i) Abstract:-

Automobiles have been the primary mode of transportation for most of us and we
depend on them for our day to day commute. Unfortunately there are lots of mishaps that
could occur while driving an automobile and Brake Failures are one such case. Of course
accidents cannot be avoided sometimes but they can sure be prevented by taking some
preventive measures. In this project we will build a Circuit that can be attached to our
Vehicles which will monitor the brake of our vehicle and provide us an audio-visual
feedback if the brake fails. Most economical vehicles depend on wire braking mechanism
to apply brakes on the vehicle. This mechanism involves a Brake wire which runs from
the brake lever to the braking mechanism set-up of the vehicle. It is this wire that gets
pulled when we apply brakes to stop our vehicle. After a long use and tear these wires
might get worn out and get cut at one point of time which eventually will cause a brake
failure. So we will build a circuit that will monitor the continuity of this wire, the circuit
will glow a green color LED if everything is fine, but is the wire fails the circuit will
blink a red color LED also will beep a buzzer to alert the rider. Let us see how we can
build this project.

ii) Detailed Project report:-

Introduction:-

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 Though the world is getting modernized, we have to face so many problems. One
of such problems is accidents. One of the thing that everyone tried to avoid is while
traveling is accidents, and sometimes it is inevitable. Now- a-days we can see accidents
in every nook and corner of the world. It results in the death of thousands of lives. With
the population ever climbing there are more vehicles than ever on road , which means
there is a higher livelihood of the brakes giving out.

In foreign countries they take remedial measures for the prevention of accidents
but our country like India takes less action against the prevention of accidents. One
common cause for accidents is brake failure. Accidents may occur due to brake failure. In
such a situation my project brake failure indicator plays an important role in controlling
accidents.

Brake failure indicator circuit is a circuit that constantly monitors the condition of brake.
The sensor which is attached to the circuit get the chance of a brake failure by monitoring
the brake switch and reminds you of the condition of brake every time when the brake is
applied.

Principle:-

The principle used to gives an early indication of brake failure . Of all the system
that make up a vehicle , the brake system might just be important.The circuit can be
assembled on any general purpose PCB or perforated board.. It is connected on the right
side of stearing. One LED is red in colour and the other LED is green in colour.

Working:-

As you can see this brake failure indicator circuit is very simple and can be easily
built on a breadboard. The main components in this project are the 555 Timer and the

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BC557 PNP transistor. The 555 Timer operates in Astable mode to produce clock pulse
and the BC557 PNP Transistor monitors the Brake wire and decides which led should
glow.
Once the connection is made power the circuit, make sure the Brake cable (here I
have used a normal green wire to represent the brake cable) is connected across the +5V
and base of BC557 through a resistor as shown in the circuit. If everything works
expected you should see the Green LED turned on and the Buzzer and Red Light Turned
Off. Now, cut/remove the brake cable the Red LED and the Buzzer should start flashing.

Innovation:-

 Try to make a easy connection circuit

 Because, so many break failure indicators circuits are very huge and complicated.
 By this circuit, we connect the circuit easily and fast

iii) Block diagram:-

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iv) Circuit diagram / drawings:-

v) Photograph of the circuit/device/model:

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vi)Scope for Further Improvement:-
 Manufacturing this circuit, after it is to arranged in automobiles like two wheelers
and four wheelers.

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Advantages:-
 To save the life.
 To avoid small number of accidents involving trains and boats caused by brake
failure.
 To measure the change in hydrolytic pressure.
 To indicate the failure of brake switch.
 It can control all the moving units in the vehicle.
 It can measure fluid leakage.
 To connect the audio visual indicator with a sensor.
 To measure the fluid breaking pressure.
 To identify whether the brake is working or not.

Literature survey;

Car safety is the avoidance of automobile accidents or the minimization of harmful

effects of accidents, in particular as pertaining to human life and health. Special safety
features have been built into car’s occupants only, and some for the safety of others. We
have pleasure in introducing our new project “automatic head light dim/bright controller
and engine over heat alarm” which is fully equipped by sensors circuit, dim/bright light
and engine over heat alarm circuit. It is genuine project which is fully equipped and
designed for automobile vehicles. This forms an integral part of best quality.
This product underwent test in our automobile vehicles and it is good.
The major components of the project are follows

 Frame

 Battery

 IR sensor circuit

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In this Project we are using control unit to check the Brake condition and Engine heat.
Here we are sending the signal voltage through the Brake Wire from one end to other
end. At the other end in the wheel the signal conditioning unit checks that whether the
signal voltage in the Brake wire is available or not.The braking system of a car is
undoubtedly one of its more important feature. The aim of this work is to create a better
braking system with indicator. Brake failure occurs only because of worn out of brake
shoe and cut in liner. It consist of two sensors. One sensor is connected with the brake
shoe. The other sensor is the brake liner. The signal from the two sensors is given to a
microcontroller. When the brake shoe is worn out, the sensor senses signal to the
microcontroller. Also if the brake liner is cut, the sensor sends signal to the
microcontroller. The microcontroller analyses the signal and operates the corresponding
indicator. It nothing wrong, green indicator will glow and if any one critical, red indicator
will glow. If the brake is failure in running time, an alternate brake will be operated by
the microcontroller automatically. This prevents unnecessary accident. Since this
indicates the status of the brake, the user can identify the condition of the brake and thus
limiting the chances of malfunction.

Figure 1.1 Block diagram

Back Ground :

Though the world is getting modernized, we have to face so many problems. One of such
problems is accidents. One of the thing that everyone tried to avoid is while traveling is
accidents, and sometimes it is inevitable. Now- a-days we can see accidents in every
nook and corner of the world. It results in the death of thousands of lives. In foreign
countries they take remedial measures for the prevention of accidents but our country like
India takes less action against the prevention of accidents.. When the driver brakes they
are actually pushing a plunger into the master cy7 and Computing, July 2016 8672
http://ijesc.org/failure like United States patent 3711827, United States patent
3914734, etc. The United States patent 3711827 is a self-test incorporated to determine if
the warning light is operated properly. But my project can indicate brake failure and the
function of the brake whenever the brake is applied and it is less expensive compared to
other products.

Ground Clearance:

Whenever we buy cars we often discuss the fuel economy, style, features, colour, price
and all that. But unless widely publicized, people hardly care to look at the physical specs
of the car - in particular the ground clearance.Ground clearance is a factor mostly
discussed when someone is buying low level cars. Indeed Luxury cars are known for
their low stance and low ground clearance. Now, anyone or any website will tell you that
ground clearance is the "minimum distance between the ground/road and the lowest
part of the car". And then manufacturers publish the ground clearance figures such as 160
mm or 170 mm or 180 mm.Figure 1.5 Demonstration of ground clearance of suspension
car.In our concept car the suspension of the car allow minimum of 600 mm ground
clearance or even beyond that becomes a major success factor of the model.In the case of
Indian roads the vehicles which have more than 200 mm of ground clearance is
appropriate for ride in urban as well as in rural areas.
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Description :

Brake failure indicator is a device used to avoid accidents and it gives an early indication
of brake failure. Of all the system that make up a vehicle, the brake system might just be
important. If a force is exerted on the piston putting pressure on the fluid confined in the
left hand container, the fluid is forced out through the narrow tube at the bottom and into
the right hand container, exerting a force on the second piston, forcing it to move upward.
The circuit can be assembled on any general purpose PCB or perforated board. The audio
indicator is black in color. It is connected on the right side of circuit.

Components Description:

It is a complete standalone voltage regulator. We only need to use 2 capacitors. One on

the input and second one on the output of 7812 in order to achieve clean voltage output
and even these capacitors are optional to use. To achieve 12v 1A current, 7812 should be
mounted on a good heat sink plate. Thanks to the transistor like shape of 7812 which
makes it easy to mount on. 7812 is a famous IC which is being widely used in 12V
voltage regulator circuits. Truly speaking a heat sink plate. 7812 has built in over heat
and short-circuit protection which makes it a good choice for making power supplies.
In electronics markets, 7812 is sold under various names such as 7812a, 7812act, 7812t
and lm7812. All of them are almost identical with a little to no differences at all. 7812
input voltage range is 14V to 35V. Exceeding the voltage range may damage the IC.
Given bellow is 7812 pin diagram to make the pin out connections clear in case you want
to do some experiments.

Infra Red Obstacle Detection Sensor:

In the system we are using 5mm IR SENSORS as an early warning system that also made
it economic in design and simple in implementation. Infrared radiation is the portion of
electromagnetic spectrum having wavelengths longer than visible light wavelengths, but
smaller than microwaves.An IR sensor Roughly from 0.75µm to 1000 µm is the infrared
region. Infrared waves are invisible to human eyes. The wavelength8/ijesc.org/from 3 µm
to 6 µm is called mid infrared and the region higher than 6 µm is called far infrared.7812
pin diagram.If you hold upside down (pins up) and the IC number is facing you then the
left pin will be the voltage regulator output, the centred pin will be ground and the right
pin will be the voltage input pin. Under my experience, the maximum safe
current you can get from one 7812 IC is 1A. If you need more power then there are a few
ways to do so.More than one 7812 can be used in parallel in order to achieve more than
1A current but output voltage of each 7812 can slightly vary resulting in unbalanced load
on all of them. This can result in load balancing issues and can damage the IC carrying
most current. However there is a way to overcome this problem. I have given bellow a
schematic diagram in which two 7812 ICs are attached together and both of them are
carrying almost equal load. At least the current difference is not too much to damage any
ICIC 3140.The CA3140A and CA3140 are integrated circuit operational amplifiers that
combine the advantages of high voltage PMOS transistors with high voltage bipolar
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transistorso on a single monolithic chip. The CA3140A and CA3140 BiMOS operational
amplifiers feature gate protected MOSFET (PMOS) transistors in the input circuit to
provide very high input impedance, very low input current, and high speed performance.
The CA3140A and CA3140 operate at supply voltage from 4V to 36V (either single or
dual supply). These operational amplifiers are internally phase compensated to achieve
stable operation in unity gain follower operation, and additionally, have access terminal
for a supplementary external capacitor if additional frequency roll-off is desired.
Terminals are also provided for use in applications requiring input offset voltage nulling.
The use of PMOS field effect transistors in the input stage results in common mode input
voltage capability down to 0.5V below the negative supply terminal, an important
attribute for sin- gle supply applications. The output stage uses bipolar transistors and
includes built-in protection against damage from load terminal short circuiting to either
supply rail or to ground. 555 ICIC

METHODOLOGY:

The 555 Timer IC is an integrated circuit (chip) used in a variety of timer, pulse
generation and oscillator applications. The circuit arrangement of the 555 is said to be
even more common, being incorporated in many single-voltage Flash and other
electrically-erasable ICs where it is the basis for the oscillator driving the charge pump
which provides the programming overvoltage.Depending on the manufacturer, the
standard 555 package includes over 20 transistors, 2 diodes and 15 resistors on a silicon
chip installed in an 8-pin mini dual-in-line package (DIP-8). Variants available include
the 556 (a 14-pin DIP combining two 555s on one chip), and the 558 (a 16-pin DIP
combining four slightly modified 555s with DIS & THR connected internally, and TR
falling edge sensitive instead of level sensitive).

The 555 has three operating modes

 Mono stable mode: in this mode, the 555 functions as a "one-shot" pulse generator.
Applications include timers, missing pulse detection, bounce free switches, touch
switches, frequency divider, capacitance measurement, pulse-width modulation (PWM)
and so on. Astable – free running mode: the 555 can operate as anoscillator. Uses
include LED and lamp flashers, pulse generation, logic clocks, tone generation, security
alarms, pulse position modulation and so on.

 Bistable mode or Schmitt trigger: the 555 can operate as a flip-flop, if the DIS pin is
not connected and no capacitor is used. Uses include bounce free latched switches.

LED:

A light emitting diode is a semiconductor diode that emits light when the electric current
is applied in the forward direction of the device, as in the simple LED circuit. The effect
is a form of electroluminescence where incoherent and narrow spectrum light is emitted
from p-n junction. LED’s are widely used as indicator lights on electronic devices and
increasingly in higher power applications such as flashlights and area light. The colour of
emitted light depends on the composition and condition of semiconductor material used
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or ultraviolet .In brake failure indicator, the LED is used for indicationFigure 2.1.2(a)
LED is on i.e. no any obstacle is presentWhen the brake is applied, the green LED blinks
and the piezo buzzer beeps for around one second if the brake systemis intact. If the
brake fails, the red LED Glows and the buzzer stop beeping.

Diode :

A diode is a device that permits current flow predominantly in only one direction. Most
semiconductor diodes are made from germanium or silicon. A diode has two leads, an
anode and a cathode. The cathode is often marked by a band at one end is the lead by
which conventional current leaves the diode when forward biased. There are several
types of diode, each with features that suits a particular job. In brake failure indicator, the
inverting input is connected to the brake switch through diode and resistor.

Buzzer :

A buzzer or beeper is a signaling device usually electronic. These devices are used in
automobiles, household appliances such as microwave oven. It consists of a number of
switches or sensors connected to a control unit that determines if and which buttonpushed
or a present time has lapsed, sounds a warning in the form of an intermittent buzzing or
beeping sound. Buzzer or beepers are output transducers convertingelectrical energy into
sound. They contain an internal oscillator to produce the sound which is set at about 400
Hz for buzzers and about 3 KHz for beepers. In brake failure indicafibers. The
transmission of IR – radiation is affected by presence of CO2, water vapor and other
elements in the atmosphere. Due to absorption by molecules of water carbon dioxide,
ozone, etc. the atmosphere highly attenuates most IR wavelengths leaving someimportant
IR windows in the electromagnetic spectrum.

Optical Components

Often optical components are required to converge or focus infrared radiations, to limit
spectral response, etc. To converge / focus radiations, optical lenses made of quartz,
CaF2, Ge and Si, polyethylene Fresnel lenses, and mirrors made of Al, Au or a similar
material are used. For limiting spectral responses, band pass filters are used. Choppers are
used to pass interrupt the IR beams.

Infrared Detectors :

Various types of detectors are used in IR sensors. Important specifications of detectors are

 Photosensitivity or Responsivity: Responsivity is the Output Voltage/Current per watt

of incident energy. Higher the better.

 Noise Equivalent Power (NEP): NEP represents detection ability of a detector and is
the amount of incident light equal to intrinsic noise level of a detector.

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 Detectivity (D*: D-star): D* is the photosensitivity per unit area of a detector. It is a
measure of S/N ratio of a detector. D* is inversely proportional to NEP. Larger D*
indicates better sensing element.In addition, wavelength region or temperature to be
measured, response time, cooling mechanism, active area, no of elements, package,
linearity, stability, temperature characteristics, etc. are important parameters which need
attention while selecting IR detectors.

Signal Processing :

Since detector outputs are typically very small, preamplifiers with associated circuitry are
used to further process the received signals. We used these sensors as a detector which
provides early detection.Process Description Brake failure indicator is a device which is
used to avoid accidents. The brake failure indicator circuit is a circuit that constantly
monitors of the condition of brakes and gives an audio visual indication. When the brake
is applied the green LED blinks and the piezo buzzer beeps for around one second if the
brake system is intact. If brake fails the red.The circuit will work only in vehicles with
negative grounding. It also gives an indication of brake switch failure. In hydraulic brake
systems of vehicles; a brake switch is mounted on the brake cylinder to operate the rear
brake lamps.The brake switch is fluid operated and doesn’t function if the fluid pressure
due to leakage. The fluid leakage cannot be detected easily unless there is a severe
pressure drop in the brake pedal. This circuit sensor the chance of brake failure by
monitoring the brake switches and reminds you of condition of brake every time the
brake is applied. The circuit comprises of IC’s, seven resistors, seven capacitors, two
LED, Two diodes and a buzzer. The circuit uses an op-amp (IC 2) as voltage comparator
and timer in constable configuration for alarm. IC 2 senses the voltage level across, the
brake switch. Its non –inverting input gets half the supply voltage through potential
divider resistors R3 and R4 of 10 Kilo – ohms each. The inverting input of IC2 is
connected to brake switch through diode DI, ICI and resistor R2.It receives a high
voltage when the brake is applied. Normally, when the brake is not applied, the output of
IC2 remains high and the red LED glows. Resistor R1 is used for The input stability of
IC2. ICI and CI provide a ripple-free regulated supply to the inverting input of IC2. IC3
is wired as a mono stable to give pulse output of one second. Timing elements RT and C4
make the output high for one second to activate the buzzer and LED2. Usually the trigger
pin of IC3 is high due to R6 and the buzzer and LED2 remains off. When the brake pedal
is pressed, pin 2 of IC2 gets a higher voltage from the brake switch and its output goes
low to switch off the red LED. When there is a pressure drop in the brake system due to
leakage, the pressure sensor works LED1 remains ‘on’And the buzzer does not
sounperforated board. The circuit can be powered form the vehicle’s battery. The circuit
requires well-regulated power supply to avoid triggering while the battery is charging
from the dynamo. IC4, C6 and C7 provide regulated 12V to the circuit. The power supply
should be taken from the ignition switch and the circuit ground be clamped to the
vehicles body. A bicolor LED can be used in place of LED1 and LED2 if desired.

Anti Collision System:

The Anti–Collision device is a detection device meant to be incorporated into cars for the
purpose of safety. As opposed to the anti–collision devices present in the market today,
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this system is not designed to control the vehicle. Instead, it serves intended to find a way
to implement a minimum spacing for cars in traffic in an affordable way. It would also
achieve safety for the passengers of a moving car. The device is made up of an infrared
transmitter and receiver.Figure 3.1 Grid formation by transmitted rays of IR sensorAlso
incorporated into it is an audio visual alarm to workin with the receiver and effectively
alert the driver and/or the passengers.The device works by sending out streams of
infrared radiation and when these rays are seen by the other equipped vehicle, both are
meant to take the necessary precaution to avert a collision. The device would still sound
an alarm even though it is not receiving infrared beams from the oncoming vehicle.This
is due to reflection of its own infrared beams.

Conclusion:-
The main aim of my project was to develop a Brake failure indicator (BFI), which is used
to avoid accidents due to brake failure. The other objectives of the project were:-
• To identify the failure of brake switch.
• To sense the fluid leakage.
• To connect the audio visual indicator.
• To avoid small number of accidents involving trains and boats caused by brake failure.

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vii) References:-
www.Electronics for you .com
Brake failure indicator system
Fundamentals of physics by Prof. R Pillai
Vas publications
www.instructables.com
Brake failure indicator@yahoo.com
www.bmwmoa.org
www.volvofocums.com

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