VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI, 590014

Project Report on

“ANALYSIS AND DESIGN OF INTELLIGENT BRAKING

SYSTEM”
Submitted in partial fulfilment of the requirement for the award of
the degree

Bachelor of
Engineering in
“Mechanical Engineering”
Submitted by
HARSHITH K 1MJ16ME027

JUNAID PASHA 1MJ16ME029

MUDASSIR AHMED 1MJ16ME040

Under the guidance of

Dr. MADHUSUDANA CK

Associate Professor, Department of Mechanical

Engineering

MVJCE, Bengaluru-560067

Department of Mechanical Engineering Near ITPB Channasandra,

Bengaluru-560067

2019-20
 DEPARTMENT OF MECHANICAL ENGINEERING
BENGALURU

CERTIFICATE
Certified that the project work entitled “Analysis and Design of Intelligent braking system”
carried out by

HARSHITH.K 1MJ16ME027
JUNAID PASHA 1MJ16ME029

MUDASSIR AHMED

1MJ16ME040

A bonafide student of MVJ College of Engineering in partial fulfilment for the award of
Bachelor of Engineering in Mechanical Engineering of the Visveswaraiah Technological
University, Belgaum, during the year 2019-20. It is certified that all corrections/ suggestions
indicated for Internal Assessment have been incorporated in the Report deposited in the
departmental library. The project report has been approved as it satisfies the academic
requirements in respect of Project work prescribed for the said Degree.

Signature of the Signature of the HOD Signature of the

Guide Principal
(Dr Madhusudana (Mr. Vivekananda Huddar) (Dr.
CK) Mahabaleshwarappa)

External Viva

Name of the examiners Signature with date

1

2
ANALYSIS AND DESIGN OF INTELLIGENT BRAKING SYSTEM 2019-2020

DECLARATION

We, hereby declare that the project work entitled “Analysis and Design of Intelligent braking system”
has been independently carried out by us under the guidance of Dr Madhusudana.CK Associate
Professor, Department of Mechanical Engineering, MVJ College of Engineering, Bangalore, in partial
fulfilment of the requirements of the degree of BE in Mechanical branch of Visvesvaraya Technological
University, Belgaum.

We further declare that we have not submitted this report either in part or in full to any other university
for the award of any degree.

Place: MVJCE, Bengaluru Date:

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ABSTRACT: Many of the ordinary brakes, which are being used now days stop the
vehicle by means of mechanical blocking. This causes skidding and wear and tear of the
vehicle. And if the speed of the vehicle is very high, the brake cannot provide that much high
braking force and it will cause problems. These drawbacks of ordinary brakes can be
overcome by a simple and effective mechanism of braking system 'The eddy current brake'.
It is an abrasion-free method for braking of vehicles including trains. It makes use of the
opposing tendency of eddy current.

Intelligent Braking System approach represents a significant shift from the traditional
approach to safety, but it is fundamental to achieving the substantial benefits. It is
necessary to control brakes through electronic devices to minimize accident problems.
This complete setup can be fixed onto a vehicle and can be monitored in the dashboard of
the vehicle. This system employs different types of sensors to constantly monitor the
condition of the vehicle and respond in an emergency situation. These sensors provide
real-time inputs to the microprocessor by using these sensors the microprocessor in the
system activates the brakes and make the vehicle to stop.

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TABLE OF CONTENTS:
TITLE PAGE NO

ABSTRACT 4

CHAPTER 1

INTRODUCTION

1.1 EDDY CURRENT BRAKING 6

1.2 INTELLIGENT BRAKING SYSTEM 9

1.3 ULTRASONIC SENSOR 10

1.4 COMPONENTS LIST

11
1.5 ADVANTAGES AND APPLICATIONS
CHAPTER 2
2.1 LITERATURE SURVEY 12
2.2 PRESENT ART WORK 13
2.3 RESEARCH GAP
2.4 OBJECTIVES 16

CHAPTER 3

METHODOLOGY 17-22

CHAPTER 4

23
4.1 CONCLUSION
24
4.2 FUTURE SCOPE
4.3 REFERENCES 25

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 CHAPTER 1

INTRODUCTION

The current problem in the conventional brakes is that the braking torque is not sufficient
for the automobiles that are in production these days and also have consistent wear of
brake pads. The chances of failure are even higher at high speeds So a hybrid braking
system is developed in order to overcome these problems. It’s called a hybrid braking
system because it is a combination of two braking systems namely eddy current braking
and electromagnetic braking systems. The mechanism is divided into two main parts
which are listed below.

1.1EDDY CURRENT BRAKING:

PRINCIPLE: Eddy current brake works according to Faraday's law of electromagnetic

induction. According to this law, whenever a conductor cuts magnetic lines of forces, an
emf is induced in the conductor, the magnitude of which is proportional to the strength of
magnetic field and the speed of the conductor. If the conductor is a disc, there will be
circulatory currents i.e. eddy currents in the disc. According to Lenz's law, the direction of
the current is in such a way as to oppose the cause, i.e. movement of the disc.

Fig 1.1: Principal of Eddy Current Braking

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OPERATION: Essentially the eddy current brake consists of two parts, a stationary
magnetic field system and a solid rotating part, which include a metal disc. During braking,
the metal disc is exposed to a magnetic field from an electromagnet generating eddy currents
in the disc .The magnetic interaction between the applied field and the eddy currents slow
down the rotating disc.Thus the wheels of the vehicle also slow down since the wheels are
directly coupled to the disc of the eddy current brake, thus producing smooth stopping
motion.

Fig 1.2: Operation of Eddy Current Braking

WORKING: Essentially an eddy current brake consists of two members, a stationary

magnetic field system and a solid rotary member, generally of mild steel, which is
sometimes referred to as the secondary because the eddy currents are induced in it. Two
members are separated by a short air gap, they're being no contact between the two for the
purpose of torque transmission. Consequently there is no wear as in friction brake.

Stator consists of pole core, pole shoe, and field winding. The field winding is wounded on
the pole core. Pole core and pole shoes are made of east steel laminations and fixed to the
state of frames by means of screw or bolts. Copper and aluminium is used for winding
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material.

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This system consists of two parts.

1. Stator

2. Rotor

When the vehicle is moving, the rotor disc of eddy current brake which is coupled to the
wheels of the vehicle rotates, in close proximity to stationary magnetic poles. When
we want to brake the vehicle, a control switch is put on which is placed on the steering
column in a position for easy operation.

When the control switch is operated, current flows from a battery to the field winding, thus
energizing the magnet. Then the rotating disc will cut the magnetic field. When the disc
cuts the magnetic field, flux changes occur in the disc which is proportional to the strength
of the magnetic field. The current will flow back to the zero field areas of the metal plate
and thus create a closed current loop like a whirl or eddy. A flow of current always means
there is a magnetic field as well. Due to Lenz's law, the magnetic field produced by the
eddy currents works against the movement direction.

Thus instead of mechanical friction, a magnetic friction is created. In

consequence, the disc will experience a "drag" or the braking effect, and thus the disc stops
rotation. The wheels of the vehicle, which is directly coupled to the disc, also stop rotation.
Faster the wheels are spinning, stronger the effect, meaning that as the vehicle slows the
braking force is reduced producing a smooth stopping action.

The control switch can be set at different positions for controlling the excitation current to
several set values in order to regulate the magnetic flux and consequently the magnitude of
braking force. i.e. if the speed of the vehicle is lpw, a low braking force is required to stop
the vehicle. So the control switch is set at the lowest position so that a low current will be
supplied to the field winding. Then the magnetic field produced will be of low strength, so
that a required low braking force is produced.

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 1.2 INTELLIGENT BRAKING SYSTEM
The Braking System is the most critical system on your vehicle. Its maintenance and proper
functioning are vital to you, your family and other motorists. You should not attempt to
effectuate maintenance or repair work on brakes. Servicing or repairing the braking system
requires specific tools and adequate technical training. That is exactly what Auto tech
Performance offers you.

WORKING: The brake pedal, on which you apply pressure to slow down or stop your
vehicle, is connected by levers and rods to the brake booster. The brake booster multiplies
and transfers the leverage force produced by stepping on the brake pedal to the master
cylinder. In turn, the master cylinder uses that amplified leverage to pressure the brake
fluid from its reservoir through hydraulic lines toward the two front and rear brakes that
are mounted on the wheels of the vehicle.
The hydraulic pressure that reaches each wheel’s brake is then used to create friction to
slow down and stop the vehicle: the harder you push on the pedal, the more pressure is
applied to the brakes, eventually locking the wheels – that is if your vehicle if not equipped
with an Anti lock Braking System (ABS).

1.3 Ultrasonic sensor : With the proposed framework these sorts of mischances can be turned
away. Utilizing a HALL sensor the framework will sense the rate of the vehicle and with
the microcontroller, it will compute the braking separation: that is the separation required to
convey the vehicle to a complete stop for that speed. Utilizing an Optical sensor, the
framework will sense any moving or stationary hindrance in front and ceaselessly monitor
its separation. At the point when the driver sees a deterrent in front and backs off there is
no issue. Then again, in the event that he doesn’t have any significant bearing brakes and
continue the same velocity, he goes to a point where the separation of the impediment

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equivalents to braking separation. This is the last risk for the driver to apply the brake and
back off the vehicle. In the event that regardless he goes at the same speed, the
microcontroller in the framework will actuate the brakes and evade an impact by conveying
the vehicle to astop. Regularly, one would not stop at a moment that the vehicle is touching
the impediment. Some separation is left before the snag.
The separation is additionally accounted by the microcontroller.

Fig1.3: ULTRASONIC SENSOR

1.4 COMPONENT LIST:

1. ULTRASONIC SENSORS

2. MICROCONTROLLER

3. WIRELESS REMOTE CIRCUIT

4. DC MOTOR

5. BRAKES

6. SENSOR

7. bicycle

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1.5 ADVANTAGES:

 Due to contactless braking efficiency of braking increases.

 Automatic braking reduces the risk of damages.

 Reduces the possibility of brake lock up.

 Faster reactions to situations because of completely brakes are monitored by
sensors and circuits.

APPLICATIONS:

 We can use this system as safety purpose.

 accurate system for automatic braking system.

 operating force is required

 Automated operation

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 CHAPTER 2

2.1 LITERATURE SURVEY

The current development in eddy current brakes is taking place mainly in bullet trains and
not much is focused on automobiles. Even the few systems which use eddy current
brakes, use it as a secondary brakes along with conventional hydraulic brakes. The
current research is mainly focused on reducing the size of the system and fulfil its power
requirements. Electromagnetic braking systems are also being used in trains, Electric
motors in industrial and robotic applications also employ electromagnetic brakes. Recent
design innovations have led to the application of electromagnetic brakes to aircraft
applications. In this application, a combination motor/generator is used first as a motor to
spin the tires up to speed prior to touchdown, thus reducing wear on the tires, and
then as a generator to provide regenerative braking.

All vehicles have brakes, and they always did. Ever since man discovered the wheel,
stopping it was a problem. Carts, wagons and carriages had brakes, usually simple
blocks rubbing on a wheel. This established a basic that has yet to change, even with the
most sophisticated brake system. All brakes use friction to stop the vehicle. An ABS can
be expensive to maintain. Expensive sensors on each wheel can cost hundreds of dollars
to fix if they get out of calibration or develop other problems. ABS can only help if the
rider applies it in the right time manually and maintains the distance calculations. ABS
has its own braking distance. For some, this is a big reason to decline an ABS in a
vehicle.

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2.2 PRESENT ART OF WORK :

 Oscar Rodrigues et al. [2016] [1], The purpose of the study was to perform a
comparative study of theoretical and practical braking time and establish a practical
air gap limit beyond which the electromagnetic brakes lose their effectiveness. From
theoretical calculations and experimented braking time values, a maximum reduction
in braking time 23.97% is found and max air gap limit of 3 mm is obtained beyond
with electromagnetic brakes are found to be ineffective.

 Baoquan Kou et al [2015] [2], in this paper, a novel hybrid excitation linear eddy
current brake was presented. The hybrid excitation linear eddy current brake has the
advantages of high force density and low excitation loss compared to the electric
excitation linear eddy current brakes. The validity of the analytical model was verified
by the FEM and experimental tests, therefore the analytical model can be used in the
preliminary design of eddy current brakes. Parametric analysis was performed to
explore the influence of the design parameters on the eddy current brake performance.
Moreover, the experimental results show that the eddy current brake can generate
objective braking force using the controller proposed in this paper. It has been found
that the proposed eddy current brake system can be used in road and rail vehicles.

 Kumar Singh et al [2014] [3] this paper presented a detailed study of different types
Eddy Current Braking System.Various applications of ECBS such as retarders in high
speed trains, in automobiles, dampers, couplers and in the air bearing system have been
studied. Various design parameters on which the performance of ECBS depends have
been discussed. It has been observed that some parameters like air gap length, the
electrical conductivity of conductor, the speed of conductor are common in all the
applications. Effect of parameters on the performance of ECBS has also been
discussed. Main parameters which affect the performance of ECBS are the thickness
of conductor, air-gap length, the electrical conductivity of conductor,

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 properties of conductor. The value of design parameters should be taken in such a
way to achieve optimum braking performance.

 Yasuaki Sakamoto et al [2008] [4], they have estimated the performance of the eddy
current brake using a LIM for dynamic braking from experimental results of a
fundamental test machine. We confirmed that the LIM under constant current
excitation has an approximately constant braking force regardless of both the velocity
and frequency, for relatively low frequencies. The LIM generates electric power which
is determined by only the frequency. The peak value of the reduction ratio of rail
heating is 60%. These characteristics are convenient for designing a controller for the
LIM rail brake system.

 Sohel Anwar and Bing Zheng [2007] [5], they have a nonlinear sliding-mode- type
controller is presented for slip regulation in a braking event for an eddy- current-based
BBW system in this paper. It is also shown that the closed-loop system is stable in the
sense of Lyapunov. Experimental results show very good slip regulation in a braking
event on the low friction coefficient surface when compared with the non-ABS
braking condition. The results show that the proposed ABS controller provided a
smooth ABS

 Garrest N. and Vanderplaats (1979), suggests the technique of automated design

using numerical optimization. Numerical optimization first involves the concept
description in physical terms to give a basic understanding of the iterative procedure
employed by these methods. Next, the typical engineering task is presented and
converted to a form amenable to solution by numerical optimization. Basic algorithm
for solving this problem is identified. The state of the art allows for the routine
solution of nonlinear design problems of approximately 20 independent variables
subject to 100 or more constraints. In many applications, much larger design problems
may be solved. The basic approach of this study is incorporated in this design
optimization work along with the following optimization procedures in the ensuing
literatures.

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 Bal (2000), suggests that, stochastic signomial geometric programming is an
effective tool for the optimum design of a brake disc considering random nature of
design variables. This program also takes into account the probability of satisfying
constraint equation, so that, the design approach is more realistic. The calculation
equations in this approach are as such introduced for the design of a brake disc for a
light duty passenger vehicle.

 A.K. and Pratihar (2002) suggests that, optimization through genetic algorithm yields
better results in the machine element design under certain circumstances. The same
design through traditional methods has some drawbacks such as there is a chance for
the solutions get trapped into local minima. The algorithm developed for one type of
problem, may not be suitable to solve another type of problem. In this context, the real
coded genetic algorithm proved to be a versatile design optimization algorithm for
design of machine elements. The designoptimization procedure adopted by these
authors is as such incorporated in this work to determine the exact dimensions of a
brake disc.

 Book of statistical quality control (SP : 28 – 1985) (Source Indian standards (IS :
7300 – 1974), deals with methods of regression and correlation. This method deals
with the statistical methods of regression and correlation in the case of two variables.
Regression deals with situation where the variation of one variable is dependent on
the variation of second variable. This technique is as such incorporated in this work
to determine the inner and outer radius of the brake disc by satisfying the constraint
of maximum torque transmission by the brake disc.

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2.3. RESEARCH GAP:

• Eddy current braking is suitable for reducing wear and chances of failure is less at
very high speeds as it is contactless.
• Thicker the aluminum disc, more will be the braking torque.

• Increasing the magnetic flux passing through the rotor can increase the braking
torque.
• The magnetic flux in the electromagnets is directly proportional to the square of
current passing through the coils.
• The braking torque decreases as the distance between the electromagnets increases
as they are inversely proportional to each other. So the electromagnets are
supposed to be placed close to the rotor as much as possible.
• With the implementation of sensors reaction taken towards activating the brakes
increases.

2.4 OBJECTIVES:

• Develop a circuit that actuates the supply of current to the brakes.

• To program the microcontroller.

• Replacement of conventional brake pads into aluminium disk.

• Installing the circuit in bicycle.
• Speed and braking torque calculations.

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 CHAPTER 3
METHODOLOGY

3.1 Methodology Flowchart:

DEVELOPMENT OF CIRCUIT small step to emphasize

that there can be a better braking system than the conventional brakes in terms of

SELECTION OF SENSOR AND MICROPROCESSOR

PROGRAMMING OF MICROPROCESSOR

INSTALLATION OF CIRCUIT AND SENSOR ON THE BICYCLE

SELECTION OF ALUMINUM DISC

REPLACING BRAKE PADS WITH ALUMINUM DISCS

SELECTION OF SUPPORTING COMPONENTS

DEVELOPING THE MODEL AND TESTING

RESULTS AND CONCLUSION

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3.1 PRINCIPAL COMPONENTS OF INTELLIGENT BRAKING
SYSTEM ULTRASONIC SENSOR:
Ultrasonic ranging and detecting devices make use of high-frequency sound waves to
detect the presence of an object and its range. These systems either measure the echo
reflection of the sound waves from objects or detect the interruption of the sound beam as
the objects pass between the transmitter and receiver. An ultrasonic sensor typically
utilizes a transducer that produces an electrical output pulse in response to the received
ultrasonic energy. In such case, the horizontal aperture angle must be at least 8 degrees for
an inter-vehicle distance of 75 meter. The vertical aperture is fixed to be 1 degree and is
positioned in such a way to avoid fault reading due to the road conditions.

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 Fig 3.1 Ultrasonic sensor
1. Working Voltage DC 5 V

2. Working Current 15mA

3. Frequency 40Hz

4. Range 4m

5. Range 2cm

6. Angle 15 degree

7. Trigger Input Signal 10uS TTL puls

8. Output Signal Input TTL lever signal and the range in proportion

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9. Dimensions 45*20*15mm

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PROCESSOR (ARDUINO UNO)

The Arduino Uno is a microcontroller board based on the ATmega328. It has 14 digital
input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz
ceramic resonator, 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.
"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.

Fig 3.2 Arduino Processor

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DC MOTOR LINEAR ACTUATOR

Specifications:

Voltage: 12V DC
Stroke length: 2 inch
Duty cycle: 25% load
current: 3 Amp
No load current < 1 Amp

STEP DOWN LOW FREQUENCY TRANSFORMER

Specifications:

Power: 0.5 V-amp to 200 V-amp

Coil structure: Toroidal
Phase: Single phase
Winding turns: Encapsulated Transformer / Autotransformer Cooling: Air cooled

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3.2 MATHEMATICAL MODELLING

3.3 Introduction:

The current study presents the derivation of mathematical modeling of intelligent braking
system solely by carrying out various test for calculation of load distribution, braking force
and pressure analysis It is carried out to optimize the mathematical model in order to
achieve the desired results. When vehicle is in motion, different forces acts on it during
braking of vehicle i.e., sum of all the static and dynamic forces comes in picture to achieve
safe and smooth braking operation we work on different parameters as follows

Assumptions regarding Bicycle

1. Weight of bicycle:

2. Frictional coefficient of wheel:

3. Frictional coefficient between disc & cylinder:

4. Wheel base:

5. C.G. of bicycle from ground:

6. Dia. of tire:

7. Inner diameter of disc (Di):

8. Outer diameter of disc (Do):

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LOAD DISTRIBUTION ANALYSIS

Load distribution is as follows:

•On front wheel:

•On Rear wheel:

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BRAKING FORCE AND PRESSURE ANALYSIS

Static load on wheel Fs = µf× Rn

Dynamic weight transfer Fd = (m × a × h)/w Total

load FT= Fs + Fd

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 CHAPTER 4

CONCLUSION AND FUTURE SCOPE AND WORK

4.1 CONCLUSION: While concluding this part, we feel quite satisfied with having
completed the project synopsis well on time. We had enormous practical experience on
the manufacturing schedules of the working project model. We are, therefore, happy to
state that the inculcation such of mechanical aptitude proved to be very useful. We are
overwhelmed at the arriving of the targeted mission. Undoubtedly the joint venture had
all the merits of interest and enthusiasm shown by all us the credit goes to the healthy
coordination of our batch colleague in bringing out a resourceful fulfilment of our
assignment described by the university. The design criterion imposed challenging
problems which however were welcome by us due to the availability of good research
papers. The selection of choice of raw materials helped us in minimizing the level of wear
and tear.

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 4.2 FUTURE SCOPE:

This project is a small step to emphasize that there can be a better braking system than the
conventional brakes in terms of efficiency and safety.
 The braking system is very heavy so future work needs to be done in reducing its
weight.
 The braking system takes a lot of space to make it commercial it should be made as
compact as possible.
 The power requirements of the braking system is very high. So it can only be
implemented in electric cars and trains.
 New sensory systems and sensory fusion is to be explored to plug additional
information to the control system.
 This work can be extended to include different maneuvers to make the driving
system capable of dealing with all driving environments.
 Future issues may also include an algorithm for autonomous formation of the
cooperative driving.

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 REFERENCES:

1. Liu Chengye, and Shen Jianming , Design Technologies of Eddy Current

Retarder Used in an Automobile, School of Mechanical & Automotive Engineering,
Jiangsu Teachers University Applied Mechanics and Materials Vol. 251 (2013) pp
134138.[1]
2. G.L.Anantha Krishna1, K.M.Sathish Kumar, Investigation on Eddy Current
Braking. Mechanisms , BMS Institute of Technology(2014), ISSN: 1662-7482,
Vols. 592-594, pp 1089-1093[2]
3. Ren He, 1 Xuejun Liu, and Cunxiang Liu Brake Performance Analysis of ABS for
Eddy Current and Electrohydraulic Hybrid Brake Mechanism hindawi publishing
Corporation. Mathematical Problems in Engineering, Volume 2013, Article ID 979384,
11 pages.[3]
4. E. Galardi, E. Meli, D. Nocciolini, L. Pugi & A. Rindi, Development of efficient
models of Magnetic Braking Mechanisms of railway vehicles, International Journal of
Rail Transportation (2015), Vol. 3, No. 2, 97–118[4]
5. Srinivasa Chari v Dr Venkatesh pr. Dr Prasanna Rao NS, Adil Ahmed S.Automatic
pneumatic Bumper And Break Actuation Before Collision, 2015, International
Research Journal Of Engineering And Technology (Irjet) Volume: 02 Issue: 04,
Pp1015-1023
6. Dr. P. Poongodi. Mr. P. Dineshkumar, Automatic Safety System For
Automobiles
7. Dr Eung soo Kim, fabrication of Auto Braking System using Sensor, International
Journal Of Control And Automation, Vol-2, And No1.
8. Takahiro Wada, A Deceleration Control Method Of Automobile For Collision
Avoidance Based On Driver Perceptual Risk IEEE International Conference On
Intelligent Robots And Systems, Oct 4881-4886.

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