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Abstract:
The braking system of a car is undoubtedly one of its more important features. The aim of this work is to create a better braking
system with indicator. Brake failure occurs only because of worn out of brake shoe and cut in liner. It consists of two sensors.
One sensor is connected with the brake shoe. The other sensor is the brake liner. The signal from the two sensors is given to a
microcontroller. When the brake shoe is worn out, the sensor senses signal to the microcontroller. Also if the brake liner is cut, the
sensor sends signal to the microcontroller. The microcontroller analyses the signal and operates the corresponding indicator. It
nothing wrong, the vehicle will move and if any one critical, the vehicle will stops and the screen shows the indication of brake
failure. Since this indicates the status of the brake, the user can identify the condition of the brake and thus limiting the chances of
malfunction.
I. INTRODUCTION
Car safety is the avoidance of automobile accidents or the will be operated by the microcontroller automatically. This
minimization of harmful effects of accidents, in particular as prevents unnecessary accident. Since this indicates the status of
pertaining to human life and health. Special safety features the brake, the user can identify the condition of the brake and
have been built into cars occupants only, and some for the thus limiting the chances of malfunction
safety of others. We have pleasure in introducing our new Block diagram
project automatic head light dim/bright controller and engine
over heat alarm which is fully equipped by sensors circuit,
dim/bright light and engine over heat alarm circuit. It is
genuine project which is fully equipped and designed for
automobile vehicles. This forms an integral part of best quality.
This product underwent test in our automobile vehicles and it
is good.
The major components of the project are follows
Frame
Battery
IR sensor circuit
In this Project we are using control unit to check the Brake
condition and Engine heat. Here we are sending the signal
voltage through the Brake Wire from one end to other end. At
the other end in the wheel the signal conditioning unit checks
that whether the signal voltage in the Brake wire is available or Figure 1.1 Block diagram
not.
The braking system of a car is undoubtedly one of its more Back Ground
important feature. The aim of this work is to create a better Though the world is getting modernized, we have to face
braking system with indicator. Brake failure occurs only so many problems. One of such problems is accidents. One of
because of worn out of brake shoe and cut in liner. It consists the thing that everyone tried to avoid is while traveling is
of two sensors. One sensor is connected with the brake shoe. accidents, and sometimes it is inevitable. Now- a-days we can
The other sensor is the brake liner. The signal from the two see accidents in every nook and corner of the world. It results
sensors is given to a microcontroller. When the brake shoe is in the death of thousands of lives. In foreign countries they
worn out, the sensor senses signal to the microcontroller. Also take remedial measures for the prevention of accidents but our
if the brake liner is cut, the sensor sends signal to the country like India takes less action against the prevention of
microcontroller. The microcontroller analyses the signal and accidents.. When the driver brakes they are actually pushing a
operates the corresponding indicator. It nothing wrong, green plunger into the master cylinder, which in turn pushes brake
indicator will glow and if any one critical, red indicator will fluid through tubes and hoses to brake all the moving units in
glow. If the brake is failure in running time, an alternate brake the vehicle. So many other devices are there to predict brake
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failure like United States patent 3711827, United States patent Components Required
3914734, etc. The United States patent 3711827 is a self-test S. Component Specification Quantity
incorporated to determine if the warning light is operated No
properly. But my project can indicate brake failure and the 1 Diode IN4007 2
function of the brake whenever the brake is applied and it is 2 IC 7812 2
less expensive compared to other products. CA 3140 1
NE555 1
Ground Clearance 3 Resistor 10K 5
Whenever we buy cars we often discuss the fuel economy, 100K 1
style, features, colour, price and all that. But unless widely 470 2
publicized, people hardly care to look at the physical specs of 470K 1
the car - in particular the ground clearance. 4 Capacitor 1000F,25V 2
Ground clearance is a factor mostly discussed when 100F,25V 1
someone is buying low level cars. Indeed Luxury cars are 10F ,25V 2
known for their low stance and low ground clearance. Now, 0.01F 1
anyone or any website will tell you that ground clearance is the 0.02F 1
"minimum distance between the ground/road and the lowest 5 Switch Brake Switch 1
part of the car". And then manufacturers publish the ground Ignition Switch 1
clearance figures such as 160 mm or 170 mm or 180 mm. 6 LED Red LED 1
Green LED 1
7 Buzzer Plastic 1
8 DC Socket 12v 1
Components Description
It is a complete standalone voltage regulator. We only
need to use 2 capacitors. One on the input and second one on
the output of 7812 in order to achieve clean voltage output and
even these capacitors are optional to use. To achieve 12v 1A
current, 7812 should be mounted on a good heat sink plate.
Thanks to the transistor like shape of 7812 which makes it easy
to mount on. 7812 is a famous IC which is being widely used
Figure 1.5 Demonstration of ground clearance of in 12V voltage regulator circuits. Truly speaking a heat sink
suspension car plate. 7812 has built in over heat and short-circuit protection
which makes it a good choice for making power supplies.
In our concept car the suspension of the car allow In electronics markets, 7812 is sold under various names
minimum of 600 mm ground clearance or even beyond that such as 7812a, 7812act, 7812t and lm7812. All of them are
becomes a major success factor of the model. almost identical with a little to no differences at all. 7812 input
In the case of Indian roads the vehicles which have more voltage range is 14V to 35V. Exceeding the voltage range may
than 200 mm of ground clearance is appropriate for ride in damage the IC. Given bellow is 7812 pin diagram to make the
urban as well as in rural areas. pin out connections clear in case you want to do some
Description experiments.
Brake failure indicator is a device used to avoid accidents
and it gives an early indication of brake failure. Of all the Infra Red Obstacle Detection Sensor
system that make up a vehicle, the brake system might just be In the system we are using 5mm IR SENSORS as an early
important. If a force is exerted on the piston putting pressure warning system that also made it economic in design and
on the fluid confined in the left hand container, the fluid is simple in implementation. Infrared radiation is the portion of
forced out through the narrow tube at the bottom and into the electromagnetic spectrum having wavelengths longer than
right hand container, exerting a force on the second piston, visible light wavelengths, but smaller than microwaves.
forcing it to move upward. The circuit can be assembled on
any general purpose PCB or perforated board. The audio
indicator is black in color. It is connected on the right side of
steering. Both LEDs are red in color.
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from 3 m to 6 m is called mid infrared and the region higher switches, frequency divider, capacitance measurement,
than 6 m is called far infrared. pulse-width modulation (PWM) and so on.
Astable free running mode: the 555 can operate as an
7812 pin diagram oscillator. Uses include LED and lamp flashers, pulse
If you hold upside down (pins up) and the IC number is generation, logic clocks, tone generation, security alarms,
facing you then the left pin will be the voltage regulator output, pulse position modulation and so on.
the centred pin will be ground and the right pin will be the Bistable mode or Schmitt trigger: the 555 can operate as
voltage input pin. Under my experience, the maximum safe a flip-flop, if the DIS pin is not connected and no capacitor
current you can get from one 7812 IC is 1A. If you need more is used. Uses include bounce free latched switches.
power then there are a few ways to do so. LED
More than one 7812 can be used in parallel in order to A light emitting diode is a semiconductor diode that emits
achieve more than 1A current but output voltage of each 7812 light when the electric current is applied in the forward
can slightly vary resulting in unbalanced load on all of them. direction of the device, as in the simple LED circuit. The effect
This can result in load balancing issues and can damage the IC is a form of electroluminescence where incoherent and narrow
carrying most current. However there is a way to overcome spectrum light is emitted from p-n junction. LEDs are widely
this problem. I have given bellow a schematic diagram in used as indicator lights on electronic devices and increasingly
which two 7812 ICs are attached together and both of them are in higher power applications such as flashlights and area light.
carrying almost equal load. At least the current difference is The colour of emitted light depends on the composition and
not too much to damage any IC condition of semiconductor material used and infrared, visible
IC 3140 or ultraviolet .In brake failure indicator, the LED is used for
The CA3140A and CA3140 are integrated circuit indication.
operational ampliers that combine the advantages of high
voltage PMOS transistors with high voltage bipolar transistors
on a single monolithic chip. The CA3140A and CA3140
BiMOS operational ampliers feature gate protected MOSFET
(PMOS) transistors in the input circuit to provide very high
input impedance, very low input current, and high speed
performance. The CA3140A and CA3140 operate at supply
voltage from 4V to 36V (either single or dual supply). These
operational ampliers are internally phase compensated to
achieve stable operation in unity gain follower operation, and
additionally, have access terminal for a supplementary external
capacitor if additional frequency roll-off is desired. Terminals
are also provided for use in applications requiring input offset
voltage nulling. The use of PMOS eld effect transistors in the Figure 2.1.2(a) LED is on i.e. no any obstacle is present
input stage results in common mode input voltage capability When the brake is applied, the green LED blinks and the
down to 0.5V below the negative supply terminal, an important piezo buzzer beeps for around one second if the brake system
attribute for sin- gle supply applications. The output stage uses is intact. If the brake fails, the red LED Glows and the buzzer
bipolar transistors and includes built-in protection against stop beeping.
damage from load terminal short circuiting to either supply rail
or to ground. Diode
555 IC A diode is a device that permits current flow
The 555 Timer IC is an integrated circuit (chip) used in a predominantly in only one direction. Most semiconductor
variety of timer, pulse generation and oscillator applications. diodes are made from germanium or silicon. A diode has two
The circuit arrangement of the 555 is said to be even more leads, an anode and a cathode. The cathode is often marked by
common, being incorporated in many single-voltage Flash and a band at one end is the lead by which conventional current
other electrically-erasable ICs where it is the basis for the leaves the diode when forward biased. There are several types
oscillator driving the charge pump which provides the of diode, each with features that suits a particular job. In brake
programming overvoltage. failure indicator, the inverting input is connected to the brake
Depending on the manufacturer, the standard 555 package switch through diode and resistor.
includes over 20 transistors, 2 diodes and 15 resistors on a
silicon chip installed in an 8-pin mini dual-in-line package Buzzer
(DIP-8). Variants available include the 556 (a 14-pin DIP A buzzer or beeper is a signaling device usually electronic.
combining two 555s on one chip), and the 558 (a 16-pin DIP These devices are used in automobiles, household appliances
combining four slightly modified 555s with DIS & THR such as microwave oven. It consists of a number of switches or
connected internally, and TR falling edge sensitive instead of sensors connected to a control unit that determines if and
level sensitive). which button pushed or a present time has lapsed, sounds a
The 555 has three operating modes warning in the form of an intermittent buzzing or beeping
sound. Buzzer or beepers are output transducers converting
Mono stable mode: in this mode, the 555 functions as a
electrical energy into sound. They contain an internal oscillator
"one-shot" pulse generator. Applications include timers,
missing pulse detection, bounce free switches, touch to produce the sound which is set at about 400 Hz for buzzers
and about 3 KHz for beepers. In brake failure indicator, when
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the brake is applied the green LED blinks and the buzzer beeps
for one second and if the brake fails, the buzzer stops beeping. Secondary Power Supply 9V battery
Thus the buzzer functions as an indicator of brake failure.
Infrared Source
All objects above 0 K radiate infrared energy and hence
are infrared sources. Infrared sources also include blackbody
radiators, tungsten lamps, silicon carbide, and various others.
For active IR sensors, infrared Lasers and LEDs of specific IR
wavelengths are used as IR sources.
Transmission Medium
Three main types of transmission medium used for
Figure 2.1.2(c) Main Power Supply Batteries Infrared transmission are vacuum, the atmosphere, and optical
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fibers. The transmission of IR radiation is affected by 2 senses the voltage level across, the brake switch. Its non
presence of CO2, water vapor and other elements in the inverting input gets half the supply voltage through potential
atmosphere. Due to absorption by molecules of water carbon divider resistors R3 and R4 of 10 Kilo ohms each. The
dioxide, ozone, etc. the atmosphere highly attenuates most IR inverting input of IC2 is connected to brake switch through
wavelengths leaving some important IR windows in the diode DI, ICI and resistor R2.
electromagnetic spectrum. It receives a high voltage when the brake is applied.
Normally, when the brake is not applied, the output of IC2
Optical Components remains high and the red LED glows. Resistor R1 is used for
Often optical components are required to converge or the input stability of IC2. ICI and CI provide a ripple-free
focus infrared radiations, to limit spectral response, etc. To regulated supply to the inverting input of IC2. IC3 is wired as a
converge / focus radiations, optical lenses made of quartz, mono stable to give pulse output of one second. Timing
CaF2, Ge and Si, polyethylene Fresnel lenses, and mirrors elements RT and C4 make the output high for one second to
made of Al, Au or a similar material are used. For limiting activate the buzzer and LED2. Usually the trigger pin of IC3 is
spectral responses, band pass filters are used. Choppers are high due to R6 and the buzzer and LED2 remains off. When
used to pass interrupt the IR beams. the brake pedal is pressed, pin 2 of IC2 gets a higher voltage
from the brake switch and its output goes low to switch off the
Infrared Detectors red LED. When there is a pressure drop in the brake system
Various types of detectors are used in IR sensors. due to leakage, the pressure sensor works LED1 remains on
Important specifications of detectors are And the buzzer does not sound when the brake is applied. The
Photosensitivity or Responsivity: Responsivity is the circuit can be assembled on any general purpose PCB or
Output Voltage/Current per watt of incident energy. perforated board. The circuit can be powered form the
Higher the better. vehicles battery. The circuit requires well-regulated power
Noise Equivalent Power (NEP): NEP represents detection supply to avoid triggering while the battery is charging from
ability of a detector and is the amount of incident light the dynamo. IC4, C6 and C7 provide regulated 12V to the
equal to intrinsic noise level of a detector. circuit. The power supply should be taken from the ignition
Detectivity (D*: D-star): D* is the photosensitivity per switch and the circuit ground be clamped to the vehicles body.
unit area of a detector. It is a measure of S/N ratio of a A bicolor LED can be used in place of LED1 and LED2 if
detector. D* is inversely proportional to NEP. Larger D* desired.
indicates better sensing element.
In addition, wavelength region or temperature to be Anti Collision System
measured, response time, cooling mechanism, active area, no The AntiCollision device is a detection device meant to
of elements, package, linearity, stability, temperature be incorporated into cars for the purpose of safety. As opposed
characteristics, etc. are important parameters which need to the anticollision devices present in the market today, this
attention while selecting IR detectors. system is not designed to control the vehicle. Instead, it serves
as an alert in the face of imminent collision. The device is
Signal Processing intended to find a way to implement a minimum spacing for
Since detector outputs are typically very small, cars in traffic in an affordable way. It would also achieve
preamplifiers with associated circuitry are used to further safety for the passengers of a moving car. The device is made
process the received signals. We used these sensors as a up of an infrared transmitter and receiver.
detector which provides early detection.
Process Description
Brake failure indicator is a device which is used to avoid
accidents. The brake failure indicator circuit is a circuit that
constantly monitors of the condition of brakes and gives an
audio visual indication. When the brake is applied the green
LED blinks and the piezo buzzer beeps for around one second
if the brake system is intact. If brake fails the red.The circuit
will work only in vehicles with negative grounding. It also Figure 3.1 Grid formation by transmitted rays of IR sensor
gives an indication of brake switch failure. In hydraulic brake
systems of vehicles; a brake switch is mounted on the brake Also incorporated into it is an audio visual alarm to work
cylinder to operate the rear brake lamps. in with the receiver and effectively alert the driver and/or the
The brake switch is fluid operated and doesnt function if passengers.
the fluid pressure due to leakage. The fluid leakage cannot be The device works by sending out streams of infrared
detected easily unless there is a severe pressure drop in the radiation and when these rays are seen by the other equipped
brake pedal. This circuit sensor the chance of brake failure by vehicle, both are meant to take the necessary precaution to
monitoring the brake switches and reminds you of condition of avert a collision. The device would still sound an alarm even
brake every time the brake is applied. The circuit comprises of though it is not receiving infrared beams from the oncoming
ICs, seven resistors, seven capacitors, two LED, Two diodes vehicle.
and a buzzer. The circuit uses an op-amp (IC 2) as voltage This is due to reflection of its own infrared beams. At the
comparator and timer in constable configuration for alarm. IC end of the design and testing process, overall system was
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implemented with a constructed work, tested working and braking system with indicator. Brake failure occurs only
perfectly functional. because of worn out of brake shoe and cut in liner. It consists
of two sensors. One sensor is connected with the brake shoe.
The other sensor is the brake liner. The signal from the two
sensors is given to a microcontroller. When the brake shoe is
worn out, the sensor senses signal to the microcontroller. Also
if the brake liner is cut, the sensor sends signal to the
microcontroller. The micro controller analyses the signal and
operates the corresponding indicator. It nothing wrong, green
indicator will glow and when break failure signal fault detected
red indicator will glow and automatically activated external
mechanical brakes used to avoiding the accident. The system
Figure 3.1(b) Transmission and reception of the waves by automatically stops vehicle, when the IR sensor detecting the
IR sensors parts of the operator inside the machine.
This is due to reflection of its own infrared beams. At the How Brake Failure Works?
end of the design and testing process, overall system was As drivers, we need both of these features as much as we
implemented with a constructed work, tested working and need to breathe in and out. If you've ever been in a vehicle that
perfectly functional. did not stop, you know the sheer terror that brake failure can
Circuit Diagram cause. Whether your vehicle is equipped with disc or drum
brakes, you expect them to work when you hit the brake pedal.
Brakes can't talk -- or can they? If you're not distracted
with chatter or music, you might hear your brakes trying to tell
you when something's wrong. Brakes have their own language;
they squeal, click, squeak and grind. You need to listen
carefully to their noises rather than ignore them and hope the
sounds will magical.
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vehicle's brake rotors -- those flat, shiny discs that you can
sometimes see just behind the wheels of some vehicles.
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With ABS you can brake as hard as you can and steer striking the overhead structure. This means shall conform to
yourself to safety without the fear of wheels locking up and the following requirements:
skidding. 1. Prior to the time when the counterweight strikes its buffer,
it shall reduce the speed of the car to the speed for which
the counterweight buffer is designed.
2. It shall not develop an average retardation of the car in
excess of 32.2 ft./s2 (9.81 m/s2) during the stopping
phase.
3. It shall be a mechanical means independent of the driving
machine brake.
4. It shall prevent over speeding of the elevator system
Figure 4.1(d) Anti-Lock braking system through the control of one or more of the following:
a. Counterweight
Blind Support Information System (BSIS) b. Car
Using cameras set just below the outer rear view mirrors c. Suspension or compensating rope system.
the BSDS tell you if there is any vehicle in your blind spot.
This proposed rule is currently under committee review,
and consideration has been given to requiring protection to
prevent the car from leaving the landing with the doors opened
or unlocked.
An ascending elevator car accident occurred at a western
Pennsylvania coal mine on February 4, 1987 and caused
extensive structural damage and disabled the elevator for two
months. Following this accident, the Pennsylvania Bureau of
Deep Mine Safety established an advisory committee to
determine these devices that are available to provide ascending
car over speed protection for new and existing mine elevator
installations.
Figure 4.1(e) Blind Spot information system
The following four protective methods were determined to
Night Vision
Driving during the night becomes safe than ever with the be feasible based on engineering principles or extensive mine
testing.
night vision where one can see clearly on the control display
1. Weight balancing (counterweight equals the empty car
even in pitch black. Thanks to infra-red technology
weight).
2. counter weight safeties
3. dynamic braking
4. rope brake.
The Pennsylvania Bureau of Deep Mine Safety has
approved these four methods and has made ascending car over
speed protection mandatory on all existing counterweighted
mine elevators within the state of Pennsylvania, effective
December 1, 1991.
The safety code also addressed the potential risk of
Figure 4.1(f) Night vision injuries to passengers if a failure would cause the car to leave
the landing with the door open. This hazard could cause the
Rules and Regulations passenger to be crushed between the car floor and landing door
Several rulemaking committees and government safety header. This risk is also present in the down direction. To
authorities have addressed the deficiencies in the existing eliminate the "trapping risk" in both directions, additional
elevator regulations and have proposed revisions to the protective means that must detect any uncontrolled movement
elevator safety codes. of the car are required.
The report from the American Society of Mechanical
Engineers - A17 Mechanical Design Committee on "Cars Protective Devices
ascending into the building overhead,"-dated September 1987, Several methods are available to provide ascending car
contained the types of failures that could result in elevators over speed protection. Some methods are feasible only on new
accelerating into overhead structure and an analysis of the installations, and others are easily retrofitted to existing
possible solutions. In addition, a proposal to the A17.1 elevators. Three of the most viable solutions are presented here
Committee for a new code Rule 205.6 was introduced as for consideration.
follows:
Rule 205.6 ("Prevention of over speeding car from striking Counterweight Safeties
the overhead structure"): All traction elevators shall be The obvious method is to install traditional safeties on the
provided with a means to prevent an ascending car from counterweight; however, the reliability of this old technology
is being questioned. In addition, this method can be difficult to
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install on existing elevators, especially if the counterweight Speed Testing
guide rails and brackets need to be replaced to accommodate With the help of this test, we can confirm that the brake
the additional load forces. Clearances may not be available for failure indicator is working in all the above conditions. This
the counterweight safeties due to limited shaft way dimensions. test was under taken to check the working of brake switch as
There is also a problem with maintaining the safety system well as brake failure indicator. From this testing, we find out
under the less than desirable operating environment that is that whether the speed is high or low, the brake failure
present in the mine shaft way. indicator is working in all condition. It is working at even low
speed also. So from speed test we can confirm that it is
Dynamic Braking working properly.
A second solution used in the United States mining
industry is the application of passive dynamic braking to the Petrol level Testing: From the above test, we can confirm that
elevator drive motor. As mentioned earlier, most elevators use the level of petrol does not cause any problem to the condition
direct current drive motors that can perform as generators of brake. Thus the brake failure indicator worked properly at
when lowering an overhauling load. Dynamic braking simply all conditions. Tests were conducted to determine if the rope
connects a resistive load across the motor armature to dissipate brake would operate reliably in the mining environment to
the electrical energy generated by the falling counterweight. provide ascending car over speed protection.
The dynamic braking control can be designed to function when First, accelerated mechanical testing was performed to
the main power is interrupted. Dynamic braking does not stop determine if the braking system could withstand repeated
the elevator but limits the runaway speed in either direction; operation without experiencing significant wear or failure.
therefore, the buffers can safely stop the conveyance. These tests were performed while the suspension ropes were
stationary. This testing was conducted at both the mine site
Mechanical Modification installation and in the laboratory.
Prior to testing, several mechanical modifications were Mine site testing was conducted every 4 hr. Mechanical
required to protect the rope brake system from environmental counters were installed on both the machine brake and the rope
and mechanical damage. The modifications also reduced the brake to record the total number of operations for each brake.
possibility and the undesirable effect of an air leak in the Every 4 hr, the number of times the machine brake had set
pneumatic system. The following modifications were included during the previous 4 hr period was noted, and then, the rope
in the rope brake design: brake was operated an equal number of times.
1. The 200 lbf/m2 rated plastic air hose was replaced with The mechanical testing concluded after 30 days of around
2,000 lbf/m2 rated metal braided hose with integral the clock testing. The total number of rope brake operations
couplings. was 3430. The temperature range varied from 25 to 83F.
2. The air hose compression fittings were replaced by One of the rope brake components subjected to wear was
stainless steel threaded connectors. the piston ring gasket. This gasket provides the air seal
3. All the electrical components were installed in protective between the moving piston, which presses against the traveling
enclosures, and the wiring was installed in conduit. brake pad, and the stationary cylinder. An overload test was
4. A check valve was installed in the compressed air supply conducted to determine the integrity of this seal.
line to hold the rope in the applied position once it was set For the test, 8750 lb (125% of rated load) was loaded onto
even if air pressure was lost in the air compressor tank. the car at the bottom of the shaft. Then, the rope brake was set,
5. The added check valve required an additional pressure and the machine brake was disengaged. The air pressure was
switch to monitor the supply air pressure. The original released from the air compressor tank, and the air pressure
pressure switch would not detect a pressure loss in the air inside the rope brake cylinder was monitored. The load was
compressor tank when the check valve was installed. The successfully held stationary for 1 hr. The initial air pressure
contacts of the two pressure switches were installed in was 114 lbf/in 2, and after 1 hr, the pressure was 102 lbf/in2.
series. The pressured reduction may be attributed to an air leak
through the check valve or past the piston ring gasket as a
MECHANICAL TESTING result of wear.
After 2 mo of testing and 146,836 operations, the rope
Product brake was disassembled and inspected for wear. The pneumatic
In order to detect the efficiency and its working of Brake piston ring gasket exhibited minimal wear. Superficial rust was
failure indicator, several tests were conducted. Before releasing evident where the compressed air entered the rope brake and
it as a new product into the market, every product undergo displaced the lubricant.
testing. So product testing is essential to verify the working of Over the 70 days of testing, the temperature ranged from 5
the product. The test should be decided in order to verify to 82F, and the relative humidity varied from 25 to 100%. At
whether the product satisfied all the objectives. With the help times, thick accumulations of frost build up on the air line
of speed test, we can verify the different levels of speed. In between the magnetic valve and the rope brake cylinder.
order to detect the effect of petrol level on this device, the Therefore, the formation of ice inside the compressed air lines
petrol level testing is also conducted. The condition of brake is was possible; however, no adverse effects were observed.
also detected with the help of another methods. Therefore, with
the help of this tests, we find out whether the Brake Failure Rope Pulse Tachometer Test
Indicator is working properly or not. The brake control logic obtains the speed reference signal
from an independent pulse tachometer assembly. The pulse
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tachometer assembly consists of two proximity switches the rope brake electronic control and was required to be
mounted 45 mechanical degrees apart around a rotating rubber mechanically disabled.
wheel. Two sheet metal screws are installed into the rubber
wheel on opposite sides (180 apart). The rubber wheel is Dynamic Performance Tests
friction driven by the suspension ropes. A spring tension arm The retarding capacity of the Bode rope brake model 580
maintains pressure between the rubber friction wheel and was tested at the mine site on three occasions over a 6-mo
suspension ropes. Electrical pulses are generated as the screw period. During the test procedure, the elevator motor armature
heads pass beneath the proximity switches. This pulse train is current, field current, armature voltage, speed (analog
interpreted by the brake control box to obtain the speed of the tachometer feedback), and rope brake cylinder air pressure
elevator. were monitored and recorded on an eight-channel thermal
array recorder.
Speed Relay Input Test
The brake control logic also monitors a speed relay to Low Air Pressure Tests
determine if the elevator should be running. For this A series of tests were conducted with the air compressor
installation, the elevator speed relay RL2 is monitored by the motor disconnected from the power source to determine the
brake control logic. The normally closed contact of RL2 opens number of times the rope brake could stop the elevator from
when the elevator reaches 60% of the rated speed. The speed the stored pressurized air in the compressor tank. The test were
contact serves as a check on the rope tachometer. When RL2 is conducted with no car load in the upward direction.
opened, the brake control should be receiving a signal from the
rope tachometer. The rope brake and machine brake set if the
tachometer fails for any reason to produce a signal when the
elevator control has a run command.
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The rope brake was also capable of stopping the maximum [5] J. A. Nederbragt, "Uncontrolled Speed, Up and Down,"
rated load (7000 lb) traveling down at rated speed. The Elevator World, Dec. 1985.
measured deceleration rate was 5.88 ft/s2, which translates into
a stopping distance of 8.5 ft when traveling at 600 ft/min. [6] T.D. Barkand, W.J. Helfrich, Application of Dynamic
The dynamic braking system produces a retarding force Braking to Mine Hoisting Systems", IEEE Transactions on
proportional to the speed with an initial deceleration rate of 2.7 Industry Applications, September / October 1988.
ft/s2. The dynamic braking system begins retarding the elevator
immediately since the motor contactor connects a resistor [7] J.A. Nederbragt, "Rope Brake: As Precaution Against
across the motor armature instead of opening the circuit and Overspeed," Elevator World, July 1989.
allowing the counterweight to accelerate downward. The
dynamic braking effort is reduced as the speed decreases until [8] -----, "Report of Test Results" conducted by TNO-
an equilibrium is reached between the retarding effort and the IWECO, Delft Tech. Univ., June 7, 1989.
load forces, resulting in a steady-state speed [6].
Dynamic braking is an excellent system to assist the
mechanical brake since the dynamic brake limits the initial
overspeed conditions without having a significant compound
braking effect.
CONCLUSION
We are proud to express our delight as the project we
embarked upon is successfully finished within the target date.
The project gave us more confidence that we will be able to
put in practice, whatever theoretical knowledge. we gained
during our course of study till now. If really persuades us to do
more and more, perhaps in better way in our future. Brake
failure indicator is a early warning system. it constantly
monitors the condition of the brake and give audio visual
indication.
REFERENCES
[1] A17 Mechanical Design Committee Report on Cars
Ascending into the Building Overhead, ASME, Sept.
1987.
International Journal of Engineering Science and Computing, July 2016 8681 http://ijesc.org/