Project seminar on

Design and Fabrication of Reverse

Locking Mechanism for Heavy
Vehicles.
Guide:- P.N.Sidhappa
(Assistant professor)
Project Team:
Abhishek.S
Arun Kumar.N
Hemanth Kumar.C
Mahesh.S

PROBLEM STATEMENT

Heavy vehicles such as Lorries, trucks, sports utility vehicles

and cars, these vehicles experience a reverse motion while
traveling on a gradient due to less power capacity because of
increasing loads.

Induces much stresses on the driver.

Wear of clutch and brake parts.

Efficiency of hand brakes is low.

Accidents are inevitable due to reverse motion.

REQUIRED OBJECTIVES
Restrict the movement of the vehicle using an electromagnetic brake.
To avoid the reverse motion of the vehicles in a slope.
To act as an additional or supplementary braking device.
To avoid the wear on brake, accelerator and clutch pads.
Heating of brake drums can be avoided.

INTRODUCTION
While travelling on a gradient the vehicle with full load experiences reverse motion.
The power developed in the engine is low due to increasing loads.
The driver has to be skilled enough to control all the pedals.
The consumption of fuel is more under these load conditions.
To overcome these situations we are using an electromagnetic brake.
The brake is mounted on the rear axle of the vehicle.
The brake actuates by an electric switch and it is powered by a battery.
The brake when actuated acts as a retarder and stops the vehicle efficiently.
The brake has to be designed with respect to the torque characteristics.

Assembled View of Electromagnetic brake using Solid Edge

Electromagnetic brake

LITERATURE SURVEY
Hand Brakes:
The parking brake, also called hand brake, emergency brake, or ebrake, is a latching brake usually used to keep the vehicle
stationary.
It is sometimes also used to prevent a vehicle from rolling when
the operator needs both feet to operate the clutch and acceleration
pedals.
The Brake consists of a cable, which actuates through a hand
operated lever, this causes the braking action.
Rachet and Paul mechanism or hydraulic actuators are used based
on the type of vehicle.

Transmission:
The power from the engine has to be transmitted to the
wheels, Hence transmission is required.
Transmission is the heart of the system, the energy actuated by
the gears and clutch is transmitted to the propeller shaft.
The propeller shaft by using universal joints transmits power
to the rear axle with the use of bevel gears.

There are different types of transmissions, manual and automatic types namely.
sliding-mesh, constant mesh and synchromesh systems are manual transmission systems.
Automatic transmissions are non synchronous which are semi automatic and planetary gear
systems

V-Belts:
The v belt dive gives compactness due to the small distances between
centres of pulleys.
The drive is positive, because the slip between the belt and the pulley
groove is negligible.
Since v belts are made endless and there is no joint trouble, therefore the
drive is smooth.
It provides longer life, 3-5 years.
It can be easily installed and removed.
The operation of the pulley and belt is quite.
The belts have the ability to cushion the shock when machines are
started.
High velocity ratio can be obtained.

Pulleys:

Front view

Side view

Pulleys are wheels on an axle that have a groove around their outer edge on which
a rope or belt can fit.
The application of pulleys can be for many different functions; lifting loads,
applying forces or transmitting power.
The Velocity ratio of the system can be varied.
They reduce the work done, while carrying or lifting the loads.
During transmission of power, balancing of pulley is very important.

Induction Motors:
It is an AC electric motor in which the electric current in the rotor is needed to
produce torque.
Torque is mainly induced by electromagnetic induction from the magnetic field of
the stator winding.
An induction motor does not require any means to transfer energy from stator to
rotor, as in universal, DC and large synchronous motors.

Induction motor

An induction motor's rotor can be either wound type or squirrel-cage type.

In induction motors rotor rotates slower than stator or armature windings.
The oscillations of the A.C current with respect to the time produces reverse
polarity, this causes the rotation in the rotor in the direction of magnetic field.
Principle of operation

Switched Mode Power Supply:

SMPS is an electronic power supply that incorporates a switching regulator to convert electrical
power efficiently.
It converts the A.C supply into D.C voltage.
Switching regulators are used as replacements for linear regulators when higher efficiency, smaller
size or lighter weight are required.
The main advantage is greater efficiency because the switching transistor dissipates little power
when acting as a switch.

Electromagnetic Brake:

Top View

Side View

It works On the principle of Faradays law and Lenz law on Electromagnetism.

Faradays law states that a current carrying conductor when introduced in a magnetic field a force is generated which
is nothing but Electromagnetic force which is directly proportional to the magnitude of the moving conductor
Lenz law states that When an emf is generated by a change in magnetic flux according to Faradays law the polarity
of the induced emf is such that it produces a current whose magnetic field opposes the change which produces it

Working principle of electromagnetic brake:

Exploded view of the Electromagnetic Brake using Solid Edge

ADVANTAGES:
The response action is very quick.
There are no mechanical losses as it actuates through electric charge.
Electromagnetic brakes have better heat dissipation.
The wear on the brake pads is negligible compared to the friction brakes.
Electromagnetic brakes have been used as supplementary retardation equipment in addition to the regular
friction brakes on heavy vehicles.
Electromagnetic brakes has great braking efficiency and has the potential to regain energy lost in braking.
Maintenance is less.
It can also be used as a safety device.
DISADVANTAGES:
The installation of an electromagnetic brake is very difficult.
The weight of the brake adds additional weight to the Vehicle.
Initial cost is high.

COMPONENTS USED FOR THE PROTOTYPE

Electromagnetic brake
Induction motor
Journal bearings
V-belts and pulleys
Shafts
SMPS

Electromagnetic Brake:

Top View

Side View

Specifications:

Diameter
Voltage
Torque
Wattage

- 12mm
- 110V
- 40 to 80N-m
- 250 to 300W

Induction motor:
Specification:

Current - 0.91amps
Torque - 0.13kg-m
Speed - 900 2700rpm
Voltage 220V

Journal Bearing:
Specifications:

Inner diameter 25mm

Outer diameter
30mm
Oil cooled
Length 35mm

They are used as supporting members for shafts.

They reduce friction.
They reduce the noises subjected to rotation of shafts.
They have good damping capability.

DESIGN PROCEDURE
Design of V-belt:
Centre Distance = c = 310mm
Diameter of smaller pulley = d = 76.2mm
Diameter of larger pulley = D = 152.4mm
Groove angle = 2 = 40
Co-efficient of friction = = 0.27
Speed of the shaft = n = 1200rpm
Selection of belt c/s:
Equivalent pitch diameter of smaller pulley
=----- 21.35 (DDHB)
= d = 76.2mm
= smaller diameter factor = 1 ----- Table 21.25
= 76.2*1 = 76.2mm
Based on the c/s of belt from 21.13 (DDHB)
Belt designation = 3A
Belt direction = A

Velocity :

= 9.57m/s
Power capacity:
N* = - N* = - - = 0.983kW
Number of V belts:

N = Total power transmitted in kW

N* = Power capacity
= Service factor from table 21.28

Pitch length:
L = 2C + (D + d) +
L = = 984mm
Angle of Contact for smaller pulley:
= = - = 2.9rad
Angle of Contact for Larger pulley:
= +
= + = 3.38rad

Capacity:
= = 9.86
= = 14.41
Smaller value is the Capacity = 9.86
Belt Tensions:
Tensile Stress = = 1N/
= c/s of v belt * permissible tensile stress

= *
= * = * = 84N-mm

= 0.536


Power transmitted:

0.641kW

Correct centre distance:

----- 21.39(DDHB)

Design of Journal Bearing

Length of the Bearing l = 3.5cm
Diameter of the bearing d = 2.54cm
Length to diameter ratio = 1.37
Pressure on the bearing,
P=
P=
Somerfeld number S =
Temperature= c
Dynamic viscosity = = 0.3
Kinematic viscosity = 19.5
Selecting Oil SAE 20
Speed of the Shaft:
=

= 20 rps

Sommerfeld number = S =
S = 0.076
To find the frictional factor F:
F = 3.8*
F = 0.01496
Velocity of the shaft:
V=
V=
V=1.59m/s

Heat Generated in the Bearing:

Temperature developed in the bearing:

C=33.5 w/ for moving air

B=0.667 oil bath moving in air
A=20*0.035*0.035*0.667=0.017

EXPERIMENTAL CALCULATIONS ON BRAKE FORCE

Vehicle in a Slope

Calculations of Brake force, required Torque and Efficiency for a Truck:

Front Axle Loads:


= 4749.74 Kg
Traction Force:

42168.32N

Total Dynamic Load:

Where:
a = deceleration velocity

Center of Gravity:

X=
X=0.3
*11000

Braking force:

Kinetic Energy:
KE =
KE = 0.5*11000*
KE = 137500 J
Potential Energy:
It is nothing but the traction force. The total weight of the truck which is stored as a form of energy
which has to be in contact with the road when the truck is stopped by the brake in a slope.
Time required for braking:

t = 0.1019s
Power:
176.31 KW

Required Torque of the brake:

T=
T=
T=447.77 Nm
Efficiency of the brake:

The calculations of Brake force and Efficiency of the prototype:

Magnetic field:

Magnetic Flux:

Torque developed by the Motor shaft (braking force):

Kinetic energy:
KE=
KE= 0.5*1.7*0.21614
KE=0.1837 J
Potential Energy:
PE=
PE= 1.2*9.81*0.06
PE= 0.70632 J
Time:

Power:

Required Torque of the brake:

T=
T=
T=69.47Nm
Efficiency of the brake:

Pulleys

Isometric view and Front view of Larger Pulley

Isometric view and Front view of Smaller Pulley

Electromagnetic Brake:

Assembled View of Electromagnetic

Blast view

FABRICATION OPERATIONS

Facing

Turning

Drilling

Tapping

Boring

Counter Sinking

PLANNED OVERVIEW
1
2
1) SMPS
3

2) Induction Motor
3) V-Belts

4
4) Shafts
6
5

5) Electromagnetic
Brake
6) Bearing

FINAL EXPERIMENTAL SETUP

SL.NO
1
2
3
4
5
6
7
8
9

ITEM DESCRIPTION
Motor (1/2 Hp)
Support Block (Nylon)
SMPS (48v 5amps)
Journal bearing (25 )
V-Belt
Mild Steel Frame (882x558mm)
Shaft
Electromagnetic Brake
Switch

QUANTITY
1
18
1
4
2
1
2
1
1

Top View

Front View

Test Results
Description

Load of the vehicle in N

Hand Brake
efficiency in %

Electromagnetic
brake Force in N

Efficiency in %

1.89003

Not Available

2.96

69.90

Car

19284.657

48

58860

67.23

Truck

179668.32

42

539550

66.70

SUV

81667.422

52

19167.42

66.80

Prototype

when the brake is mounted close to centre of gravity, the loads acting on the brake reduces.
When multiple brakes are used the load is distributed evenly, inducing less stresses on the brakes.
Reverse motion of the vehicle is restricted.
Usage of hand brake can be avoided in a gradient when moving from rest.
Heating of the brake drums will be avoided.
Clutch pad wear is avoided when clutch pedal is not released properly in a gradient.
Engine jerking is avoided in a gradient.

Discussions
Problems encountered in directly mounting the mechanism on driven
shaft
A small wobbling of shaft completely damages the mechanism.
Limited protection against environment factors.
Replacements or repairing is a problem.
Interchangeability is a problem.
Space availability problem.
Studies can be done to overcome to above mentioned problems and the
cost of the project can be reduced.

SCOPE OF IMPROVEMENTS
By using alternative materials in design of components which possess good
mechanical properties.
The weight of the mechanism can be considerably reduced by using lighter
materials
Necessary modification and design of new components can be made to over come
problems such as wobbling of shafts, environment problems, space availability and
interchangeability.

CONCLUSION
Partial elimination of the hand brake or parking brake and it acts as additional safety device. The
reverse motion on the gradient can be stopped by using electromagnetic brake of required torque.
The driver has to operate all the pedals. I.e. accelerator, brake and clutch in dense traffic which is
sometimes very dangerous but by using reverse lock mechanism, the driver can control the vehicle with
less stress and drive efficiently.
By testing the prototype we can conclude that the design of the electromagnetic brakes can be based
on torque characteristics. The torque of the brake determines the loads to be stopped both dynamic and
static by braking action. The brakes uses 24v or 48v Direct current in the vehicles.

REFERENCES
L.Pearce Williams, Michael faraday Professor of the History of Science
at Cornell Universitys Department of history, 1965 pp. 182-183 and pp.
191-195.
K. Lingaiah, McGraw Hill, Design and Data Hand Book 2nd Ed.2003.
V.B. Bhandari, Design of Machine Elements Tata McGraw Hill
Publishing Company Ltd, New Delhi, 2nd Ed 2007.
Ganeshan, Tata McGraw Hill, Internal Combustion Engines, 2nd Ed 2003.
M.L. Mathur, R.P. Sharma, A Course in I.C. Engines, 2001.
R.S. Khurmi, Machine Design S.Chand Publication New Delhi 2007.
J.B.K. Das, P.L. Srinivas Murthy, Design of Machine Elements 1 and 2
Sapna Pb.

THANK YOU