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MEPCOSCHLENKENGINEERINGCOLLEGE,SIVAKASI

(AnAutonomousInstitutionaffiliatedtoAnnaUniversityChennai)

BONAFIDECERTIFICATE

Certified that this Report titled DESIGN AND FABRICATION OF

BRAKEFAILUREINDICATORANDCONTROLINAUTOMOBILES is the

bonafide work of MAHENDRAN G (Reg. No: 201766114) who carried out the

workundermysupervision.Certifiedfurtherthattothebestofmyknowledgethe

workreportedhereindoesnotformpartofanyotherthesisordissertationonthebasis

ofwhichadegreeorawardwasconferredonanearlieroccasiononthisoranyother

candidate.

SUPERVISOR HEADOFTHEDEPARTMENT

Mr.k.Maheswaran,M.E., Dr.P.Nagaraj, M.E., Ph.D

Assistantprofessor(SeniorGrade), ProfessorandHead,
DepartmentofMechanicalEngineering, DepartmentofMechanicalEngineering,
MepcoSchlenkEngineeringCollege, MepcoSchlenkEngineeringCollege,
Sivakasi626005 Sivakasi626005

SubmittedfortheVivaVoceExaminationheldon atMepcoSchlenk
EngineeringCollege,Sivakasi(Autonomous).

INTERNALEXAMINER EXTERNALEXAMINER
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ABSTRACT

Car safety is an avoidance of automobile accidents or the minimization of

harmful effects of accidents, in particular as pertaining to human life and health.

Special features have been built into cars for years, some for safety of occupant

only, and some for safety of others. The braking system of car is undoubtedly

one of its more important feature. The aim of the project is to design and

fabrication of brake failure indicator and control in automobiles. The indication

system is consist of buzzer, and LED and the control system is control by

solenoid operated pneumatic system. There is a brake failure means the system

activated and the motion of the vehicle is restricted by to cut the power supply

of the engine and to apply a handbrake by using a solenoid operated pneumatic

cylinder. The brake failure indicator and control system is used to protect the

man and vehicle. This system is only activated when the brake pedal touches the

floor, due to lack of brake fluid or breakage of linkage system. The objective of

the present work is to indication and control the vehicle after failure of brake

system.
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ACKNOWLEDGEMENT

I express my grateful thanks to our honorable and respected principal

Dr.S.Arivazhagan, M.E.,Ph.D., who has supported us always.

I would like to express our hearty gratitude to our beloved Dr.P.Nagaraj,

M.E.,Ph.D., Senior professor, Head of the Department, Department of Mechanical

Engineering for his constant support towards the completion of this project.

I also express my sincere thanks to our Project guide

Mr.K.Maheswaran,M.E., Assistant Professor(Senior Grade) in Mechanical

Engineering who has been a symbol of motivation and pillar of support through his

valuable suggestions, assistance and guidance in collecting materials and for sharing

ideas during the project work. He has been the source of inspiration and strength

throughout this project by his innovative ideas towards this project.

I express deep gratitude to Mr.M.Anandhan, M.E.(Ph.D), Staff In charge for

his valuable and timely assistance towards this project.

I also thank all Faculty, Technicians of Mechanical Engineering Department,

friends and family members who have contributed either directly or indirectly towards

the success of this project.

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MAHENDRAN
G TABLE OF CONTENTS

CHAPTE
TITLE PAGE NO
R

Bonafide certificate (i)

Abstract (ii)
Acknowledgement (iii)
List of tables (vi)
List of figures (vii)
1 INTRODUCTION 1
1.1 AIM 2
1.2 OBJECTIVE OF THE PROJECT 2
2 LITERATURE SURVEY 3
3 PROBLEM IDENTIFICATION 5
4 METHODOLOGY 6
5 DESIGN OF PROPOSED SYSTEM 7
6 THEORTICAL BACKGROUND 8
6.1 TYPES OF BRAKE 8
6.2 HAND BRAKE 9
6.3 HYDRAULIC BRAKE 10
7 EXPERIMENTAL STUDY 11
7.1 SELECTION OF PNEUMATICS 11
7.2 PNEUMATIC COMPONENTS 11
7.2.1 Pneumatic Cylinder 11
7.2.2 Double acting Cylinder 12
7.2.3 Parts Of Pneumatic Cylinder 12
7.3 SOLENOID VALVE WITH 13
CONTROL UNIT
7.3.1 Parts of a Solenoid Valve 14

7.3.2 Working Of 3/2 Single Acting 15

Solenoid
7.4 RELAY 16
 7.5 BUZZER 16
7.6 MAGNETIC SWITCH 17
7.7 TRANSFORMER AND RECTIFIER 18
8 FABRICATION OF PROJECT 19
8.1 ASSEMBLED MODEL 19
8.2 WORKING AND TESTING OF 20
FABRICATED MODEL
8.3 COST ACCOUNTING 21
9 CONCLUSION 22
REFERENCES 23

LIST OF TABLES
 TITLE PAGE NO
TABLE

8.1 Cost Accounting 21

LIST OF FIGURES

FIGURE
 TITLE PAGE NO

4.1 Methodology 6
5.1 Block diagram 7
6.1 Hydraulic Brake 10
7.1 Double Acting Cylinder 12
7.2 Single Acting Solenoid 15
7.3 Relay 16
7.4 Buzzer 17
7.5 Magnetic Switch 18
7.6 Transformer and Rectifier 18
8.1 Assembled Model 19
8.2 Fabricated model 20