MEE3999

Technical Answers to Real World

Problems (TARP)
SLOT – TF1
FACULTY – PROF. ANTHONY XAVIOR M

PROJECT TOPIC: Automatic Braking System and

Crash Analysis of Automobiles

PREPARED BY: -
NAME REGISTER NUMBER
SUYASH MANKAR 16BME0431
AKASH SAVALIYA 16BME0386
SACHIN KUMAR VERMA 16BME0430
SHIVAM KENCHE 16BME0241
K.S.N SAI ABHISHEK 16BME0092
M.RAMANUJA 16BME0229
SACHIT AGARWAL 16BME0814
OBJECTIVES: -
 To design a vehicle with less human attention to the driving
The main objective of this system is to help driver prevent car collisions due to over
speeding in the car by letting the system control the braking of the car automatically
 To develop a safety car braking system using ultrasonic sensor
This is achieved by calculating the distance by means of an ultrasonic sensor, which is
connected to the brake control system, triggering it in case of emergency, thereby
preventing road accidents.
 To perform crash analysis of car to check the crashworthiness of a car during
accidents
To check the automotive crashworthiness physical tests are to be done which are both
costly and time consuming, to prevent this various method like FEA and computational tools
are being used to analyze a car crash. Designing a optimized vehicle structure that can
absorbs crash energy by controlled vehicle deformation while maintaining adequate space
for passengers.

PROBLEM STATEMENT: -
• Nowadays, the number of accidents is so high and uncertain. Accident will occur
every time and everywhere and cause worst damage, serious injury and dead. These
accidents are mostly cause by delay of the driver to hit the brake.
• So, our problem statement is to develop a mechatronic system that can avoid this
accident where drivers may not brake manually but the vehicles can stop
automatically due to obstacles using ultrasonic as a ranging sensor.

EXPERIMENTS (HARDWARE REQUIRED): -

SOLUTION APPROACH :-
 When the car prototype is powered on, both the motors of the car will run normally,
and the car moves forward. During this time, the ultrasonic sensor continuously
calculates the distance between the car and the reflective surface.
 This information is processed by the Arduino. If the distance between the car and
the obstacle is less than 15cm, the car stops and scans in left and right directions for
new distance using Servo Motor and Ultrasonic Sensor. If the distance towards the
left side is more than that of the right side, the car will prepare for a left turn. But
first, it backs up a little bit and then activates the Left Wheel Motor in reversed in
direction.
 Similarly, if the right distance is more than that of the left distance, the car prepares
right rotation. This process continues forever, and the car keeps on moving without
hitting any obstacle.

DESIGN OF THE SYSTEM: -

WORKING MODEL: -

RESULTS: -
 The ultimate result of our developed mechatronic system is that if a car is moving at
a speed which is higher than a particular speed and suddenly a obstacle come in
front of it and the driver is not able to respond quickly, our automatic braking
system activates and stops the car.
 Moreover, after breaking the cars scans its left and right direction and if there is no
obstacle present in the defined range the car will automatically start moving in that
direction. So in this way we will be able to avoid collisions and continue our motion.

Automotive Crashworthiness: -
 Vehicle collisions – frontal, side, rear and roll-over.

 3 categories of tests –
1) Component Test
2) Sled Test
3) Full-scale barrier impacts.
 It costs around $250-$300K for each test.
 Around 200-250 tests over a period of 5
years.
  Computational and analytical tools: -
1) Lumped Mass Spring Models (LMS)
2) Finite Element Methods (FEA)

Crashworthiness Analysis Methodology: -

• A new design and development of a bumper are proposed for a Hyundai i10 car.
• The developed bumper is analyzed for crash worthiness. The performance is
compared with different bumper materials, such as ABS, E-glass epoxy resin, and
glass fibers.
• In this work, impact and collision of a car are simulated and analyzed using ANSYS
explicit dynamics. The car is modelled using SolidWorks and exported to ANSYS.
• The bumper is first analyzed using the basic design and material. Thereafter, the
analysis is done with the bumper with added reinforcement and change in material.
• Two cases of impact have been considered: they are full frontal impact barrier and
half impact barrier. The purpose of the frontal crash analysis is to understand the
impact of the crash.

Procedure :-
The dimensions taken from the car are used to design a bumper model in SolidWorks.. The
bumper is assembled with the rest of the car shell model. The entire car model is then
exported to ANSYS explicit dynamics. The car is meshed, and the boundary conditions are
set. After the boundary conditions, the simulations are done and the values are taken. The
different scenarios in crash simulation are full barrier impact, offset barrier impact, and pole
impact. The simulations are run for the mentioned scenarios. Then, the bumper model is
modified by adding a reinforcement tube in SolidWorks.. The model is then exported to
ANSYS for simulations. The model is meshed. The boundary conditions are the same as the
basic bumper model. The crash scenarios is the same as the basic bumper. The front view of
the actual bumper and the one designed in SolidWorks.
Modified Bumper
In order to improve the impact resistance of the bumper, a reinforcement member is placed
behind the bumper. The dimension of the bumper is same as that of the conventional
bumper. The reinforcement member is a hollow tube made of materials of high impact
resistance. Different materials are used separately in the reinforcement tube, and the
simulations are done.
Modelling of Bumper for crash analysis: -

Total deformation of conventional bumper in offset frontal barrier impact: -

Equivalent stress of conventional bumper in offset frontal barrier impact: -

Equivalent Stress of ABS: -

Total deformation using E-glass/epoxy resin: -

Equivalent stress using E-glass/epoxy resin: -

Results: -
 Comparison of total deformation of two bumpers: -
Impact scenario: - Full frontal barrier impact
Conventional bumper deformation - 363.63 mm
Reinforced bumper deformation (mm)
ABS - 77.4 mm
E-glass/epoxy fibre - 75.68 mm
Polyamide 30% glass fibre - 75.23 mm

 Comparison of equivalent stress of two bumpers: -

Impact scenario: - Full frontal barrier impact
Conventional bumper equivalent stress - 3844.2 Mpa
Reinforced bumper equivalent stress (MPa) :-
ABS - 3647.2 MPa
E-glass/epoxy fibre - 4169.7 MPa
Polyamide 30% glass fibre - 3114.5 MPa
RESULTS AND CONCLUSION: -
• New bumper reinforcement is designed and analyzed using crash analysis. From the
result, it is observed that the reinforced bumper is better than the conventional
bumper in event of a crash. In particular, the reinforcement tube made with
polyamide 30% glass fibre is better than ABS and E-glass/epoxy fibres. It is found that
the response in terms of stress and deflection of the reinforced bumper is much
better than the conventional bumper. Therefore, it justifies the use of reinforcement
tube in the bumper.
• By the comparison of results between conventional bumper and reinforced bumper
from the analysis, the impact on the frontal part of the car decreases by using
reinforced bumper. The deflection of the bumper is also reduced. The figures
mentioned above show the difference between the conventional bumper and
reinforced bumper through the difference in values obtained in the total
Deformation and equivalent stress. The stress also got reduced in the reinforced
bumper of the used car. By getting reduction in the stress value, the frontal part can
withstand low-speed impact better than a conventional bumper equipped car. This
in turn contributes to the protection of the mechanical parts like radiator, air
conditioning condenser, etc. in low speed impact. It is found that reinforced bumper
is better than the conventional bumper. The comparison of total case of a low-speed
impact and protect the mechanical parts behind it. Therefore, it can be concluded
that the proposed reinforced bumper is an effective replacement for the
conventional bumper in low-budget cars.