CHAPTER 1

INTRODUCTION

The one of most important part in the automobile is the hand brake which is also known as a
latching brake. It is used generally when the automobile is parked, thus the alternative name i.e.,
parking brakes is used to keep the car stationary also called as automobile brakes. The most common
use of a parking brake is to keep the vehicle motionless when it is parked. Car emergency brakes have
a ratchet locking usually consist of a cable directly connected to the brake mechanism this will keep
them engaged until a release mechanism button is pressed by the driver.
Automotive safety experts recommend the use of both systems to immobilize a parked car, and
the use of both systems is required by law in some places yet many individuals use only the "Park"
position on the automatic transmission and not the parking brake. It's similar with manual transmission
cars: They are recommended always to be left with the handbrake engaged, in concert with their lowest
gear (usually either first or reverse). The use of both systems is also required by law in some
jurisdictions. However, when parking on level ground, many people either only engage the handbrake
(gear lever in neutral), or only select a gear (handbrake released). If parking on a hill with only one
system results in the car rolling and damaging the car or other property, insurance companies in some
countries, for example in Germany, are not required to pay for the damages.

Hand brakes are also used to assist in hill starts on vehicles with manual transmissions. Use of the
handbrake frees both feet for use on the accelerator and clutch pedals, allowing the car to move off
without rolling back at all.

Our project comprises an electric circuit which consists microcontroller and two position sensors.
After switching on the ignition and automatically releases the hand brake & when the ignition switch
turns off it automatically engage the hand brake.

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CHAPTER 2
PROBLEM DEFINITION

1. When any driver forgets to pull the hand brake in regular car while parking. This may lead to
accidental situation. But by using the concept of automatic handbrake system, there is no
possibility of risk because by turning OFF the ignition switch, the hand brake system
automatically gets locked.
2. And also when driver forgets to remove the hand brake and drives the car then it causes damage
to the braking system of vehicle. But by using the concept of automatic handbrake system, there
is no possibility of this risk because by turning ON the ignition switch, the hand brake system
automatically gets unlocked.

CHAPTER 3
OBJECTIVES

1. Automatic hand brake release mechanism is beneficial for operator’s safety by reducing accident
chances. This system can be used in commercial cars for ease of operation. Thus, our project is
still a demonstration of it, no car has yet used such concept on ignition switch.
2. Design of Pneumatic System.
3. Design of Electronics System.

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CHAPTER 4
MAIN COMPONENTS

Main components of automatic handbrake release mechanism has been designed and manipulated in
the figures as given below,

4.1 Hydraulic Operated Brake System

Hydraulic Operated Brake system consist of following components

4.1.1 Master Cylinder.

4.1.2 Circular Disc.

4.1.3 Brake Caliper.

4.1.4 Brake Fluid.

4.1.1 Master Cylinder 

In automotive engineering, the master cylinder is a control device that converts non-hydraulic
pressure (commonly from a driver's foot) into hydraulic pressure. This device controls slave cylinders
located at the other end of the hydraulic system.

As piston(s) move along the bore of the master cylinder, this movement is transferred through
the hydraulic fluid, to result in a movement of the slave cylinder(s). The hydraulic pressure created by
moving a piston (inside the bore of the master cylinder) toward the slave cylinder(s) compresses the
fluid evenly, but by varying the comparative surface-area of the master cylinder and/or each slave
cylinder, one can vary the amount of force and displacement applied to each slave cylinder, relative
to the amount of force and displacement applied to the master cylinder.

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 Figure 4.1.1: Dimensions of brake cylinder
4.1.2 Circular Disc

Floating discs have better disc centering with a fixed caliper. A floating disc also avoids disc
warping and reduces heat transfer to the wheel hub. Lambretta were the first manufacturer to use
floating discs on a volume production motor cycle. Wavy discs place the mass closer to the axle for
reduced inertia, better heat dissipation and lower weight. They were originally developed for Motor
cross bikes however they have since seen use on road going motorcycles as well.

Figure 4.1.2: Two Wheeler Disc

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4.1.3 Brake Caliper

The brake caliper is the assembly which houses the brake pads and pistons. The pistons are
usually made of plastic, aluminum or chrome-plated steel.

Calipers are of two types, floating or fixed. A fixed caliper does not move relative to the disc
and is thus less tolerant of disc imperfections. It uses one or more pairs of opposing pistons to clamp
from each side of the disc, and is more complex and expensive than a floating caliper.

A floating caliper (also called a "sliding caliper") moves with respect to the disc, along a line
parallel to the axis of rotation of the disc; a piston on one side of the disc pushes the inner brake pad
until it makes contact with the braking surface, then pulls the caliper body with the outer brake pad so
pressure is applied to both sides of the disc. Floating caliper (single piston) designs are subject to
sticking failure, caused by dirt or corrosion entering at least one mounting mechanism and stopping
its normal movement. This can lead to the caliper's pads rubbing on the disc when the brake is not
engaged or engaging it at an angle. Sticking can result from infrequent vehicle use, failure of a seal or
rubber protection boot allowing debris entry, dry-out of the grease in the mounting mechanism and
subsequent moisture incursion leading to corrosion, or some combination of these factors.
Consequences may include reduced fuel efficiency, extreme heating of the disc or excessive wear on
the affected pad. A sticking front caliper may also cause steering vibration.

Figure 4.1.3: Working of Caliper

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4.1.4 Brake Fluid

Brake fluid is a type of hydraulic fluid used in hydraulic brake and hydraulic clutch
applications in automobiles, motorcycles, light trucks, and some bicycles. It is used to transfer force
into pressure, and to amplify braking force. It works because liquids are not appreciably compressible
in their natural state, the component molecules do not have internal voids and the molecules pack
together well, so bulk forces are directly transferred to compress the fluid's chemical bonds.

Most brake fluids used today are glycol-ether based, but mineral oil (Citroën/Rolls-Royce
liquid hydraulic mineral (LHM) and silicone (DOT 5) based fluids are also available.

Brake fluids must meet certain requirements as defined by various standards set by
organizations such as the SAE, or local government equivalents. For example, most brake fluid sold
in North America is classified by the US Department of Transportation (DOT) under its own ratings
such as "DOT 3" and "DOT 4". Their classifications broadly reflect the concerns addressed by the
SAE's specifications, but with local details - Alaska and the Azores have different normal temperature
and humidity ranges to consider, for example; many countries defer explicitly to the SAE
specifications, or simply refer to "best practice" which in application would defer to SAE standard.
All approved fluids must be colorless or amber to be acceptable for street use in the U.S, except for
DOT 5 silicone, which must be purple.

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4.2 Pneumatic System

4.2.1 Pneumatic Cylinder (Single Acting Cylinder).

4.2.2 Pneumatic 5/2 Solenoid Valve.
4.2.1 Pneumatic Cylinder (Single Acting Cylinder)

Pneumatic cylinder(s) (sometimes known as air cylinders) are mechanical devices which use the
power of compressed gas to produce a force in a reciprocating linear motion.

Single-acting cylinders (SAC) use the pressure imparted by compressed air to create a driving
force in one direction (usually out), and a spring to return to the "home" position. More often than not,
this type of cylinder has limited extension due to the space the compressed spring takes up. Another
downside to SACs is that part of the force produced by the cylinder is lost as it tries to push against
the spring.

Figure 4.2.1: Single Acting Cylinder

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4.2.2 Pneumatic 5/2 Solenoid Valve

A valve is a device that regulates the flow of fluid (gases, liquids, fluidized solids, or slurries)
by opening and closing or partially obstructing passage ways.

A 5/2 way directional valve from the name itself has 5 ports equally spaced and 2 flow
positions. It can be used to isolate and simultaneously bypass a passage way for the fluid which for
example should retract or extend a double-acting cylinder. There are variety of ways to have this valve
actuated. A solenoid valve is commonly used, a lever can be manually twist or pinch to actuate the
valve, an internal or external hydraulic or pneumatic pilot to move the shaft inside, sometimes with a
spring return on the other end so it will go back to its original position when pressure is gone, or a
combination of any of the mention above.

Figure 4.2.2: 5/2 Way Solenoid Valve.

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4.3 Ignition Switch

An ignition switch or starter switch is a switch in the control system of an internal combustion
engine motor vehicle that activates the main electrical systems for the vehicle. Besides providing
power to the starter solenoid and the ignition system components (including the engine control unit
and ignition coil) it also usually switches on power to many "accessories" (radio, power windows,
etc.). The ignition switch usually requires a key be inserted that works a lock built into the switch
mechanism. It is frequently combined with the starter switch which activates the starter motor. The
ignition locking system may be bypassed by disconnecting the wiring to the switch and manipulating
it directly; this is known as hotwiring.

Figure 4.3 Ignition Switch

4.4 Arduino Uno

The Arduino Uno is a microcontroller board based on the ATmega328 (datasheet). It has 14 digital
input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz crystal
oscillator, a USB connection, a power jack, an ICSP header, and a reset button. It contains everything
needed to support the microcontroller; simply connect it to a computer with a USB cable or power it
with a AC-to-DC adapter or battery to get started. The Uno differs from all preceding boards in that it
does not use the FTDI USB-to-serial driver chip. Instead, it features the Atmega8U2 programmed as
a USB-to-serial converter.

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"Uno" means "One" in Italian and is named to mark the upcoming release of Arduino 1.0. The Uno
and version 1.0 will be the reference versions of Arduino, moving forward. The Uno is the latest in a
series of USB Arduino boards, and the reference model for the Arduino platform; for a comparison
with previous versions, see the index of Arduino boards.

Technical Specifications

Microcontroller ATmega328.

Operating Voltage 5V.

Supply Voltage (recommended) 7-12V.

Maximum supply voltage (not recommended) 20V.

Digital I/O Pins 14 (of which 6 provide PWM output)

Analog Input Pins 6.

DC Current per I/O Pin 40 mA.

DC Current for 3.3V Pin 50 mA.

Flash Memory 32 KB of which 0.5 KB used by boot loader.

SRAM 2 KB (ATmega328).

EEPROM 1 KB (ATmega328).

Clock Speed 16 MHz

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CHAPTER 5
AUTOMATIC HANDBRAKE RELEASE MECHANISM

The newer concept was to introduce Microcontroller which can lead to efficient as well as
flexible in design and manipulate the Pneumatic Actuator. The use of Pneumatic Actuator made our
operation easy and risk free.
The construction of newer circuit is much differs from primary one. In this, we used only one master
cylinder of regular braking system. We have used the master cylinder of two wheeler disc brake.
Because, use of four wheeler master cylinder requires the extra force by Pneumatic Actuator, which
have a high cost. So, just we replaced it with help of small master cylinder. In regular braking system,
the master cylinder is connected to the brake pedal and then to the caliper on disc brake. The difference
between regular brake system and an automatic handbrake system is as shown in figure:

Figure 5.1: Regular Handbrake System and Automatic Handbrake System

List of Components consists of as follows,

a) Hydraulic operated braking system i.e., Master Cylinder, Brake Caliper,
b) Braking –using Disk brake to ensure optimal braking force and minimum braking distance
c) Electronically operated solenoid valve.
d) Single acting cylinder.
e) Power supply unit and recharging unit.
f) Microcontroller.

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 Figure 5.2: Overall logic diagram of an automatic handbrake release mechanism.

The working basically consist of three conditions as follows,

5.1 Normal running condition:

When the vehicle is normal running condition then, the solenoid valve which is fitted in a fluid
supply line is in an on condition. By using microcontroller the solenoid valve energizes and there is
regularly flow of fluid supply as per normal braking action. Fluid passes through master cylinder to
the brake disc.

5.2 Ignition switch turning OFF condition:

When ignition switch is turned off, the position sensor sends signal to microcontroller which
gives a command to the Solenoid Valve (5/2 valve). The Solenoid valve supplies compressed air to
single acting cylinder(Spring return) force will act in the Master Cylinder piston and fluid gets
pressurized therefore brake gets applied.

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5.3 Ignition switch turning ON condition:

When ignition switch is turned on, signal passes to the Microcontroller. Microcontroller give
command to the Solenoid valve and it de-energizes fluid pressure in Master Cylinder and brake
disengages.

Figure 5.3: Overall assembly.

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CHAPTER 6
DRAWING ASSEMBLY

6.1 Assembly Design on Frame

Fig 6.1 Assembly of Project Design

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CHAPTER 7
DESIGN AND CALCULATIONS

7.1 Design of Frame

The Frame fabricated for our project which is made up of M.S. It is welded accordingly for
arrangement of the system components. The Frame along with dimension is shown in figure below:

Fig 7.1 Frame Construction

Frame Specification:
 Size of Frame: 60 x 30 mm
 Material of Frame: Mild Steel
 Unloaded Weight of Frame: 2.65 kg
 Loaded weight of frame: 9.7 kg

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7.2 Force Calculation

Fig 7.2 Dimension and Force applied

By lever principal:
32 × 1.9 = 8 x A
60.8 ÷ 8 = A
A = 7.6 kg
A = 74.556 N.
Applying Pascal’s law:
i.e., “Pressure exerted on a confined liquid is transmitted undiminished in all directions and acts at
right angles with equal force on all areas of the container”.
P=F÷A
P = 74.556 † [(π/4) × (12.7)2] P = 0.588 N/mm2
The intensity of pressure is constant throughout system, for caliper:
There are two cylinders in caliper. Therefore, force for one cylinder is: F = P × A
F = 0.588 × [(π/4) × 252] F = 288.63 N.
But the force is applied by two cylinders, so force developed by 2 cylinders is: 288.63 + 288.63 =
577.20 N.
In case of handbrake, generally only 60% of handbrake we use while braking instead of total brake.
So force required for handbrake is 60% of total.
Therefore, 60% of total brake is, 0.6 × 74.55 = 44.73 N
Now, for our automatic handbrake system, we have to choose an actuator which will produce nearby
45 N of force.

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CHAPTER 8
COST ESTIMATION

SL LIST OF COMPONENTS QUANTITY PRICE

NO.
1 Master Cylinder of two wheeler 1 1200
2 Disc Caliper 1 1500
3 Hose Pipe 1 250
4 Pneumatic Cylinder (Single acting) 1 1000
5 Solenoid Valve(5/2) 1 1800
6 Ignition Switch 1 200
7 Frame 1 500
8 Microcontroller 1 600
9 Fabrication - 650
10 Miscellaneous Cost 2000

Total Cost 9700

Table No 8.1: Cost Estimation

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CHAPTER 9
ADVANTAGES AND DISADVANTAGES

9.1 ADVANTAGES

1. Driver or Operator does not require any extra efforts.

2. Operator safety by reducing accident chances as well as disengaging chance of braking.

3. The Hydraulic braking system avoid rare wheel skid.

4. The Hydraulic braking system reduces speed and stops the vehicle with less force.

5. The Hydraulic braking system stopping distance is generally reduced.

6. Steering can be controlled easily.

7. There is no chance of brake failure.

8. Hydraulic braking is powerful and faster than the standard.

9. Automatic Handbrake System apply handbrake for all four wheel.

10. Automatic Handbrake System saves the fuel by turning off the engine in traffic signal.

9.2 DISADVANTAGES

1. For Automatic Handbrake System always require power energy.

2. Automatic Handbrake System cannot be implemented in Rally Cars.

3. Automatic Handbrake System does not assist in hill starts on vehicles.

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CHAPTER 10
CONCLUSIONS

1. Automatic hand brake release mechanism is beneficial for operator’s safety by reducing accident
chances as well as disengaging chances of braking. This system can also be used in commercial
cars for ease of operating as well for reducing cost purpose. Along with it, we can also modify our
system by using the spring at the power actuator by using it as reverse purpose. Thus, our project
is still a demonstration of it, no car has yet used such concept on ignition switch.
2. This project gives a new idea of automatic hand braking system which can be applied in car
manufacturing industries as well as companies.
3. The working is quite simple and doesn’t require any extra effort to operator or driver.
4. Even though when any driver forgets to pull the hand brake in regular car, the driver can be in any
critical situation but by using the concept of automatic handbrake system, there is no possibility
of risk because by putting the ignition switch OFF, the hand brake system is automatically gets
locked.

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