FABRICATION OF AIR BRAKE SYSTEM USING

ENGINE EXHAUST

ABSTRACT

The main objective of our project is to design and fabricate an air brake

system using engine exhaust system. This is one of the efficient braking systems

using the vehicle’s exhaust gas

The aim is to design and develop a brake system based on exhaust gas is

called “AIR BRAKE SYSTEM USING EXHAUST GAS”. The main aim of this

project is to reduce the workloads of the engine drive to operate the air compressor.

In this project, we used exhaust gas from the engine to rotate the generator turbine.

Then the power is loaded to the D.C compressor and it is used to the pneumatic

cylinder to apply brake.

INTRODUCTION

With the development of highways, logistics and the pace of life, weight and

velocity of vehicles has become more and larger, which has reduced the safety of

driving. The braking load of vehicles increases quickly so that the primary brake

system is easily overloaded and can be damaged by overheating.

 Hence an alternative braking system is necessary for the safety of the driver.

This project proposes a braking system which actually works on the engine exhaust

gases.

Baking system is necessary in an automobile for stopping the vehicle.

Brakes are applied on the wheels to stop or to slow down the vehicle. There are

two main functions of brakes:

 To slow down or stop the vehicle in the shortest possible time at the time of

need.

 To control the speed of vehicle at turns and also at the time of driving down

on a hill slope.

These objectives are done with the help of the engine exhaust gas itself. The

only difference between the conventional braking system and this type of braking

system is that in this system, no external power is required to activate the brakes.

The engine exhaust gas is re-circulated to apply the brakes.

WORKING PRINCIPLE

The air brake system using exhaust gas consist of a generator which is

connected to the exhaust system of the vehicle, when the exhaust gas from the

silencer comes out of it, it is sent to the turbine generator setup which converts the

flow pressure of the exhaust system into the rotary motion of the generator rotor.
 Which produces electrical energy from the rotary motion of the rotor and

through the wire connections the produced electrical energy is stored in the battery.

The battery unit supplies the power to the control unit, compressor. The power

from the battery is sent to the DC compressor where the atmospheric air is

compressed and stored in the air tank near the compressor. Then the air from the

air tank flow through the flow control valve due to the compressed action, which

controls the flow of the air into the forthcoming system. The flow control valve

leads to the solenoid valve which is controlled by the control unit.

When the brakes are applied, the control unit is activated, which actuates the

solenoid valve. When the solenoid valve is activated the pneumatic pressure flows

through the solenoid valve, which controls the movement of the pneumatic

cylinder. The pneumatic cylinder piston has the brake show on its end, when the

air flows through the pneumatic cylinder the piston rod moves forward and makes

the brake shoe to come in contact with the brake wheel.

Due to the friction between the brake shoe and the wheel, the vehicle is

slowed down. These continuous operations happen within seconds. When the

brakes are released, the solenoid valve is deactivated by the control unit, and the

air from the pneumatic cylinder gets retarded due to the spring action of the

pneumatic cylinder (single cylinder pneumatic cylinder with spring).

2D DRAWING
ADVANTAGES

1. It reduces the battery power

2. It increases the engine efficiency

3. It occupies less floor space

4. It reduces the air pollution

DISADVANTAGES

1. Initial cost is high

2. Need a separate compressor

3. Maintenance cost is high

APPLICATIONS

1. For automobile application

2. Industrial application