DESIGN AND FABRICATION OF

AUTOMOBILE REVERSE
LOCKING DIFFERENTIAL
MECHANISM

ABSTRACT

The “Automobile Reverse Locking Differential Mechanism” is a preferred

embodiment provides systems and methods for preventing a vehicle from reverse
movement on a slope.

This system consists of a heavy commercial vehicle, ratchet and pawl device
connected to at least one wheel of the vehicle and actuator which will control the
movement of the pawl while engaging or disengaging the mechanism where in the
system may be engaged using an engaging mechanism when reverse motion is
undesirable or to be restricted, and may be disengaged when the reverse motion is
desirable.
1
 CHAPTER - 1

NEED OF THE PROJECT

To protect the driver and passenger life

To protect the vehicle from accident

To make the driver feel easy to park the vehicle

For safe driving

SCOPE OF THE PROJECT

To stop the vehicle while moving reverse at slopes uncontrollably.

2
 CHAPTER - 2

INTRODUCTION

A differential is a device which is used in vehicles over a few decades and

when vehicle is negotiating a turn, the outside wheel travels a greater distance and
turns faster than the inside wheel. The Differential is the device transmitting the
Power to each wheel, allows one wheel to turn faster than the other. It splits the
engine torque two ways, allowing each output to spin at a different speed. The
differential is found on all modern cars and trucks, and also in many all-wheel-
drive (full-time four-wheel drive) vehicles. The land transport sector encompasses
the commercial use of many different vehicles including Lorries, light vans, taxis,
buses, cars construction and agricultural machinery, emergency service vehicles,
motorcycles, mopeds and bicycles. Road transport safety is an important issue in
the land transport sector. Driving mistakes made by heavy goods vehicle drivers
may be more serious because of the weight, size, shape, abilities, braking abilities,
etc., of the vehicle.

The main types of transport accidents are:

 Vehicle crashes

 People being struck or run over by moving vehicles

 People falling from vehicles

 People struck by objects falling from vehicles, or vehicles overturning.
 Recent advancement in the automobile industry has opted many people to
use their own vehicle for travelling. This has increased effect on car ownership.
But to park all these cars in the major metro cities is quite tedious and difficult.
Parking problems are becoming ubiquitous and ever growing at an alarming rate in
every major city.

3
 Lot of research and development is being done all over the world to
implement better and smarter parking management mechanisms. Widespread use
of wireless technologies paired with the recent advances in wireless applications
for parking, manifests that digital data dissemination could be the key to solve
emerging parking problems. Wireless Sensor Network (WSN) technologies has
attracted & increased attention and are rapidly emerging due to their enormous
application potential in diverse fields. This buoyant field is expected to provide an
efficient and cost-effective solution to the efficient car parking problems have
taken a lot of the guesswork out of driving.

BRAKE

Brake is the indispensible part of automobile vehicle without which the

automobile vehicle is incomplete. It also acts as safety device to the vehicle to
control its unwanted motion. But when the brakes are apply all the wheels of the
vehicle gets locked ie the vehicle will not be able to move in forward as well as in
the reverse direction. This is considerable only when our intention is to stop the
vehicle but when moving on gradient roads such as ghats that time the reverse
motion is to constraint to provide safe ride to driver as well as to other vehicles on
the roads. So to overcome the problem associated with the brake ie. It locks all the
four wheels of the vehicle, we have design such a concept that it will allow the
motion in forward direction only thereby constraining the reverse motion of the
vehicle. The concept consists of Ratchet and Pawl mechanism. This mechanism
will be mounted on rear side of the vehicle such that the ratchet will have the drive
with the rear wheels of the vehicle.
 They can help us pinpoint the nearest gas station, navigate to an obscure
destination, and avoid heavy traffic and construction. Nabbing a parking spot on a
crowded downtown street, on the other hand, has remained a matter of luck and the

4
occasional fearless maneuver.But now, new intelligent parking systems are poised
to make that easy. This paper proposes a Parking (MCPS/WSN) Management
System based on wireless sensor network technology which provides advanced
features like remote parking monitoring, automated guidance.

It describes the overall system architecture of MCPS from hardware to software

implementation in the view point of sensor networks. Here we have proposed a
software implementation using wireless sensor network for management of car
parking system without entering into the parking lot. Parking status can be known by
the driver at the entrance of the parking lot only. That means a car driver can know
whether the car parking space is available in the parking lot or not without entering
into the parking lot by observing the parking space.

This system will save most of the time of the driver for seeing the parking
space and also headache of drive the car inside the parking lot and see the parking
space. A wireless sensor network is a collection of nodes organized into a
cooperative network. Each node consists of processing capability (one or more
microcontrollers, CPUs or DSP chips), may contain multiple types of memory
(program, data and flash memories), have a RF transceiver (usually with a single
Omni-directional antenna), have a power source (e.g., batteries and solar cells),
and accommodate various sensors and actuators.

The nodes communicate wirelessly and often self-organize after being

deployed in an ad hoc fashion. Systems of 1000s or even 10,000 nodes are
anticipated. Such systems can revolutionize the way we live and work. Currently,
wireless sensor networks are beginning to be deployed at an accelerated pace.
 It is not unreasonable to expect that in 10-15 years that the world will be
covered with wireless sensor networks with access to them via the Internet. This can

5
be considered as the Internet becoming a physical network. This new technology is
exciting with unlimited potential for numerous application areas including
environmental, medical, military, transportation, entertainment, crisis management,
homeland defense, and smart spaces.

Since a wireless sensor network is a distributed real-time system a natural

question is how many solutions from distributed and real-time systems can be used
in these new systems. Obviously, an indispensable element of parking system is
vehicle detectors. Inductive loop is the most widely used detector today. New
parking garages will at least install them at the entrances and exits.

It yields an accurate vehicle count. The major drawbacks, however, include

difficulties in installation and maintenance processes that involve road surface
excavation. This installation and maintenance can prevent normal operation within
under-operation parking garages. Other detectors include video cameras, ultrasonic
sensors, and Doppler radars. To avoid installation and maintenance difficulties, we
proposed a wireless sensor network (WSN) to monitor Parking of vehicular traffic.
The organization of this paper is as follows.

In section II we focuses on the related work topics. In section III the

Architecture of MCPS/WSN system based on wireless sensor network is
introduced. In section IV the design of AVR controller is introduced along with the
experimental results and interfacing of hardware structure with the software
installation. The performance of the system will be presented in section V and the
following is the conclusion in section VI.
6
 CHAPTER - 3

LITERATURE REVIEW

Development of Working Model Of Anti-Reverse Differential System,

Gandhar Brid , Sangram Waghule , Vivek Tiwari and Sairaj Bhosale

Road safety is a multi-sectoral and multi-dimensional issue.Roads in hilly

areas are more accident prone due to inadequate sight distances, sharp curves, poor
weather conditions, steep gradients. 9% of fatal accidents occur because of loss of
control of vehicles due to unexpected reverse motion on steep gradients. Hence the
problem we have focused on is to prevent this reverse motion. Possible factors of
defined problem are apparent loss of braking effectiveness, pedal misapplication,
mechanical and electrical failures. The objectives of the project are to provide
safety measure against unexpected reverse motion to provide a simple and
economical solution and to provide self-locking provision without driver’s active
involvement. To achieve this, the project integrates locking mechanism with the
differential. Locking mechanism involves the use of freewheel. The project permits
only the forward motion of vehicle due to the mechanism involved. Reverse
motion of the vehicle can be achieved only when the driver desires to do so.

To achieve this, we have prepared a model wherein a Freewheel sprocket is

coupled to an additional differential pinion engaged with the existing differential
system of the automobile vehicle. The project integrates locking mechanism with
the differential. Locking mechanism involves the use of freewheel.
 A Freewheel is nothing but a mechanical device that allows continuous linear
or rotary motion in only one direction while preventing motion in the opposite
direction. With this equipment we can prevent the unwanted reverse motion of a
vehicle during all situations. The attachment is engaged and coupled with the

7
differential system. The project permits only the forward motion of vehicle due to
the mechanism involved. The Freewheel resists the reverse motion of the vehicle
by a locking solenoid valve actuator mechanism. Disengagement of the Freewheel
permits the reverse motion. Reverse motion of the vehicle can be achieved only
when the driver desires to do so.

When a normal vehicle is moving on an inclined path in a heavy traffic or if

it is stopped on the slope and then suddenly started, it tends to move backwards.
This can cause an accident with the vehicle just behind. In the normal running of a
vehicle we have to perform three tasks at the same time i.e. disengaging the
handbrake, releasing the clutch and at the same time accelerating the car. It can
prove to be difficult for a novice driver. To solve this problem, we make use of the
Freewheel, which is attached to the differential. This freewheel is engaged with the
help of hand lever and is coupled with the bevel gear of the differential.

Here we conclude that with the use of this system, the unwanted reverse
motion of the vehicles can be prevented It provides working vehicle with
differential locking system to be capable of reliable straight running and excellent
working performance. Since engagement of freewheel will completely prevent the
reverse motion of the vehicle, there is no need to specifically pay attention as it is
paid while applying brakes and clutches. This will lead to the considerable
reduction in the accidents on mountain and hilly roads. The system eliminates the
problem of excessive wear of the brake shoe and increases brake life. The system
is of great use for all the drivers and especially for heavy load vehicles.
8
Automobile Reverse Locking Differential Mechanism by Mrunmay
Raut, Chetan Gajmal, Rahul Meher, Ashutosh Mishra

The “Automobile Reverse Locking Differential Mechanism” is a preferred

embodiment provides systems and methods for preventing a vehicle from reverse
movement on a slope. This system consists of a heavy commercial vehicle, ratchet
and pawl device connected to at least one wheel of the vehicle and actuator which
will control the movement of the pawl while engaging or disengaging the
mechanism where in the system may be engaged using an engaging mechanism
when reverse motion is undesirable or to be restricted, and may be disengaged
when the reverse motion is desirable.

When a normal vehicle is moving on an inclined path in a heavy traffic or if

it is stopped on the slope and then suddenly started, it tends to move backwards.
This can cause an accident with the vehicle just behind. In the normal running of a
vehicle we have to perform three tasks at the same time i.e. disengaging the
handbrake, releasing the clutch and at the same time accelerating the car. It can
prove to be difficult for a novice driver.

To solve this problem, we make use of a freewheel, which is attached to the

differential. This freewheel is engaged with the help of actuator and is coupled
with the bevel gear of the differential.

The motion of freewheel is restricted in reverse direction. So, when the vehicle
is moving in the forward direction then freewheel also moves in the forward direction,
But when the vehicle is moving in reverse direction then the freewheel restricts the
reverse motion. Hence, the accidents can be avoided. Also, freewheel doesn’t have to
be disengaged for the vehicle to move in the forward direction. It can move in forward
direction without any problem. To move the vehicle in the

9
reverse direction freewheel has to be disengaged. To disengage freewheel an
actuator is used.

The selection of the materials depends upon the various types of stresses that
are set up during operation. The material selected should with stand it. Another
criterion for selection of metal depends upon the type of load because a machine part
resist load more easily than a live load and live load more easily than a shock load.

Our project “Anti Reverse Differential” helps in avoiding the reverse motion
of the vehicle on the inclined roads and Ghats. Since no complex structures are
used in our design, it can be easily use by novice drivers. Thus the mechanism can
stop the vehicle from rolling back in hill roads. This would be more helpful for the
drivers to drive their cars comfortably in hilly roads and he can take off the car in
the uphill without rolling back the car.
10
 CHAPTER - 4

COMPONENTS USED

DC Power Supply

DC Motor

Wheels

Frame

Belt

Pulley

Free Wheel
11
 CHAPTER – 5

COMPONENTS DESCRIPTION

DC POWER SUPPLY

A power supply is an electronic device that supplies electric energy to an

electrical load. The primary function of a power supply is to convert one form of
electrical energy to another. As a result, power supplies are sometimes referred to
as electric power converters.

Some power supplies are discrete, stand-alone devices, whereas others are
built into larger devices along with their loads. Examples of the latter include
power supplies found in desktop computers and consumer electronics devices.

Every power supply must obtain the energy it supplies to its load, as well as
any energy it consumes while performing that task, from an energy source.
Depending on its design, a power supply may obtain energy from various types of
energy sources, including electrical energy transmission systems, energy storage
devices such as a batteries and fuel cells, electromechanical systems such as
generators and alternators, solar power converters, or another power supply.

All power supplies have a power input, which receives energy from the
energy source, and a power output that delivers energy to the load. In most power
supplies the power input and output consist of electrical connectors or hardwired
circuit connections, though some power supplies employ wireless energy transfer
in lieu of galvanic connections for the power input or output. Some power supplies
have other types of inputs and outputs as well, for functions such as external
monitoring and control

12
TRANSFORMER

A transformer is an electrical device that transfers electrical energy between

two or more circuits through electromagnetic induction. A varying current in one
coil of the transformer produces a varying magnetic field, which in turn induces a
voltage in a second coil. Power can be transferred between the two coils through
the magnetic field, without a metallic connection between the two circuits.
Transformers are devices used in electrical circuits to change the voltage of
electricity flowing in the circuit. Transformers can be used either to increase the
voltage (called "stepping up") or decrease the voltage ("step down").
 A transformer needs an alternating current that will create a changing
magnetic field. A changing magnetic field also induces a changing voltage in a coil.

... The primary coil is connected to an AC supply. An alternating current passes

through a primary coil wrapped around a soft iron core.

13
TYPES

 Laminated core.

 Toroidal.

 Autotransformer.

 Variable autotransformer.

 Induction regulator.

 Polyphase transformer.

 Grounding transformer.

CORES

Transformers generally have one of two types of cores: Core Type and
Shell Type. These two types are distinguished from each other by the manner in
which the primary and secondary coils are place around the steel core. Core type -
With thistype, the windings surround the laminated core.

BRIDGE RECTIFIER

A diode bridge is an arrangement of four (or more) diodes in a bridge circuit

configuration that provides the same polarity of output for either polarity of input.
 When used in its most common application, for conversion of an alternating
current (AC) input into a direct current (DC) output, it is known as a bridge
rectifier. A bridge rectifier provides full-wave rectification from a two-wire AC
input, resulting in lower cost and weight as compared to a rectifier with a 3-wire
input from a transformer with a center-tapped secondary winding

14
DC MOTOR

Workings of a brushed electric motor with a two-pole rotor (armature) and

permanent magnet stator. "N" and "S" designate polarities on the inside axis faces
of the magnets; the outside faces have opposite polarities. The + and -signs show
where the DC current is applied to the commutator which supplies current to the
armaturecoils

A DC motor is any of a class of electrical machines that converts direct

current electrical power into mechanical power. The most common types rely on
the forces produced by magnetic fields. Nearly all types of DC motors have some
internal mechanism, either electromechanical or electronic, to periodically change
the direction of current flow in part of the motor. Most types produce rotary
motion; a linear motor directly produces force and motion in a straight line.

DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's speed can
be controlled over a wide range, using either a variable supply voltage or by changing
the strength of current in its field windings. Small DC motors are used in tools, toys,
and appliances. The universal motor can operate on direct current but is

15
a lightweight motor used for portable power tools and appliances. Larger DC
motors are used in propulsion of electric vehicles, elevator and hoists, or in drives
for steel rolling mills. The advent of power electronics has made replacement of
DC motors with AC motors possible in many applications. Electromagnetic motors

A coil of wire with a current running through it generates an electromagnetic

field aligned with the center of the coil. The direction and magnitude of the
magnetic field produced by the coil can be changed with the direction and
magnitude of the current flowing through it.

A simple DC motor has a stationary set of magnets in the stator and an

armature with one or more windings of insulated wire wrapped around a soft iron
core that concentrates the magnetic field. The windings usually have multiple turns
around the core, and in large motors there can be several parallel current paths.

The ends of the wire winding are connected to a commutator. The commutator
allows each armature coil to be energized in turn and connects the rotating coils with
the external power supply through brushes. (Brushless DC motors have electronics
that switch the DC current to each coil on and off and have no brushes.)

The total amount of current sent to the coil, the coil's size and what it's
wrapped around dictate the strength of the electromagnetic field created.

The sequence of turning a particular coil on or off dictates what direction the
effective electromagnetic fields are pointed. By turning on and off coils in sequence a
rotating magnetic field can be created. These rotating magnetic fields interact with the
magnetic fields of the magnets (permanent or electromagnets) in the stationary part of
the motor (stator) to create a force on the armature which causes it to rotate.

16
In some DC motor designs the stator fields use electromagnets to create their
magnetic fields which allow greater control over the motor.

Different number of stator and armature fields as well as how they are
connected provide different inherent speed/torque regulation characteristics. The
speed of a DC motor can be controlled by changing the voltage applied to the
armature. The introduction of variable resistance in the armature circuit or field
circuit allowed speed control. Modern DC motors are often controlled by power
electronics systems which adjust the voltage by "chopping" the DC current into on
and off cycles which have an effective lower voltage.

Since the series-wound DC motor develops its highest torque at low speed, it
is often used in traction applications such as electric locomotives, and trams. The
DC motor was the mainstay of electric traction drives on both electric and diesel-
electric locomotives, street-cars/trams and diesel electric drilling rigs for many
years. The introduction of DC motors and an electrical grid system to run
machinery starting in the 1870s started a new second Industrial Revolution. DC
motors can operate directly from rechargeable batteries, providing the motive
power for the first electric vehicles and today's hybrid cars and electric cars as well
as driving a host of cordless tools.

Today DC motors are still found in applications as small as toys and disk
drives, or in large sizes to operate steel rolling mills and paper machines. Large DC
motors with separately excited fields were generally used with winder drives for
mine hoists, for high torque as well as smooth speed control using thyristor drives.
These are now replaced with large AC motors with variable frequency drives.
 If external power is applied to a DC motor it acts as a DC generator, a dynamo.
This feature is used to slow down and recharge batteries on hybrid car and electric

17
cars or to return electricity back to the electric grid used on a street car or electric
powered train line when they slow down. This process is called regenerative braking
on hybrid and electric cars. In diesel electric locomotives they also use their DC
motors as generators to slow down but dissipate the energy in resistor stacks. Newer
designs are adding large battery packs to recapture some of this energy.

BRUSHED

A brushed DC electric motor generating torque from DC power supply by

using an internal mechanical commutation. Stationary permanent magnets form the
stator field. Torque is produced by the principle that any current-carrying
conductor placed within an external magnetic field experiences a force, known as
Lorentz force. In a motor, the magnitude of this Lorentz force (a vector represented
by the green arrow), and thus the output torque,is a function for rotor angle,
leading to a phenomenon known astorque ripple) Since this is a single phase two-
pole motor, the commutator consists of a split ring, so that the current reverses
each half turn ( 180 degrees).

The brushed DC electric motor generates torque directly from DC power

supplied to the motor by using internal commutation, stationary magnets
(permanent or electromagnets), and rotating electrical magnets.

Advantages of a brushed DC motor include low initial cost, high reliability,

and simple control of motor speed. Disadvantages are high maintenance and low
life-span for high intensity uses. Maintenance involves regularly replacing the
carbon brushes and springs which carry the electric current, as well as cleaning or
replacing the commutator. These components are necessary for transferring
electrical power from outside the motor to the spinning wire windings of the rotor
inside the motor. Brushes consist of conductors.

18
BRUSHLESS

Typical brushless DC motors use one or more permanent magnets in the

rotor and electromagnets on the motor housing for the stator. A motor controller
converts DC to AC. This design is mechanically simpler than that of brushed
motors because it eliminates the complication of transferring power from outside
the motor to the spinning rotor. The motor controller can sense the rotor's position
via Hall effect sensors or similar devices and can precisely control the timing,
phase, etc., of the current in the rotor coils to optimize torque, conserve power,
regulate speed, and even apply some braking.

Advantages of brushless motors include long life span, little or no maintenance,

and high efficiency. Disadvantages include high initial cost, and more complicated
motor speed controllers. Some such brushless motors are sometimes referred to as
"synchronous motors" although they have no external power supply to be
synchronized with, as would be the case with normal AC synchronous motors.

UNCOMMUTATED

Homopolar motor – A homopolar motor has a magnetic field along the axis
of rotation and an electric current that at some point is not parallel to the magnetic
field. The name homopolar refers to the absence of polarity change.

Homopolar motors necessarily have a single-turn coil, which limits them to

very low voltages. This has restricted the practical application of this type of motor.
 Ball bearing motor – A ball bearing motor is an unusual electric motor that
consists of two ball bearing-type bearings, with the inner races mounted on a
common conductive shaft, and the outer races connected to a high current, low

19
voltage power supply. An alternative construction fits the outer races inside a metal
tube, while the inner races are mounted on a shaft with a non-conductive section
(e.g. two sleeves on an insulating rod). This method has the advantage that the tube
will act as a flywheel. The direction of rotation is determined by the initial spin
which is usually required to get it going.

PERMANENT MAGNET STATORS

A PM motor does not have a field winding on the stator frame, instead
relying on PMs to provide the magnetic field against which the rotor field interacts
to produce torque. Compensating windings in series with the armature may be used
on large motors to improve commutation under load. Because this field is fixed, it
cannot be adjusted for speed control.

PM fields (stators) are convenient in miniature motors to eliminate the

power consumption of the field winding. Most larger DC motors are of the
"dynamo" type, which have stator windings. Historically, PMs could not be made
to retain high flux if they were disassembled; field windings were more practical to
obtain the needed amount of flux. However, large PMs are costly, as well as
dangerous and difficult to assemble; this favors wound fields for large machines.

To minimize overall weight and size, miniature PM motors may use high
energy magnets made with neodymium or other strategic elements; most such are
neodymium-iron-boron alloy. With their higher flux density, electric machines
with high-energy PMs are at least competitive with all optimally designed singly
fed synchronous and induction electric machines.
 Miniature motors resemble the structure in the illustration, except that they
have at least three rotor poles (to ensure starting, regardless of rotor position) and

20
their outer housing is a steel tube that magnetically links the exteriors of the curved
field magnets.

WOUND STATORS

A field coil may be connected in shunt, in series, or in compound with the

armature of a DC machine (motor or generator)

There are three types of electrical connections between the stator and rotor
possible for DC electric motors: series, shunt/parallel and compound (various
blends of series and shunt/parallel) and each has unique speed/torque
characteristics appropriate for different loading torque profiles/signatures.

SERIES CONNECTION

A series DC motor connects the armature and field windings in series with a
common D.C. power source. The motor speed varies as a non-linear function of
load torque and armature current; current is common to both the stator and rotor
yielding current squared (I^2) behavior.

21
 A series motor has very high starting torque and is commonly used for
starting high inertia loads, such as trains, elevators or hoists.[2] This speed/torque
characteristic is useful in applications such as dragline excavators, where the
digging tool moves rapidly when unloaded but slowly when carrying a heavy load.

A series motor should never be started at no load. With no mechanical load

on the series motor, the current is low, the counter-EMF produced by the field
winding is weak, and so the armature must turn faster to produce sufficient
counter-EMF to balance the supply voltage. The motor can be damaged by
overspeed. This is called a runaway condition.

Series motors called universal motors can be used on alternating current.

Since the armature voltage and the field direction reverse at the same time, torque
continues to be produced in the same direction. However they run at a lower speed
with lower torque on AC supply when compared to DC due to reactance voltage
drop in AC which is not present in DC.

Since the speed is not related to the line frequency, universal motors can
develop higher-than-synchronous speeds, making them lighter than induction motors
of the same rated mechanical output. This is a valuable characteristic for hand-held
power tools. Universal motors for commercial utility are usually of small capacity, not
more than about 1 kW output. However, much larger universal motors were used for
electric locomotives, fed by special low-frequency traction power networks to avoid
problems with commutation under heavy and varying loads.

SHUNT CONNECTION
 A shunt DC motor connects the armature and field windings in parallel or
shunt with a common D.C. power source. This type of motor has good speed

22
regulation even as the load varies, but does not have the starting torque of a series
DC motor. It is typically used for industrial, adjustable speed applications, such as
machine tools, winding/unwinding machines and tensioners.

COMPOUND CONNECTION

A compound DC motor connects the armature and fields windings in a shunt

and a series combination to give it characteristics of both a shunt and a series DC
motor. This motor is used when both a high starting torque and good speed
regulation is needed. The motor can be connected in two arrangements:
cumulatively or differentially. Cumulative compound motors connect the series
field to aid the shunt field, which provides higher starting torque but less speed
regulation. Differential compound DC motors have good speed regulation and are
typically operated at constant speed.

OPERATING PRINCIPLES

All objects above absolute zero emit heat energy in the form of optical
radiation (light). Usually this light is invisible to the human eye because body
temperature radiates at infrared wavelengths, but it can be detected by electronic
devices designed for such a purpose.

The term passive in this instance refers to the fact that PIR devices do not
generate or radiate any energy for detection purposes. They work entirely by
detecting the energy given off by other objects.
23
WHEEL SYSTEM

Wheels reduce friction. Instead of simply sliding over the ground, the wheels
dig in and rotate, turning around sturdy rods called axles. Wheels provide leverage
(in other words, they are examples of force multipliers or simple machines).
 A wheel is a circular component that is intended to rotate on an axle bearing.
The wheel is one of the key components of the wheel and axle which is one of the
six simple machines. Wheels are also used for other purposes, such as a ship's
wheel, steering wheel, potter's wheel and flywheel.

The low resistance to motion (compared to dragging) is explained as follows

(refer to friction):

-the normal force at the sliding interface is the same.

24
 -the sliding distance is reduced for a given distance of travel.

-the coefficient of friction at the interface is usually lower.

Bearings are used to help reduce friction at the interface. In the simplest and
oldest case the bearing is just a round hole through which the axle passes (a "plain
bearing").

A wheel can also offer advantages in traversing irregular surfaces if the

wheel radius is sufficiently large compared to the irregularities.

The wheel alone is not a machine, but when attached to an axle in conjunction
with bearing, it forms the wheel and axle, one of the simple machines. A driven wheel
is an example of a wheel and axle. Note that wheels pre-date driven wheels by about
6000 years, themselves an evolution of using round logs as rollers to move a heavy
load—a practice going back in pre-history so far, it has not been dated.
25
BELT:

A belt is a loop of flexible material used to link two or more rotating shafts
mechanically, most often parallel. Belts may be used as a source of motion, to
transmit power efficiently or to track relative movement. Belts are looped over
pulleys and may have a twist between the pulleys, and the shafts need not be
parallel.
 In a two pulley system, the belt can either drive the pulleys normally in one
direction (the same if on parallel shafts), or the belt may be crossed, so that the
direction of the driven shaft is reversed (the opposite direction to the driver if on
parallel shafts). As a source of motion, a conveyor belt is one application where the
belt is adapted to carry a load continuously between two points.

Power transmission:

Belts are the cheapest utility for power transmission between shafts that may
not be axially aligned. Power transmission is achieved by specially designed belts and
pulleys. The demands on a belt-drive transmission system are huge, and this has led to
many variations on the theme. They run smoothly and with little noise, and

26
cushion motor and bearings against load changes, albeit with less strength than
gears or chains. However, improvements in belt engineering allow use of belts in
systems that only formerly allowed chains or gears.

TYPES:

 Flat belt

 Rope drives

 Round belt

 V-Belt


 Timing/toothed belts

V-Belt:

V belts (also style V-belts, vee belts, or, less commonly, wedge rope) solved
the slippage and alignment problem. It is now the basic belt for power
transmission. They provide the best combination of traction, speed of movement,
load of the bearings, and long service life. They are generally endless, and their
general cross-section shape is roughly trapezoidal (hence the name "V").

The "V" shape of the belt tracks in a mating groove in the pulley (or sheave),
with the result that the belt cannot slip off. The belt also tends to wedge into the
groove as the load increases—the greater the load, the greater the wedging action—
improving torque transmission and making the V-belt an effective solution, needing
less width and tension than flat belts. V-belts trump flat belts with their small center
distances and high reduction ratios. The preferred center distance is larger than the
largest pulley diameter, but less than three times the sum of both pulleys. Optimal

27
speed range is 1,000–7,000 ft/min (300–2,130 m/min). V-belts need larger pulleys
for their thicker cross-section than flat belts.
 For high-power requirements, two or more V-belts can be joined side-by-side
in an arrangement called a multi-V, running on matching multi-groove sheaves. This
is known as a multiple-V-belt drive (or sometimes a "classical V-belt drive").

V-belts may be homogeneously rubber or polymer throughout, or there may

be fibers embedded in the rubber or polymer for strength and reinforcement. The
fibers may be of textile materials such as cotton, polyamide (such as Nylon) or
polyester or, for greatest strength, of steel or aramid (such as Twaron or Kevlar).

28
FRAME:

Steel frame is a building technique with a "skeleton frame" of vertical steel

columns and horizontal I-beams, constructed in a rectangular grid to support the
floors, roof and walls of a building which are all attached to the frame. The
development of this technique made the construction of the skyscraper possible.

PULLEY:

A pulley is a wheel on an axle that is designed to support movement of a

cable or belt along its circumference. Pulleys are used in a variety of ways to lift
loads, apply forces, and to transmit power.
 Hero of Alexandria identified the pulley as one of six simple machines used
to lift weights. Pulleys are assembled to form a block and tackle in order to provide
mechanical advantage to apply large forces. Pulleys are also assembled as part of
belt and chain drives in order to transmit power from one rotating shaft to another.

29
DIRECT DRIVE PULLEY:

A "Direct Drive" pump has a hollow shaft, which simply slides onto the
drive shaft of a motor or engine. The flange on the pump is mounted to the face of
the engine or shaft end of the motor. Normal gasoline engine speed is about 3450
RPM. Since the pump is connected directly to the engine shaft, the pump RPM is
the same as the engine RPM. Electric motors typically will turn a direct drive
pump at 45 RPM or 75 RPM. Direct drive pumps allow for a more compact
designed pressure washer. Another advantage is that this drive system is simple,
with fewer moving parts; therefore less expensive. The disadvantage is by having
the pump spin as much as the engine or motor, the bearings and other parts get
more wear and tear, reducing the life span of the pump. Direct drive pressure
washers transfer the vibration of the engine or motor directly to the pump. Also,
the faster pumps of direct drive pressure washers are spinning so fast that they
cannot draw water from a tank very well. However, they tend to work just fine
when the water is forced into the pump, like when it is hooked-up to a hose.

FREE WHEEL

In mechanical or automotive engineering, a free wheel or overrunning clutch

is a device in a transmission that disengages the driveshaft from the driven shaft
when the driven shaft rotates faster than the driveshaft. An overdrive is sometimes
mistakenly called a free wheel.
30
 The simplest freewheel device consists of two saw-toothed, spring-loaded
discs pressing against each other with the toothed sides together, somewhat like a
ratchet. Rotating in one direction, the saw teeth of the drive disc lock with the teeth
of the driven disc, making it rotate at the same speed. If the drive disc slows down
or stops rotating, the teeth of the driven disc slip over the drive disc teeth and
continue rotating, producing a characteristic clicking sound proportionate to the
speed difference of the driven gear relative to that of the (slower) driving gear.

A freewheel assembly is also widely used on engine starters as a kind of

protective device. Starter motors usually need to spin at 3,000 RPM to get the
engine to turn over. When the key is held in the start position for any amount of
time after the engine has started, the starter can not spin fast enough to keep up
with the flywheel. Because of the extreme gear ratio between starter gear and
flywheel (about 15 or 20:1) it would spin the starter armature at dangerously high
speeds, causing an explosion when the centripetal force acting on the copper coils
wound in the armature can no longer resist the outward force acting on them.

In starters without the freewheel or overrun clutch this would be a major

problem because, with the flywheel spinning at about 1,000 RPM at idle, the starter,

31
if engaged with the flywheel, would be forced to spin between 15,000 and 20,000
RPM. Once the engine has turned over and is running, the overrun clutch will
release the starter from the flywheel and prevent the gears from re-meshing (as in
an accidental turning of the ignition key) while the engine is running. A freewheel
clutch is now used in many motorcycles with an electric starter motor. It is used as
a replacement for the Bendix drive used on most auto starters because it reduces
the electrical needs of the starting system.

A more sophisticated and rugged design has spring-loaded steel rollers

inside a driven cylinder. Rotating in one direction, the rollers lock with the cylinder
making it rotate in unison. Rotating slower, or in the other direction, the steel
rollers just slip inside the cylinder.

Most bicycle freewheels use an internally step-toothed drum with two or

more spring-loaded, hardened steel pawls to transmit the load. More pawls help
spread the wear and give greater reliability although, unless the device is made to
tolerances not normally found in bicycle components, simultaneous engagement of
more than two pawls is rarely achieved.

The freewheel meant that the engine returned to its idle speed on the overrun, thus
greatly reducing noise from both the engine and gearbox and reducing oil
consumption. The mechanism could usually be locked to provide engine braking if
needed. A freewheel was also used in the original Land Rover vehicle from 1948
to 1951. The freewheel controlled drive from the gearbox to the front axle, which
disengaged on the overrun. This allowed the vehicle to have a permanent 4 wheel
drive system by avoiding 'wind-up' forces in the transmission. This system worked,
but produced unpredictable handling, especially in slippery conditions or when
towing, and was replaced by a conventional selectable 4WD system.
32
 During the Second World War, the military Volkswagen vehicles produced
by KdF (Kübelwagen, Schwimmwagen) were fitted with a ZF differential system
composed of two freewheels, which sent the whole of the engine power to the
slowest-turning of the two wheels.

ENGINE START

Other car makers fitted a free wheel between engine and gearbox as a form
of automatic clutch. Once the driver released the throttle and the vehicle was on the
overrun the free wheel would disengage and a gear change could be made without
the use of the clutch pedal. This feature appeared mainly on large, luxury cars
which often had heavy clutches and gearboxes without synchromesh as the free
wheel permitted a smoother and quieter change. Citroën combined a free wheel
and a centrifugal clutch to make the so-called 'TraffiClutch' where the car could be
started, stopped and the lower gears be changed without using the clutch pedal.
This was an option on Citroën 2CVs and its derivatives and, as the name implied,
was marketed as a benefit for driving in congested urban areas. Similarly, the Saab
93 was available with an optional Saxomat clutch.

A common use of freewheeling mechanisms is in automatic transmissions.

For instance traditional, hydraulic General Motors transmissions such as the
Turbo-Hydramatic 400 provide freewheeling in all gears lower than the selected
gear. E.g., if the gear selector on a three-speed transmission is labelled 'drive'(3)-
'super'(2)-'low'(1) and the driver has selected 'super', the transmission will
freewheel if first gear is engaged, but not in second or third gears; if in 'drive' it
will freewheel in first or second; finally, if in low, it will not freewheel in any gear.
This allows the driver to select a lower range to achieve engine braking at various
speeds, for instance when descending steep hills.
33
 CHAPTER - 6

BLOCK DIAGRAM

Hand Brake

Differential

Mechanism

Free Wheel Setup

Reverse Motion

Arrested

Lever

Released

Reverse Motion

Released

34
 CHAPTER - 7

WORKING PRINCIPLE

When a normal vehicle is moving on an inclined path in a heavy

traffic or if it is stopped on the slope and then suddenly started, it tends to move
backwards. This can cause an accident with the vehicle just behind. In the normal
running of a vehicle we have to perform three tasks at the same time i.e.
disengaging the handbrake, releasing the clutch and at the same time accelerating
the car. It can prove to be difficult for a novice driver.

To solve this problem, we make use of a free wheel, which is attached to the
differential. This freewheel is engaged with the help of actuator and is coupled
with the bevel gear of the differential. The motion of freewheel is restricted in
reverse direction. So, when the vehicle is moving in the forward direction then
freewheel also moves in the forward direction, But when the vehicle is moving in
reverse direction then the freewheel restricts the reverse motion. Hence, the
accidents can be avoided. Also, freewheel doesn’t have to be disengaged for the
vehicle to move in the forward direction. It can move in forward direction without
any problem. To move the vehicle in the reverse direction freewheel has to be
disengaged. To disengage freewheel an actuator is used.
35
 CHAPTER - 8

ADVANTAGES

 Simple Construction

 Decrease in accidents on slopes by driver

 Easy Operation

 Low Cost

 Easy to Install
36
FUTURE SCOPE

The modifications that can be done in this project are:-

 With the advancement in material technology, the design strength should

be so given that the mechanism can work for longer period of time without
failure.

 A sensor can be put in the car to sense the inclination of the road. If it
senses an inclination (which is more than desired) it will engage freewheel
automatically.
37
APPLICATIONS

 All automobiles

 Hospital vehicles

 Wheel chairs
38
 CHAPTER - 9

COST ESTIMATION

S1. PARTS Qty. Cost

1 Control switch 1 100

2 DC Motor 2 2000

3 Stand (Frame) 1 1000

4 Connecting Wire 150

5 Wheel arrangement 4 500

6 Power supply 2 1000

7 Labor Charges 1000

TOTAL 5750
39
 CHAPTER - 10

CONCLUSION

The project has been successfully completed and the automation has been
achieved at a very low cost. The major consideration while doing this project is
safety of human and nothing is important in front of human life. This mechanism is
user-friendly. And in our market survey we came to know that no any industry is
manufacturing such mechanism for low budget.
40
 CHAPTER - 11

REFERENCES

1) R. N. Thorve, Patent no- US5, 388, 672, Year 2012.

2) Design, Development And Testing of Automatic Differential Locking

Mechanism, Prof. A.S. Todkar, R.S.Kapare.

3) Kazuhiko Satou, Patent No. US2003/0146035 A1

4) Reverse Lock For Vecrhiles, Chest O Hunter.

5) Alfred sigl, Sershiem; Germany (1987) ; ”Vehicle with lockable differential”

U.S. patent,no 4,671,373 June 1987.

6) Mahesh shahapuri-Anti-roll back system for manual transmission vehicles

(WO 2013024491 A2).

7) Kwang-Hee Lee, Kyungki Do, July 2001,“Brake control system and method
for preventing a vehicle from rolling downward on a slope”, Patent No: US

6,260,934 B1.

8) Urs Giger, Edwin Fernand Jakob-Schild, Grenchen, 1971, “Free-wheel

mechanism.”
41