAKES ELECTRICAL BRAKES -13 VACCUM BRAKES REGENERATIVE BRAKES -14 -16 -16 -14 -13

1.2.

IR SENSOR
1.2.1. 1.2.2. 1.2.3. 1.2.4.

SENSORS TYPES OF SENSORS -16 IR TRANSMITTER IR RECIEVER

-18 -18 -19

2. 3.

LITERATURE SURVEY COMPONENTS AND DESCRIPTION -21

3.1.

SELECTION OF PNEUMATICS -21

2 PNEUMATIC COMPONENTS AND ITS DESCRIPTION

3.2.1. 3.2.2. 3.2.3. 3.2.4.

-21

PNEUMATIC SINGLE ACTING CYLINDER -22 SOLENOID VALVE FLO! CONTROL VALVE -28 IR SENSOR UNIT IR TRANSMITTER CIRCUIT -3" IR RECIEVER CIRCUIT -31 -29 -26

3.2.4.1. 3.2.4.2. 3.2.5. 3.2.6. 3.2.7. 3.2.8. 3.3. 3.4. 3.5. 3.6. 4. 5. 6.

!HEEL AND BRAKE ARRANGEMENT -32 CONNECTOR# REDUCER# HOSE COLLAR -33 STAND SINGLE PHASE ACTING INDUCTION MOTOR -33 -33

BLOCK DIAGRAM OF IBS -3$ CIRCUIT DIAGRAM OF IBS -38 LAYOUT OF THE IBS !ORKING OPERATION -42 -39

APPLICATIONS AND ADVANTAGES -44 COST ESTIMATION CONCLUSION -45 -46

3 7.

REFERENCES

-4$

ABSTRACT Braking is nothing but bringing a moving vehicle or moving body to a stop. o!adays sa"ety is an important "eature in the automotive industry. #he intelligent braking system is the ne$t step to automation. %resently cars have the alarm system !here !hen the car gets too close to an ob&ect an alarm is triggered !hich !arns the driver about an ob&ect close by. But this "eature has produced lot o" problems and are prone to human error. 'e have enhanced the "acility by using the same system but !e have altered it so that the car brakes automatically !hen an obstacle is close by. #he aim is to design and develop a control system based on intelligent electronically controlled automotive braking system is called ( INTELLIGENT

REVERSE BRAKING SYSTEM% . )ensor *perated %neumatic Brake consists o"

+, transmitter and ,eceiver circuit- .ontrol /nit- %neumatic breaking system. #he +, sensor is used to detect the obstacle. #here is any obstacle in the path- the +, sensor senses the obstacle and giving the control signal to the breaking system. #he pneumatic breaking system is used to brake the system. )o basically here the car brakes on its o!n by determining the distance "rom the ob&ect.

LIST OF FIGURES .hapter ame *" #he 0igure %age umber 3.2.4.1 +, #ransmitter circuit 3.2.4.2 +, ,eceiver circuit 3.2.8 .apacitor start motors 3.2.8 )plit %hase motor 3.2.8 %ermanent )plit .apacitor 2otor 36 3.3 Block 3iagram 3.4 .ircuit 3iagram 3.5 4ayout *" +B) 3.5 6$perimental )etup71 3.5 6$perimental )etup72

31 31 34 36 37 38 35 41 41

INTRODUCTION

'e have pleasure in introducing our ne! pro&ect ( BRAKING SYSTEM%#

INTELLIGENT

!hich is "ully e8uipped by +, sensors circuit and

%neumatic breaking circuit. +t is a genuine pro&ect !hich is "ully e8uipped and designed "or 9utomobile vehicles. #his "orms an integral part o" best 8uality. #he ( PNEUMATIC BRAKING CIRCUIT : can stop the vehicle !ithin 2

to 3 seconds running at a speed o" 51 ;2. #he intelligent braking system is a "ully automated. #his is an era o" automation !here it is broadly de"ined as replacement o" manual e""ort by mechanical po!er in all degrees o" automation. #he operation

remains an essential part o" the system although !ith changing demands on physical input as the degree o" mechani<ation is increased.

3egrees o" automation are o" t!o types- vi<. = = 0ull automation. )emi automation.

+n semi automation a combination o" manual e""ort and mechanical po!er is re8uired !hereas in "ull automation human participation is very negligible.

NEED FOR AUTOMATION&

9utomation can be achieved through computers- hydraulics- pneumaticsrobotics- etc.- o" these sources- pneumatics "orm an attractive medium "or lo! cost automation. #he main advantages o" all pneumatic systems are economy and simplicity. 9utomation plays an important role in mass production. 0or mass production o" the product- the machining operations decide the se8uence o" machining. #he machines designed "or producing a particular product are called trans"er machines. #he components must be moved automatically "rom the bins to various machines se8uentially and the "inal component can be placed

separately "or packaging. 2aterials can also be repeatedly trans"erred "rom the moving conveyors to the !ork place and vice versa. o!adays almost all the manu"acturing process is being atomi<ed in order to deliver the products at a "aster rate. #he manu"acturing operation is being atomi<ed "or the "ollo!ing reasons.

= = = = = = = = = =

#o achieve mass production to reduce man po!er #o increase the e""iciency o" the plant #o reduce the !ork load #o reduce the production cost #o reduce the production time #o reduce the material handling #o reduce the "atigue o" !orkers #o achieve good product 8uality 4ess 2aintenance

TYPES OF BRAKING #he brakes "or automotive use may be classi"ied according the "ollo!ing considerations.

1. %/,%*)6 2. 4*.9#+* 3. .* )#,/.#+* 4. 26#>*3 *0 9.#/9#+* 5. 6?#,9 B,9;+ @ 600*,#

Based on the above considerations- brakes are classi"ied !ith respect to "ollo!ing "actors.

1. 'ith respect to applicationa. 0oot brake b. >and brake

2. 'ith respect to the number o" !heelsa. #!o !heel brakes b. 0our !heel brakes

3. 'ith respect to the method o" braking contact a. +nternal e$panding brakes b. 6$ternal contracting brakes

4. 'ith respect to the method o" applying the braking "orce. a. )ingle acting brake b. 3ouble acting brakes.

5. 'ith respect to the brake geara. 2echanical brake b. %o!er brakes

6. 'ith respect to the nature o" po!er employed

11

a. Aacuum brake b. 9ir brake c. >ydraulic brake d. >ydrostatic brake e. 6lectric brake

7. 'ith respect to po!er transmissiona. 3irect acting brakes b. @eared brakes

8. 'ith respect to po!er unita. .ylinder brakes b. 3iaphragm brake

#he "oot brake or service brake is al!ays applied by a pedal- !hile the parking brake is applied by a hand lever. #he parking brake is intended chie"ly to hold the car in position. #he parking brake can be set in the (* : position by means o" a latch !hile the service brake remains on only as long as the driver presses do!n on the pedal.

#he hand brake is normally used only a"ter the driver has stopped the car by using the "oot brake. +ts other use is as an emergency brake to stop the car i" the "oot braked system should "ail. #he hand or parking brakes operates on a pair o" !heels- "re8uently the rear !heels. 'hen drum type rear brakes are used- the same shoes can be used "or both hand and "oot control.

11

#he drum type o" brake may either be a band brake or a shoe brake. Both band brakes and shoe brakes may be either e$ternal or internal. #he band brakes generally are e$ternal and shoe brakes internal. +n drum brakes the drum is attached to the !heel and revolves !ith it. 0riction to slo! the drum is applied "rom inside by the shoes !hich do not rotate but are mounted on a stationary metal back plate. #here are di""erent types o" drum brakes such as a t!o leading shoe arrangement B !hich gives an augmented response to pedal e""ort because o" its sel" applying arrangement. 9 leading7trailing shoe is a cheaper and better

alternative as it is e8ually e""ective !hether the car is going "or!ard or back!ards.

2anu"acturers design drum brakes so that rain- sho! or ice or grit cannot get inside and decrease braking e""iciency "or moisture greatly reduces the "riction bet!een the linings and the drum.

#he dissipate 8uickly the considerable amount o" heat generated !hen braking a "ast moving heavy car large brake drums !ould be re8uired. 3isc brakes do the &ob more e""iciently- "or the cooling air can get to the rubbing bet!een each piston and the disc- there is a "riction pad held in position by retaining pins- spring plates etc. %assages are drilled in the caliper "or the "luid to enter or leave the each housing. #hese passages are also connected to another one "or bleeding. 6ach cylinder contains a rubber selling ring bet!een the cylinder and the piston.

12

#he brakes are applied- hydraulically actuated piston move the "riction pads into contact !ith the disc- applying e8ual and opposite "orces on the later. *n releasing the brakes- the rubber sealing rings act as return springs and retract the pistons and the "riction pads a!ay "rom the disc.

MECHANICAL BRAKE&

+n a motor vehicle- the !heel is attached to an au$iliary !heel called drum. #he brake shoes are made to contact this drum. +n most designs- t!o shoes are used !ith each drum to "orm a complete brake mechanism at each !heel. #he brake shoes have bake linings on their outer sur"aces. 6ach brake shoe is hinged at one end by on anchor pinC the other end is operated by some means so that the brake shoe e$pands out!ards. #he brake linings come into contact !ith the drum. ,etracting spring keeps the brake shoe into position !hen the brakes are not applied. #he drum encloses the entire mechanism to keep out dust and moisture. #he !heel attaching bolts on the drum are used to contact !heel and drum. #he braking plate completes the brake enclosure- holds the assembly to car a$le- and acts the base "or "astening the brake shoes and operating mechanism.

HYDRAULIC BRAKES&

13

#he hydraulic brakes are applied by the li8uid pressure. #he pedal "orce is transmitted to the brake shoe by means o" a con"ined li8uid through a system o" "orce transmission.

#he "orce applied to the pedal is multiplied and transmitted to brake shoes by a "orce transmission system. #his system is based upon %ascalDs principle!hich states that (#he con"ined li8uids transmit pressure !ithout loss e8ually in all directions:.

+t essentially consists o" t!o main components B master cylinder and !heel cylinder the master cylinder is connected by the !heel cylinders at each o" the "our !heels. #he system is "illed !ith the li8uid under light pressure !hen the brakes are not in operation. #he li8uid is kno!n as brake "luid- and is usually a mi$ture o" glycerin and alcohol or caster7oil- denatured alcohol and some additives )pring pressure- and thus the "luid pressure in the entire system drops to its original lo! valve- !hich allo!s retracting spring on !heel brakes to pull the brake shoes out o" contact !ith the brake drums into their original positions. #his causes the !heel cylinder piston also to come back to its original in!ard position. #hus- the brakes are released. AIR BRAKE&

9ir brakes are !idely used in heavy vehicle like buses and trucks !hich re8uire a heavier braking e""ort that can be applied by the driverDs "oot. 9ir brakes are applied by the pressure o" compressed air- instead o" "oot pressure- acting

14

against "le$ible diaphragms in brake chamber. #he diaphragms are connected to the !heel brakes. #hese diaphragms are controlled through a hand or "oot

operated valve. #he brake valve controls brake operation by directing the "lo! o" air "rom a reservoir against diaphragms in the brake chamber !hen the brakes are applied and "rom brake chambers to tube atmosphere !hen the brakes are released. #he air compressor- driven by the engine "urnishes compressed air to the reservoir "all belo! a set valve.

ELECTRIC BRAKE&

6lectric Brakes are also used in some motor vehicles- although these are not very popular. 'arner electric brake is one o" the e$amples o" such brakes. 9n electric brake essentially consists o" an electromagnet !ithin the brake drum. #he current "rom the battery is utili<ed to energi<e the electromagnet- !hich actuates the mechanism to e$pand the brake shoe against the brake drum- thus applying the brakes. #he severity o" braking is controlled by means o" a rheostat- !hich is operated by the driver through the "oot pedal.

6lectric brakes are simpler. #hese brakes do not re8uire complicated operating linkage. *nly cable is re8uired to take current "rom the battery to the electromagnet. 9lso- these are very 8uick in action as compared to other types o" brakes. VACUUM BRAKES ' SERVO BRAKES&

15

9 serve mechanism "itted to the braking system reduces the physical e""ort the driver has to use on the brake pedal most servo mechanisms are o" the vacuum assistance type. 9 pressure di""erential can be established by sub&ecting one side o" the piston to atmospheric pressure and the other side to a pressure belo! atmospheric pressure by e$hausting air "rom the corresponding end o" the servo cylinder.

REGENERATIVE BRAKING&

6lectricity po!ered vehicles use regenerative braking "or stopping the vehicle. 'ith regenerative braking pressing the brake pedal does not necessarily activate a conventional "riction brake. #he motor controller controlling the vehicle is treated as a generator !hich slo!s the vehicle and simultaneously provides an output "or charging the battery. #he e""ectiveness o" regenerative braking "alls o" !ith vehicle speed. 6lectric vehicles !ill have to be "itted !ith conventional hydraulic "riction brakes as !ell as !ith regenerative systems.

16

IR SENSOR SENSORS

9 sensor is a transducer used to make a measurement o" a physical variable. 9ny sensor re8uires calibration in order to be use"ul as a measuring device. .alibration is the procedure by !hich the relationship bet!een the measured variable and the converted output signal is established.

17

.are should be taken in the choice o" sensory devices "or particular tasks. #he operating characteristics o" each device should be closely matched to the task "or !hich it is being utili<ed. 3i""erent sensors can be used in di""erent !ays to sense same conditions and the same sensors can be used in di""erent !ays to sense di""erent conditions.

TYPES OF SENSOR&

P())*+, ),-)./)

detect the re"lected or emitted electro7magnetic radiation (01*+, ),-)./) detect re"lected responses "rom ob&ects

"rom natural sources- !hile

!hich are irradiated "rom arti"icially generated energy sources- such as radar. 6ach is divided "urther in to -.--)0(--*-2 and )0(--*-2 )3)1,4) .

9 sensor classi"ied as a combination o" passive- non7scanning and

-.--

*4(2*-2 4,15.6 is a type o" pro"ile recorder- "or e$ample a micro!ave radiometer. 9 sensor classi"ied as passive- non7scanning and *4(2*-2 4,15.6 - is a

camera- such as an aerial survey camera or a space camera- "or e$ample on board the ,ussian .*)2*) satellite. )ensors classi"ied as a combination o" passive- scanning and imaging are classi"ied "urther into solid state scanners- and *4(2, 78(-, )0(--*-2 ),-)./) - such as #A cameras and - such as multi7spectral

.9:,01 78(-, )0(--*-2 ),-)./)

scanners Eoptical7mechanical scannerF and scanning micro!ave radiometers.

18

9n e$ample o" an active- non7scanning and non7imaging sensor is a pro"ile recorder such as a laser spectrometer and laser altimeter. 9n active- scanning and imaging sensor is radar- "or e$ample synthetic aperture radar E)9,F- !hich can produce high resolution- imagery- day or night- even under cloud cover. #he most popular sensors used in remote sensing are the camera- solid state scanner- such as the ..3 Echarge coupled deviceF images- the multi7spectral scanner and in the "uture the passive synthetic aperture radar. 4aser sensors have recently begun to be used more "re8uently "or monitoring air pollution by laser spectrometers and "or measurement o" distance by laser altimeters. +n our pro&ect +, transmitter and +, receiver are used to detect the obstacle. #hese sensors are "itted at the "ront side o" the vehicle. IR TRANSMITTER& #he +, transmitting circuit is used in many pro&ects. #he +, transmitter sends 41 k>< E"re8uency can be ad&ustedF carrier under 555 timer control. +, carriers at around 41 k>< carrier "re8uencies are !idely used in #A remote controlling and +.s "or receiving these signals are 8uite easily available.

IR RECEIVER& #he transmitted signal re"lected by the obstacle and the +, receiver circuit receives the signal and giving control signal to the control unit. #he control unit activates the pneumatic breaking system- so that break !as applied.

15

LITERATURE SURVEY

P-,;4(1*0) #he !ord GpneumaD comes "rom @reek and means breather !ind. the !ord pneumatics is the study o" air movement and its phenomena is derived "rom the !ord pneuma. #oday pneumatics is mainly understood to means the application o" air as a !orking medium in industry especially the driving and controlling o" machines and e8uipment.

%neumatics has "or some considerable time bet!een used "or carrying out the simplest mechanical tasks in more recent times has played a more important role in the development o" pneumatic technology "or automation.

21

%neumatic systems operate on a supply o" compressed air !hich must be made available in su""icient 8uantity and at a pressure to suit the capacity o" the system. 'hen the pneumatic system is being adopted "or the "irst time- ho!ever it !ills indeed the necessary to deal !ith the 8uestion o" compressed air supply.

#he key part o" any "acility "or supply o" compressed air is by means using reciprocating compressor. 9 compressor is a machine that takes in air- gas at a certain pressure and delivered the air at a high pressure.

.ompressor capacity is the actual 8uantity o" air compressed and delivered and the volume e$pressed is that o" the air at intake conditions namely at atmosphere pressure and normal ambient temperature.

T5, 0.47/,))*9*8*13 .< 15, (*/ =() <*/)1 *-+,)1*2(1,6 93 R.9,/1 B.38, *- 1962 (-6 15(1 <.;-6 15(1 15, 7/.6;01 .< 7/,));/, (-6 +.8;4, .< ( 7(/1*0;8(/ >;(-1*13 .< 2()

#he usual !ritten as pv H c EorF pivi H p2v2 +n this e8uation the pressure is the absolute pressured !hich "or "ree is about 14.7 psi and is o" courage capable o" maintaining a column o" mercurynearly 31 inches high in an ordinary barometer. 9ny gas can be used in pneumatic system but air is the mostly used system no! a days.

21

COMPONENTS AND DESCRIPTION

SELECTION OF PNEUMATICS& 2echani<ation is broadly de"ined as the replacement o" manual e""ort by mechanical po!er. %neumatics is an attractive medium "or lo! cost mechani<ation particularly "or se8uential or repetitive operations. 2any "actories and plants already have a compressed air system- !hich is capable o" providing both the po!er or energy re8uirements and the control system Ealthough e8ually pneumatic control systems may be economic and can be advantageously applied to other "orms o" po!erF.

22

T5, 4(*- (6+(-1(2,) .< (- (88-7-,;4(1*0 )3)1,4 (/, ;);(883 ,0.-.43 (-6 )*478*0*13# 15, 8(11,/ /,6;0*-2 4(*-1,-(-0, 1. ( 8.= 8,+,8 I1 0(- (8). 5(+, .;1 )1(-6*-2 (6+(-1(2,) *- 1,/4) .< )(<,13

PNEUMATIC COMPONENTS AND ITS DESCRIPTION #he pneumatic bearing press consists o" the "ollo!ing components to "ul"ill the re8uirements o" complete operation o" the machine.

1F % 6/29#+. )+ @46 9.#+ @ .I.4+ 36, 2F )*46 *+3 A94A6 3F 04*' .* #,*4 A94A6 4F +, )6 )*, / +# 5F '>664 9 3 B,9;6 9,,9 @626 # 6F %/ .* 7F )#9 3 8F )+ @46 %>9)6 + 3/.#+* 2*#*, 6.#*,- ,63/.6,- >*)6 .*449,

1F

PNEUMATIC SINGLE ACTING CYLINDER

%neumatic cylinder consist o" 9F %+)#* BF .I4+ 36,

#he cylinder is a )ingle acting cylinder one- !hich means that the air pressure operates "or!ard and spring returns back!ard. #he air "rom the

23

compressor is passed through the regulator !hich controls the pressure to re8uired amount by ad&usting its knob. 9 pressure gauge is attached to the regulator "or sho!ing the line pressure. #hen the compressed air is passed through the single acting 3K2 solenoid valve "or supplying the air to one side o" the cylinder. *ne hose take the output o" the directional .ontrol E)olenoidF valve and they are attached to one end o" the cylinder by means o" connectors. *ne o" the outputs "rom the directional control valve is taken to the "lo! control valve "rom taken to the cylinder. #he hose is attached to each component o" pneumatic system only by connectors.

CYLINDER TECHNICAL DATA&

P*)1.- R.6& 2.). hard .hrome plated S,(8)& itrile EBuna B F 6lastomer E-6 C.+,/)& .ast iron graded "ine grained "rom 25mm to 311mm

24

P*)1.-& 9luminium.

M,6*(& 9ir.

T,47,/(1;/, R(-2,& 1Lc to 85Lc P(/1) .< P-,;4(1*0 C38*-6,/ P*)1.-& #he piston is a cylindrical member o" certain length !hich reciprocates inside the cylinder. #he diameter o" the piston is slightly less than that o" the cylinder bore diameter and it is "itted to the top o" the piston rod. +t is one o" the important parts !hich convert the pressure energy into mechanical po!er.

#he piston is e8uipped !ith a ring suitably proportioned and it is relatively so"t rubber !hich is capable o" providing good sealing !ith lo! "riction at the operating pressure. #he purpose o" piston is to provide means o" conveying the pressure o" air inside the cylinder to the piston o" the oil cylinder.

@enerally piston is made up o"

9luminium alloy7light and medium !ork. Brass or bron<e or .+7>eavy duty.

25

#he piston is single acting spring returned type. #he piston moves "or!ard !hen the high7pressure air is turned "rom the right side o" cylinder.

#he piston moves back!ard !hen the solenoid valve is in *00 condition. #he piston should be as strong and rigid as possible. #he e""iciency and economy o" the machine primarily depends on the !orking o" the piston. +t must operate in the cylinder !ith a minimum o" "riction and should be able to !ithstand the high compressor "orce developed in the cylinder and also the shock load during operation.

#he piston should posses the "ollo!ing 8ualities.

a. #he movement o" the piston not creates much noise. b. +t should be "rictionless. c. +t should !ithstand high pressure.

P*)1.- R.6 #he piston rod is circular in cross section. +t connects piston !ith piston o" other cylinder. #he piston rod is made o" mild steel ground and polished. 9 high "inish is essential on the outer rod sur"ace to minimi<e !ear on the rod seals. #he piston rod is connected to the piston by mechanical "astening. #he piston and the piston rod can be separated i" necessary. *ne end o" the piston rod is connected to the bottom o" the piston. #he other end o" the piston rod is connected to the other piston rod by means o" coupling. #he piston transmits the !orking "orce to the oil cylinder through the piston rod. #he piston rod is designed to !ithstand the high compressive "orce. +t

26

should avoid bending and !ithstand shock loads caused by the cutting "orce. #he piston moves inside the rod seal "i$ed in the bottom cover plate o" the cylinder. #he sealing arrangements prevent the leakage o" air "rom the bottom o" the cylinder !hile the rod reciprocates through it.

C38*-6,/ C.+,/ P8(1,) #he cylinder should be enclosed to get the applied pressure "rom the compressor and act on the pinion. #he cylinder is thus closed by the cover plates on both the ends such that there is no leakage o" air. 9n inlet port is provided on the top cover plate and an outlet ports on the bottom cover plate. #here is also a hole drilled "or the movement o" the piston.

#he cylinder cover plate protects the cylinder "rom dust and other particle and maintains the same pressure that is taken "rom the compressor. #he "lange has to hold the piston in both o" its e$treme positions. #he piston hits the top plat during the return stroke and hits the bottom plate during end o" "or!ard stroke. )o the cover plates must be strong enough to !ithstand the load. C38*-6,/ M.;-1*-2 P8(1,)& +t is attached to the cylinder cover plates and also to the carriage !ith the help o" G4D bends and bolts.

2 SOLENOID VALVE !ITH CONTROL UNIT& #he directional valve is one o" the important parts o" a pneumatic system. .ommonly kno!n as 3.A- this valve is used to control the direction o" air "lo! in the pneumatic system. #he directional valve does this by changing the position o" its internal movable parts.

27

#his valve !as selected "or speedy operation and to reduce the manual e""ort and also "or the modi"ication o" the machine into automatic machine by means o" using a solenoid valve. 9 solenoid is an electrical device that converts electrical energy into straight line motion and "orce. #hese are also used to operate a mechanical operation !hich in turn operates the valve mechanism. )olenoids may be push type or pull type. #he push type solenoid is one in !hich the plunger is pushed !hen the solenoid is energi<ed electrically. #he pull type solenoid is one is !hich the plunger is pulled !hen the solenoid is energi<ed. #he name o" the parts o" the solenoid should be learned so that they can be recogni<ed !hen called upon to make repairs- to do service !ork or to install them.

P(/1) .< ( S.8,-.*6 V(8+, 1 C.*8 #he solenoid coil is made o" copper !ire. #he layers o" !ire are separated by insulating layer. #he entire solenoid coil is covered !ith an varnish that is not a""ected by solvents- moisture- cutting oil or o"ten "luids. .oils are rated in various voltages such as 115 volts 9.- 231 volts 9.- 461 volts 9.- 575 Aolts 9.- 6 Aolts 3.- 12 Aolts 3.- 24 Aolts 3.- 115 Aolts 3. M 231 Aolts 3.. #hey are designed "or such "re8uencies as 51 >< to 61 ><.

2 F/(4, #he solenoid "rame serves several purposes. )ince it is made o" laminated sheets- it is magneti<ed !hen the current passes through the coil. #he magneti<ed coil attracts the metal plunger to move. #he "rame has provisions "or attaching the mounting. #hey are usually bolted or !elded to the "rame. #he "rame has provisions "or receivers- the plunger. #he !ear strips are mounted to the solenoid "rame- and are made o" materials such as metal or impregnated less "iber cloth.

28

3 S.8,-.*6 P8;-2,/ #he )olenoid plunger is the mover mechanism o" the solenoid. #he plunger is made o" steel laminations !hich are riveted together under high pressure- so that there !ill be no movement o" the lamination !ith respect to one another. 9t the top o" the plunger a pin hole is placed "or making a connection to some device. #he solenoid plunger is moved by a magnetic "orce in one direction and is usually returned by spring action.)olenoid operated valves are usually provided !ith cover over either the solenoid or the entire valve. #his protects the solenoid "rom dirt and other "oreign matter- and protects the actuator. +n many applications it is necessary to use e$plosion proo" solenoids.

!ORKING OF 3'2 SINGLE ACTING SOLENOID ?OR@ CUT OFF VALVE& #he control valve is used to control the "lo! direction is called cut o"" valve or solenoid valve. #his solenoid cut o"" valve is controlled by the emergency push button. #he 3K2 )ingle acting solenoid valve is having one inlet port- one outlet port and one e$haust port. #he solenoid valve consists o" electromagnetic coil- stem and spring. #he air enters to the pneumatic single acting solenoid valve !hen the push button is in * position. T,05-*0(8 D(1(& )i<e %ressure 2edia #ype J 3K2 J N: J 1 to 7 kg K cm2 J 9ir

25

9pplied Aoltage J 231A 9.. 0re8uency J 51 ><

3 FLO! CONTROL VALVE&

1 T,05-*0(8 D(1(&

)i<e %ressure 2edia

J N: J 1 to 11 kg K cm2 J 9ir

?9@ P;/7.),& #his valve is used to speed up the piston movement and also it acts as an one B !ay restriction valve !hich means that the air can pass through only one !ay and it canDt return back. By using this valve the time consumption is reduced because o" the "aster movement o" the piston.

4 IR SENSOR UNIT&-

31

#he +, transmitter and +, receiver circuit is used to sense the obstacle. +t is "i$ed to the back side o" the "rame stand !ith a suitable arrangement. #he pneumatic cylinder is controlled by the "lo! control valve- single acting solenoid valve and control unit. AT NORMAL CONDITION& #he +, transmitter sensor is transmitting the in"rared rays !ith the help o" 555 +. timer circuit. #hese in"rared rays are received by the +, receiver sensor. #he #ransistor #1- #2 and #3 are used as an ampli"ier section. 9t normal condition #ransistor #5 is *00 condition. 9t that time relay is *00- so that the vehicle running continuously.

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32

33

AT OBSTACLE CONDITION& 9t *bstacle conditions the +, transmitter and +, receiver- the resistance across the #ransmitter and receiver is high due to the non7conductivity o" the +, !aves. )o the output o" transistor #5 goes "rom *00 condition to * stage. +n that time the relay is * position. +n that time- the solenoid valve is on so that the vehicle stops.

5 !HEEL AND BRAKING ARRANGEMENT& #he simple !heel and braking arrangement is "i$ed to the "rame stand. ear the brake drum- the pneumatic cylinder piston is "i$ed.

6 CONNECTORS# REDUCER AND HOSECOLLAR& +n our pneumatic system there are t!o types o" connectors usedC one is the hose connector and the other is the reducer. >ose connectors normally comprise an adapter EconnectorF hose nipple and cap nut. #hese types o" connectors are made up o" brass or 9luminium or hardened steel. ,educers are used to provide inter connection bet!een t!o pipes or hoses o" di""erent si<es. #hey may be "itted straight- tee- (A: or other con"igurations. #hese reducers are made up o" gunmetal or other materials like hardened steel etc.

34

$ STAND& #his is a supporting "rame and made up o" mild steel.

SINGLE PHASE INDUCTION MOTOR&+t is "ound to drive the roller sha"t !hich "i$ed on the end o" the "rame structure. #he "ree end o" the sha"t in the motor a large pulley is "ound around !hich the belt runs. #he other speci"ication about the motor is discussed in design part o" the machine. S*-28,-P5(), T5,./3 Because it has but a single alternating current source- a single7phase motor can only produce an alternating "ieldJ one that pulls "irst in one direction- then in the opposite as the polarity o" the "ield s!itches. 9 s8uirrel7cage rotor placed in this "ield !ould merely t!itch- since there !ould be no moment upon it. +" pushed in one direction- ho!ever- it !ould spin. #he ma&or distinction bet!een the di""erent types o" single7phase 9. motors is ho! they go about starting the rotor in a particular direction such that the alternating "ield !ill produce rotary motion in the desired direction. #his is usually done by some device that introduces a phase7shi"ted magnetic "ield on one side o" the rotor. #he "igure the per"ormance curves o" the "our ma&or types o" single7phase 9. motors. #hey are described belo!.

35

S78*1-P5(), M.1./)& #he split phase motor achieves its starting capability by having t!o separate !indings !ound in the stator. #he t!o !indings are separated "rom each other. *ne !inding is used only "or starting and it is !ound !ith a smaller !ire si<e having higher electrical resistance than the main !indings. 0rom the rotorOs point o" vie!- this time delay coupled !ith the physical location o" the starting !inding produces a "ield that appears to rotate. #he apparent rotation causes the motor to start. 9 centri"ugal s!itch is used to disconnect the starting !inding !hen the motor reaches appro$imately 75P o" rated speed. #he motor then continues to run on the basis o" normal induction motor principles.

36

C(7(0*1./-S1(/1 M.1./) .apacitor start motors "orm the largest single grouping o" general purpose single phase motors. #hese motors are available in a range o" si<es "rom "ractional through 3>%. #he !inding and centri"ugal s!itch arrangement is very similar to that used in a split phase motor. #he main di""erence being that the starting !inding does not have to have high resistance. +n the case o" a capacitor start motor- a speciali<ed capacitor is utili<ed in a series !ith the starting !inding. #he addition o" this capacitor produces a slight time delay bet!een the magneti<ation o" starting poles and the running poles. #hus the appearance o" a rotating "ield e$ists. 'hen the motor approaches running speed- the starting s!itch opens and the motor continues to run in the normal induction motor mode. #his moderately priced motor produces relatively high starting tor8ue- 225 to 411P o" "ull load tor8ue. #he capacitor start motor is ideally suited "or hard to start loads such as conveyors- air compressors and re"rigeration compressors. 3ue to its general overall desirable characteristics- it also is used "or many applications !here high starting tor8ue may not be re8uired. #he capacitor start motor can usually be recogni<ed by the bulbous protrusion on the "rame !here the starting capacitor is located.

37

P,/4(-,-1-S78*1 C(7(0*1./ M.1./) #he capacitor o" this motor is le"t in series !ith the starting !inding during normal operation. #he starting tor8ue is 8uite lo!- roughly 41P o" "ull7load- so lo!7inertia loads such as "ans and blo!ers make common applications.

,unning per"ormance and speed regulation can be tailored by selecting an appropriate capacitor value. o centri"ugal s!itch is re8uired.

38

BLOCK DIAGRAM

+, PO!ER SUPPLY #,9 )2+##6, .* #,*4 / +# +, ,6.6+A6,

FLO! CONTROL VANVE

)*4+ *+3 A94A6

% 6/29#+. .I4+ 36, AIR TANK

B,69; 9,,9 @626

35

CIRCUIT DIAGRAM

41

LAYOUT OF THE INTELLIGENT BRAKING SYSTEM

41

EAPERIMENTAL SETUP-I

42

EAPERIMENTAL SETUP-II

43

!ORKING OPERATION #he important components o" our pro&ect are= = = = = = +, transmitter +, receiver .ontrol /nit !ith %o!er supply )olenoid Aalve 0lo! control Aalve 9ir #ank E.ompressorF

#he IR TRANSMITTER circuit is to transmit the +n"ra7,ed rays. +" any obstacle is there in a path- the +n"ra7,ed rays re"lected. #his re"lected +n"ra7,ed rays are received by the receiver circuit is called ( IR RECEIVER%

#he +, receiver circuit receives the re"lected +, rays and giving the control signal to the control circuit. #he control circuit is used to activate the solenoid valve. +" the solenoid valve is activated- the compressed air passes to the )ingle 9cting %neumatic .ylinder. #he compressed air activate the pneumatic cylinder and moves the piston rod. +" the piston moves "or!ard- then the breaking arrangement activated. #he breaking arrangement is used to break the !heel gradually or suddenly due to the piston movement. #he breaking speed is varied by ad&usting the valve is called BFLO! CONTROL VALVE%

44

+n our pro&ect- !e have to apply this breaking arrangement in one !heel as a model. #he compressed air dra!n "rom the compressor in our pro&ect. #he compressed air "lo! through the %olyurethene tube to the "lo! control valve. #he "lo! control valve is connected to the solenoid valve.

45

APPLICATIONS AND ADVANTAGES

APPLICATION&

= =

0or automobile application +ndustrial application

ADVANTAGES

= = =
= =

Brake cost !ill be less. 0ree "rom !ear ad&ustment. 4ess po!er consumption 4ess skill drivers is su""icient to operate. +t gives very simpli"ied operation. +nstallation is simpli"ied.
=

#o avoid other burnable interactions vi<.Q E3iaphragmF is

not used.

46

COST ESTIMATION

MATERIAL COST&

S8 N. PARTS i. )ingle 9cting %neumatic .ylinder 1 1211 ii. 0lo! .ontrol Aalve 1 611 iii. 'heel iv. )olenoid Aalve 1 611 v. )ingle %hase induction motor 1 2111 vi. )ensor /nit 1 811 vii. %ulley viii. %olyethylene #ube 7 61 i$. >ose .ollar and ,educer 7 151 ? )tand E0rameF 1 251

C13 A4.;-1 ?R)@

1 511

1 81

TOTAL COST DR) 624"ER) 26" ?4*)0,88(-,.;) 0.)1@ DR) 65"" CONCLUSION

47

#his pro&ect !ork has provided us an e$cellent opportunity and e$perienceto use our limited kno!ledge. 'e gained a lot o" practical kno!ledge regardingplanning- purchasing- assembling and machining !hile doing this pro&ect !ork. 'e "eel that the pro&ect !ork is a good solution to bridge the gap bet!een institution and industries. 'e are proud that !e have completed the !ork !ith the limited time success"ully. #he INTELLIGENT PNEUMATIC BRAKE is !orking !ith

satis"actory conditions. 'e are able to understand the di""iculties in maintaining the tolerances and also 8uality. 'e have done to our ability and skill making ma$imum use o" available "acilities. +n conclusion remarks o" our pro&ect !ork- let us add a "e! more lines about our impression pro&ect !ork. #hus !e have developed an BINTELLIGENT

BRAKING SYSTEM !hich helps to kno! ho! to achieve lo! cost automation. #he application o" pneumatics produces smooth operation. By enhancing this techni8ue- the system can be modi"ied and developed according to the applications.

,606,6 .6)

48

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