emergency reverse brake
TRANSCRIPT
EMERGENCY REVERSE BRAKE
NO. NAME REGISTRATION NUMBER
1. MUHAMMAD BIN ZAINUL ABIDIN 13DAD10F1053
2. MUHAMMAD ZUL AIZAT BIN
ROSLAN
13DAD10F1011
3. MEGAT ABU SUFFIAN BIN
BAHARI
13DAD10F1026
DEPARTMENT OF MECHANICAL ENGINEERING
POLITEKNIK SULTAN MIZAN ZAINAL ABIDIN
DISEMBER SESSION 2012
KE
JUR
UT
ER
AA
N
ME
KA
NI
KAL
(AUTOMOT
IF)
DI
SE
MB
ER
2012
EMERGENCY REVERSE BRAKE
NO NAME REGISTRATION NUMBER
1. MUHAMMAD BIN ZAINUL ABIDIN 13DAD10F1053
2. MUHAMMAD ZUL AIZAT BIN ROSLAN 13DAD10F1011
3. MEGAT ABU SUFFIAN BIN BAHARI 13DAD10F1026
This Report Submitted to the Department of Mechanical Engineering Partial
Fulfillment of Requirements For Diploma in Mechanical Engineering (Automotive)
PROJECT APPROVAL
Project report entitled "Emergency Brake Reverse" was submitted, reviewed and
certified as eligible projects and writing requirements as specified.
Checked by:
Supervisor Name : Mr. Fazri bin Che Mohd Irwan Mohd Nor
Signature of Supervisor :
Date :
Confirmed by:
Coordinator Name : Mr. Khalid Bin Ahmad Airfan.
Signature of Coordinator :
Date :
"We Acknowledge Work This Is Our Own Work Except Citations Which Are
Individually We Explain The source"
1. Signature :
Name : Muhammad bin Zainul Abidin.
Registration No: 13DAD10F1053
Date :
2. Signature :
Name : Muhammad Zul Aizat Bin Roslan
Registration No: 13DAD10F1011
Date :
3. Signature :
Name : Megat Abu Suffian Bin Bahari
Registration No: 13DAD10F1026
Date :
APPRECIATION
Alhamdulillah, because we have the strength and spirit to prepare a full report
of final semester project without facing any problem at the time was set successfully.
Special thanks for our many parents encourage and support both financial and
thoughtful ideas in helping us complete this project.
Here, we would like to express appreciation to the millions of our project
supervisor, Mr. Mohd Irwan Fazri bin Che Mohd Nor for giving us the opportunity
to do our projects contribute creative ideas successfully. In addition, my thanks also
go to the project coordinator, Mr Ahmad Bin Khalid Airfan for their support and
guidance throughout the process of completing this final project. Not forgetting to
thank all lecturers, friends and contacts on external workshop helped directly or
indirectly in the production of the "Emergency Brake Reverse".
Finally, my thanks to all involved. All services and kindness that they gave us
during the completion of this project is highly appreciated.
Thank you.
ABSTRAK
Pelbagai jenis sistem keselamatan yang telah wujud sejak bertahun-tahun.
Sistem keselamatan yang kita ingin tegaskan adalah sistem brek. Ini adalah kerana
sistem brek adalah salah satu ciri-ciri keselamatan yang penting di dalam kenderaan.
Walau bagaimanapun, kami memperkenalkan sistem ini mempunyai pelbagai yang
unik dan tersendiri kerana sistem yang sedia ada tertumpu di bahagian hadapan
kenderaan. Lain-lain dalam projek-projek kami di bahagian posterior. Sistem ini
berfungsi apabila kenderaan terbalik atau lebih mudah untuk mengatakan bahawa
apabila kita memasuki gear 'R', sistem akan mengaktifkan 'Brek Songsang Darurat'
jika ada objek atau objek di belakang kenderaan yang kita tidak perasan. Andaikan
kita tahu objek yang di belakang tidak mengganggu operasi untuk mengubah, kita
boleh mematikan sistem. Dengan mempunyai sistem keselamatan yang belum
diperkenalkan lagi seperti ini, maka ia boleh mengurangkan kadar kemalangan kecil
yang melibatkan pelanggaran di belakang kenderaan.
ABSTRACT
Various types of security systems that have existed over the years. Security
system that we wish to emphasize is the braking system. This is because the braking
system is one of the security features that are key in a vehicle. However, we
introduce the system to have a unique and distinctive varieties because the existing
system is highly concentrated in the front of the vehicle. Others on our projects in the
posterior part. The system works when the vehicle in reverse or easier to say that
when we enter the gear 'R', the system will activate the 'Emergency Brake Reverse' if
there is an object or an object behind the vehicle that we had not noticed. Assuming
we know the object that is behind not interfere with the operation to reverse, we can
turn off the system. By having a security system that has not been introduced yet as
this, then it can reduce the rate of minor accidents involving violations behind the
vehicle.
CONTENTS
………………………………………………………………………………………….
CHAPTER TITLE PAGE
I. INTRODUCTION
1.1 Introduction 1
1.2 Statement of the Problem 1
1.3 Objective 1
1.4 Scope 2
II. LITERATURE REVIEW
2.1 Introduction 3
2.2 Preliminary ideas
2.3 Design concept 6
2.4 Base selection 6
2.5 Selection framework project 7
2.6 Accident history 7
2.7 Components selected 7
2.8 Bolt and nut 7
2.9 Nut
III. METADOLOGY
3.1 Introduction 8
3.2 Selection of components
3.3 Reverse sensor types 9
3.3.1 Ultrasonic Parking Sensor 12
3.3.2 Electromagnetic parking sensor 12
3.4 Motor 16
3.4.1 Power window motor 16
3.4.2 Wiper motor 17
3.5 Pic microcontroller 17
3.6 Battery 18
3.6.1 Car batteries 19
3.6.2 Motorcycle batteries 20
3.7 Project cost 30
IV. FINDINGS, ANALYSIS AND DISCUSSION
4.1 Introduction 32
V. CONCLUSION AND RECOMMENDATION
5.1 Conclusion 44
5.2 Recommendation 44
5.3
LIST OF FIGURES
………………………………………………………………………………………….
Figure numbers Title Page
2.5 The accident happened at the back 4
2.6 Nut 4
3.3.1 Ultrasonic parking sensors 5
3.3.2 Electromagnectic parking sensors 6
3.4.1 Power window motor 7
3.4.2 Car Wiper Motor 1
3.5 Pic Microcontroller 2
3.6.2 Motorcycle batteries 99
CHAPTER I
INTRODUCTION
1.1 Introduction
'Emergency Brake Reverse' is a replica of a security system for a
vehicle in which it works to stop the vehicle if there are objects or vehicles
behind. The aim is to prevent the violation or accident. The frame structure is
constructed of steel. This system is an increase in the braking system. This
system can also be used on automatic transmission vehicles. Components
involved are sensors, power window motor, PIC micro-controllers, switches,
brake pedal, cable, control unit, buzzer, and plywood.
1.2 Problem Statement
a) Minor accidents often occur when reverse.
b) The driver forgot to pull handbrake when the car is on hilly roads.
c) Avoid collision.
d) Reduce accidents.
1.3 Objective
Produce a safety system to stop the vehicle in reverse to avoid a collision or
accident.
1.4 Scope
a) To produce a prototype.
b) Increase the security system.
c) Used to stop the vehicle.
d) Used in vehicle automatic shifters.
CHAPTER II
LITERATURE REVIEW
2.1 Introduction
Before starting a project, various aspects should be taken into consideration
so that the project is running smoothly without any interruption. This study is based
on accidents that often occur on the users of vehicles. This study was carried out
starting from the design to the identification of problems that may be encountered.
Therefore, careful planning and systematic will be arranged to get the best results.
All of this was the result of the ideas discussed in the group. Then, created a design
project.
2.2 Preliminary ideas
Review of existing components markets and how to use it. Complete details
and limitations are used for projects that will be produced.
i. Function - can do brake operation to achieve the objectives.
ii. Components - use of existing components and modify easily transferred.
iii. Construction - the construction of a relatively simple process.
iv. Durability - can withstand the brake pedal speed production.
iv. Security - not harmful to consumers.
After the problem is clearly identified, as much as possible the information
obtained as a result of the observations, problems experienced, analysts, trial and
related resources. Based on the information gathered, the ideas in the form of
preliminary sketches. Conducted ideas, suggestions will be selected to be analyzed
and refined further before making a prototype designed for.
2.3 Design Concept
Selection of an appropriate design is essential. Various aspects should be
taken into account. Selection should be in accordance with the project of use and
functionality. Selection of design prototypes factors are as follows:
i. Form of structural members because it represents the power structure.
ii. Good structural shape and fit to give maximum strength and stability of
the components during operation.
iii. Components selected must be appropriate and not too onerous.
iv. Selection of a strong connection to connection and long-lasting results.
iv. Safety features should be in good condition.
2.4 Base Selection
Site is rectangular in shape more balanced and stable. It is suitable for use on
the project components to accommodate the load. The site for this prototype is
rectangular shaped which aims to support and strengthen the stability of the product.
2.5 Selection Framework Project
Selection of an appropriate project framework is very important to produce
the basis for ensuring that the prototype is strong and stable. It is very important to
produce solid construction and quality.
2.6 Accident History
About 30 percent of all accidents occur when vehicles moving in reverse.
Based on the high frequency of accidents and the fact that all accidents are often
unavoidable support, emphasis must be placed on safe procedures. The accident
occurred when the vehicle is going in the back is costly to the company. Element of
risk resulting in bodily injury happened when supporting any vehicle. This is a key
factor when considering why the cost is so high accident support.
Figure 2.5: The accident happened at the back
There are many dangers that need to be considered when reverse parking:
a) Inadequate view on both sides.
b) Objects directly behind the vehicle when it started back.
c) The object moves into the path of the vehicle.
d) Blind spot created by vehicles.
2.7 Components Selected
The components we chose:
No
.
Component Explanation
1
Iron
i. Used to make body.
2 Reverse Parking Sensor i. Used to detect objects
behind the vehicle.
3
Power window motor
i. Power window motor is
used to move the cable and
the brake pedal.
ii. This motor has a diffusion.
No
.
Component Explanation
4 Pic
Microcontroller
i. That cans are electronic
circuits be programmed to
carry out a range of Vast
Tasks.
ii. Used to program to be
timers or to control a
production line and much
more.
5
Brake pedal
i. Force from driver to brake
system to stop the car.
No
.
Component Explanation
6
Battery
i. Power sources to move the
power window motor.
ii. 12 volt battery.
7
Switch on/off
i. A switch simply opens a
circuit.
ii. Stopping the flow of
electricity.
iii. Has normally open and
normally close.
No
.
Component Explanation
8
Strip Board
i. Is a widely-used type of
electronics prototyping
board.
9
Voltage regulator
i. Is designed to
automatically maintain a
constant voltage level.
10
Transistor
i. Is a semiconductor
device used to amplify
and switch electronic
signals and electrical
power.
ii. It is composed of
semiconductor material
with at least three
terminals for
connection to an
external circuit.
No
.
Component Explanation
11
Resistor
i. Is a passive two-
terminal electrical
component that
implements electrical
resistance as a circuit
element.
ii. The current through a
resistor is in direct
proportion to the
voltage across the
resistor's terminals.
No. Component Explanation
12
i. Small LED as indicator for
detection status.
ii. Obstacle detection up to
10cm.
Medium range infrared sensor
13
Plywood
i. It is flexible, inexpensive,
workable, re-usable, and
can usually be locally
manufactured.
ii. Is a manufactured wood
panel made from thin sheets
of wood veneer.
14
Ic Wire
i. Is the primary method of
making interconnections
between an integrated
circuit (IC) and a printed
circuit board (PCB) during
semiconductor device
fabrication.
No. Component Explanation
15
Cable brake
i. Can be use such as
mechanism actuator to pull
pedal brake in auto reverse
brake project.
16
Bread board
i. Is commonly used to refer to
solderless breadboard
(plugboard).
17
Usb Pic Programmer
i. To program the circuit.
2.8 Bolt And Nut
Bolt is a tightening device categorized by helix ridge, known as an external
thread, around a cylinder. Some bolt threads designed to match the thread mate,
known as threads, usually in the form of nuts. Other bolt threads are designed to cut a
helical groove in a softer material such as wood. Normal function of the bolt is to
hold objects and placing objects.
Figure 2.5: Bolt
Bolts usually have a head, which is usually found at the end of the bolt that
allows it to be rotated or driven. Tools commonly used to rotate the bolt includes a
screwdriver or spanner. The head is usually larger than the body screws, which
prevent the screw from the driven too deep than long bolts.
2.9 Nut
Nut is a type of thread fastening holes. Nat usually used against the bolt to
bind together the stack. Two couples are placed together by a combination of friction
on both threads. In applications where vibration or rotation may cause the nut open,
locking mechanisms apply: adhesive (adhesive), safety pins, or oval-shaped threads.
Figure 2.6: Nat
Nut graded by the strength of the bolt, for example, the nut with the ISO class
10 capable supporting bolt with 9.10 without the ISO class off. Similarly, nuts are
SAE Grade 5 bolts capable of supporting a load of SAE Grade 5, and so on.
CHAPTER III
METHODOLOGY
3.1 Introduction
This prototype Emergency Reverse Brake system was created to show how it
could work in a vehicle. The main purpose is to avoid violations or accidents from
the rear. This situation often occurs when the conditions in the reverse situation. The
selection of the components involved are selected to suit the size of the prototype
design so that it does not interfere with the space.
3.1.1 Project Flow Chart
START
Literature Review
Product Design
Problem Statement
Detailed Design
Figure 3.1.1 : Flow Chart Project
3.2 Selection of components
After paper work is done for the implement design framework of this project
by selecting the type of main components to build a prototype projects have been
made. Appropriate types of components have been selected to obtain a strong project
and tools that can work well for this project. Below are the components that will be
used for this project:
3.3 Reverse Sensor Types
Parking sensors are generally divided into two categories: Ultrasonic Parking
Sensors and Electromagnetic Parking Sensors.
3.3.1 Ultrasonic Parking Sensor (AutoSonar)
AutoSonar system is a safety device that accurately detects all objects,
children, toys, pets, and others that are behind your vehicle when you reverse. Sound
'beep' and the LCD display in the car warns the driver of dangers and prevent
Selection of Components
Mechanical Components
Test
Finishing
END
Analysis and Results
potential accidents. But, the most important thing is that by installing this system,
you can prevent injuries to adults or worse children. These statistics confirm the
increase in this type of accident. According to the Department of Transportation,
27% of all accidents occur in the back. Further research showed that 70% of these
accidents can be avoided with the use of collision avoidance systems as AutoSonar.
How to work
The system is activated automatically when you enter the gear 'R'. Sensors
located at the rear of the vehicle to send and receive ultrasonic radio waves, which
bounce off obstacles and alert the control unit. There is a buzzer that gradually
increase in frequency of vehicles approaching object. A continuous tone indicates
that the vehicle is 0.35m from obstacles.
Figure 3.3.1 : Ultrasonic parking sensors
3.3.2 Electromagnetic Parking Sensor
These rely on the vehicle moving slowly and smoothly towards the object to
be avoided. Once detected the obstacle, if the vehicle momentarily stops on its
approach, the sensor continues to give signal of presence of the obstacle. If the
vehicle then resumes its maneuver the alarm signal becomes more and more
impressive as the obstacle approaches. Electromagnetic parking sensors are often
sold as not requiring any holes to be drilled offering a unique design that discretely
mounts on the inner side of the bumper preserving the 'new factory look' of your
vehicle. This type of parking sensor system is also highly recommended for vehicles
fitted with externally mounted wheels or accessories - a spare wheel on the back of a
4x4, for example, or a cycle rack. These can cause false triggering or inaccurate
warnings when used with ultrasonic systems. Electromagnetic systems ignore fixed
items that are already present and look for changes to the surrounding area.
How to work
Indicates object distance with different beeping frequencies. The sensor
antenna activates 3 types of acoustic signals during approaching an obstacle at
different distances.
Zone 1: A long interval sound of Beep approximately between 0.7-0.5m
Zone 2: A short interval sound of Beep approximately between 0.5-0.3m
Zone 3: A continuous sound of Beep approximately between 0.3-0m
Simple and concealed installation. The sensor antenna is entirely installed inside
the bumper without any drilling work.
Maintenance free, no cleaning or washing is required.
Fit for any car, truck, RV or mini-van. Peel & Stick Antenna foil tape sensor for
vehicles bumpers.
Wires to Reverse Lamp (12 Volts DC)
High output Piezo buzzer alert you with a beeping sound
Detects object at 3 feet or less Detection in all directions without dead angle.
Minimize bumper damage. Totally built-in installation without impair overall
appearance.
- Electromagnetic parking sensor and Ultrasonic parking sensor
Figure 3.3.2 : Electromagnetic parking sensors
3.4 Motor
3.4.1 Power Window Motor
Most consumers prefer cars with power windows. Power window motors are
mechanisms installed inside of the car door which control the function of the window
glass enabling them to go up and down. The motor power window in a car is the
control that allows someone in a car to roll the window up or down. This function
can be accomplished in one of two ways. In early model cars, the window in a car or
truck was rolled up and down manually, by use of a turn-handle that connected to
various gears within the door of the car. Now, however, it is far more common to
see car windows that operate with a switch or a button. These power window
regulators operate under electrical power.
How it work
With inset of motor and gear reduction
The linkage has a long arm, which attaches to a bar that holds the bottom of
the window. The end of the arm can slide in a groove in the bar as the window rises.
On the other end of the bar is a large plate that has gear teeth cut into it, and the
motor turns a gear that engages these teeth.
The same linkage is often used on cars with manual windows, but instead of a motor
turning the gear, the crank handle turns it. In the next section we'll learn about some
of the neat features some power windows have, including the child lockout and
automatic-up.
Figure 3.4.1 : Power window motor
3.4.2 Motor wiper
The wipers combine two mechanical technologies to perform their task:-
i) A combination electric motor and worm gear reduction provides power to
the wipers.
ii) A neat linkage converts the rotational output of the motor into the back-and-
forth motion of the wipers.
How it work
Motor and Gear Reduction
It takes a lot of force to accelerate the wiper blades back and forth across the
windshield so quickly. In order to generate this type of force, a worm gear is used on
the output of a small electric motor.
The worm gear reduction can multiply the torque of the motor by about 50 times,
while slowing the output speed of the electric motor by 50 times as well. The output
of the gear reduction operates a linkage that moves the wipers back and forth. Inside
the motor/gear assembly is an electronic circuit that senses when the wipers are in
their down position. The circuit maintains power to the wipers until they are parked
at the bottom of the windshield, then cuts the power to the motor. This circuit also
parks the wipers between wipes when they are on their intermittent setting.
Figure 3.4.2 : Wiper Motor
3.5 Pic Microcontroller
PIC is a family of modified Harvard architecture microcontrollers made by
Microchip Technology, derived from the PIC1650 originally developed by General
Instrument's Microelectronics Division. The name PIC initially referred to
"Peripheral Interface Controller". PICs are popular with both industrial developers
and hobbyists alike due to their low cost, wide availability, large user base, extensive
collection of application notes, availability of low cost or free development tools, and
serial programming (and re-programming with flash memory) capability. They are
also commonly used in educational programming as they often come with the easy to
use 'pic logicator' software.
Function
PIC microcontrollers (Programmable Interface Controllers), are electronic
circuits that can be programmed to carry out a vast range of tasks. They can be
programmed to be timers or to control a production line and much more. They are
found in most electronic devices such as alarm systems, computer control systems,
phones, in fact almost any electronic device. Many types of PIC microcontrollers
exist, although the best are probably found in the GENIE range of programmable
microcontrollers.
Figure 3.5 : Pic Microcontroller
3.6 Battery
3.6.1 Car Batteries
Figure 3.6.2 : Car batteries
An automotive battery is a type of rechargeable battery that supplies electric
energy to an automobile. Usually this refers to an SLI battery (starting, lighting,
ignition) to power the starter motor, the lights, and the ignition system of a vehicle’s
engine. Automotive SLI batteries are usually lead-acid type, and are made of six
galvanic cells in series to provide a 12 volt system. Each cell provides 2.1 volts for a
total of 12.6 volt at full charge. Heavy vehicles such as highway trucks or tractors,
often equipped with diesel engines, may have two batteries in series for a 24 volt
system, or may have parallel strings of batteries.
Function
i) A car battery supplies power to the starter and ignition system to start the
engine.
ii) A car battery supplies the extra power necessary when the vehicle's electrical
load exceeds the supply from the charging system.
iii) A car battery acts as a voltage stabilizer in the electrical system. The battery
evens out voltage spikes and prevents them from damaging other components
in the electrical system.
3.6.2 Motorcycle Batteries
Figure 3.6.2 : Motorcycle batteries
Motorcycle batteries vary by engine size on any particular motorcycle.
Motorcycle engines range in size and are measure by cc. A small engine could be a
100cc for example, where as a larger engine size can be 1200cc. The higher the
number, the more powerful the engine. All motorcycle batteries are lead acid
batteries. There are completely recyclable and should never be thrown away with
regular waste. Motorcycles are easy to check charge with a voltmeter.
Function
A motorcycle battery has three main functions:
i) It enables the engine to start with the electrical starter.
ii) It works as an extra power supply when your bike needs it.
iii) It works as an absorber for high surges of electricity.
Table 3.7 : Project planning Month Dis 2012 Jan 2013 Feb 2013 Mar 2013
No. Weekly
Activity1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 Discussion topics project
2 Determine the project title
3 Initial sketch4 Final
drawings5 Analysis and
research projects
6 Selection of project
7 Initial installation
8 Initial testing and identify problems
9 Improvements
10 Installation and final testing
11 Achieving the objectives and final preparations
12 End
3.8 Project Costs
No. Type of material Quantity Price Per Unit Total
1 PIC 2 RM 30.00 RM 60.00
2 Strip board 2 RM 5.00 RM 10.00
3 Project board tester 1 RM 15.00 RM 15.00
4 Motor Power Window 1 RM 45.00 RM 45.00
5 Brake Pedal 1 set RM 30.00 RM 30.00
6 Reverse Sensor 1 RM 120.00 RM 120.00
7 Medium range infrared sensor 1 RM 15.00 RM 15.00
8 Iron 1 set RM 30.00 RM 30.00
9 Bolt and Nut 1 set RM 10.50 RM 10.50
10 Spray can 1 can RM 6.00 RM 6.00
11 Cable 2 ft. RM5.00 RM5.00
12 Plywood 5 ft. RM25.00 RM25.00
13 Bracket 2 ft. RM4.00 RM4.00
14 Perspect 1 set RM12.00 RM12.00
15 Electronic component 1 set RM40.00 RM40.00
16 Other RM25.00 RM25.00
TOTAL RM 452.50
CHAPTER IV
FINDINGS, ANALYSIS AND DISCUSSION
4.1 Introduction
Analysts and make learning process for a project that is produced is very
important to know and evaluate the effectiveness of the project. Ability to achieve
the objectives of the project can be proved by tests performed.
4.1.1 Car Reverse System
A sensor is placed on the rear bumper of the car, which is capable of both
emitting and detecting ultrasound. As it pulses, a computer measures the time it takes
for the sound of it emits to be heard again. Parking sensors operate at a close range
and some sensors have a minimum operating range. When the user set distance
threshold is passed, the sensor will emit an audible sound alerting the driver that is
getting close to an object.
The distance threshold is useful for those who may want to leave more room
behind their vehicles, and those who like to squeeze in as tight as possible. Some
more expensive models may also have an extra unit inside the car which can also
visually alert the driver.
Figure 4.1.1: Component of car reverse system
4.1.2 Limitations
The ultrasonic parking sensor is considered the cheapest form of a parking
sensors, thus it comes with several problem with other technologies address. The first
is that it can miss small objects or objects which lay below the sensors cone-shaped
operating range and sometime requires multiple sensors to be attached to the bumper
to get full coverage on both side car. The sensors can also be mistriggered on steep
slopes when the ground itself is “seen” by the system and wrongly considered to be
an obstacle.
Dimension of Reverse Sensor
Figure 4.1.2: Reverse sensor dimension
Figure 4.1.3: Reverse sensor installation
4.2 Distance that Reverse Sensor Detect
Usually reverse sensor that have been install in the car can detect distance
while reversing a car. The limit distance that reverse sensor can detect is from 160 to
0 cm. This table below show how the reverse sensor detect distance and make buzzer
voice.
Figure 4.2: Distance detect by sensor to operate
4.3 Motor Power Window
Power window are mechanisms installed inside of the car door which control
the function of the window glass enabling them to go up and down. When the power
window motor fails the window ceases to operate in whatever position it was in
when the power window motor failed. It can be a security concern if the window is
open when the motor fails.
Figure 4.3: Power Window Motor
Figure 4.3.1: Component inside motor power window
4.4 Specification Power Window Motor
4.4.1 No load specification
The no load speed or speed when no torque is applied to the motor shaft is 95
rotation per minute (rpm) and the no load current is less than 1.5 amperes.
4.4.2 Basic specification
The power window motor has four mounting hole positions. There is a
working voltage of 12 volts DC current. The unit is waterproof and ISO 9001
certified. Rated torque is 3 N.m (30 Kg.cm) and it rated speed is 65 rpm (55-
75).Besides that the stall current is 28 A and stall torque is 25 Kg. The noise of the
power window motor is 55 DB.
Figure 4.4.3: Example table of power window motor operation
4.5 Performance Curve of Power Window Motor
Figure 4.5: Example of performance curve of power window motor
4.6 Dimension of Power Window Motor
Figure 4.6: Dimension of Power Window Motor
4.7 Pedal Brake
The brake pedal is a simple class 2 layer attached to the master cylinder
piston by a rod. As force is applied to the brake pedal, it is multiplied through
leverage.
For example:
The brake pedal has a ratio of 3 to 1.The force is multiplied by 3, i.e, a force
of 100 psi becomes 300 psi at the master cylinder.
Figure 4.5.1: Car pedal brake
Conclusion
The force of the pads clamping on the rotor, or shoes pressing against the
drum, now can convert the kinetic energy of the moving vehicle into heat energy. As
the kinetic energy is converted, less and less of it is available for conversion and the
vehicle slows and eventually stops.
Analysis Data
4.8 Force
4.8.1 Definition
In physics, a force is any influence that causes an object to undergo a certain change,
either concerning its movement, direction, or geometrical construction. It is measured with
the SI unit of newton and represented by the symbol F. In other words, a force is that which
can cause an object with mass to change its velocity (which includes to begin moving from
a state of rest), i.e., to accelerate, or which can cause a flexible object to deform. Force can
also be described by intuitive concepts such as a push or pull. A force has
both magnitude and direction, making it a vector quantity.
The original form of Newton's second law states that the net force acting upon an object is
equal to the rate at which its momentum changes with time.[1] If the mass of the object is
constant, this law implies that the acceleration of an object is directly proportional to the net
force acting on the object, is in the direction of the net force, and is inversely proportional
the mass of the object. As a formula, this is expressed as:
Figure 4.8.1: Forces are also described as a push or pull on an object. They
can be due to phenomena such as gravity, magnetism, or anything that might cause a
mass to accelerate.
4.8.2 Car pedal brake ratio
In a sitting position (diagram below), the average driver can comfortably
generate 70 lbs. of force on the rubber pad at the end of the brake pedal. The brake
pedal is nothing more than a mechanical lever that amplifies the force of the driver.
This is where the pedal ratio comes into play. Pedal ratio is the overall pedal length
or distance from the pedal pivot to the centre of the pedal pad divided by the distance
from to the pivot point to where the push rod connects.
The optimal pedal ratio is 6.2:1 on a disc/drum vehicle without vacuum or other
assist method. This means that the 70 lbs. the driver has applied now is amplified to
434 lbs. (6.2 x 70 lbs.) of output force. The problem is that the travel of the pedal is
rather long due to the placement pivot point and master cylinder connection.
Figure 4.8.2.: Diagram of Sitting position
4.8.3 Brake Boosters
A booster increases the force of the pedal so lower mechanical pedal ratio can
be used. A lower ratio can give shortened pedal travel and better modulation. Most
vacuum boosted vehicles will have a 3.2:1 to 4:1 mechanical pedal ratio. The size of
the booster’s diaphragm and amount of vacuum generated by the engine, will
determine how much force can be generated. Most engines will generate around -8
psi of vacuum (do not confuse with inches of HG or Mercury). If a hypothetical
booster with 7-inch diaphragm is subjected to -8 psi of engine vacuum, it will
produce more than 300 lbs. of addition force. Here is the math:
π(3.14) X radius(3.5)2 = 38.46 sq/inches of diaphragm surface area X 8 psi
(negative pressure becomes positive force)= 307.72 lbs of output force
To keep things simple, let’s return to our manual brake example. The rod coming
from the firewall has 434 lbs. of output force. When the force is applied to the back
of the master cylinder, the force is transferred into the brake fluid.
The formula for pressure is force divided by the surface area.
If the master cylinder has a 1-inch bore, the piston’s surface area is .78 square
inches. If you divide the output force of 434 lbs. by the surface area of the piston,
you would get 556 psi(434 lbs. divided by .78 inches) at the ports of the master
cylinder. Not bad for a 70 lbs. of human effort. If you reduce the surface area of the
piston you, will get more pressure.
This is because the surface area is smaller, but the output force from the pedal stays
the same. If you used a master cylinder with a bore of .75 inches that has a piston
that has .44 inches of piston surface area, you would get 986 psi at the ports for the
master cylinder (434 lbs. divided by .44 inches).
4.9 Torque
Torque, moment or moment of force, is the tendency of a force to rotate an object about an axis, fulcrum, or pivot. Just as a force is a push or a pull, a torque can be thought of as a twist to an object. Mathematically, torque is defined as the cross product of the lever-arm distance and force, which tends to produce rotation. Loosely speaking, torque is a measure of the turning force on an object such as a bolt or
a flywheel. For example, pushing or pulling the handle of a wrench connected to a nut or bolt produces a torque (turning force) that loosens or tightens the nut or bolt.
The symbol for torque is typically τ, the Greek letter tau. When it is called moment, it is commonly denoted M. The magnitude of torque depends on three quantities: the force applied, the length of the lever arm connecting the axis to the point of force application, and the angle between the force vector and the lever arm. In symbols:
Where
τ is the torque vector and τ is the magnitude of the torque,
r is the displacement vector (a vector from the point from which torque is
measured to the point where force is applied), and r is the length (or
magnitude) of the lever arm vector,
F is the force vector, and F is the magnitude of the force,
× denotes the cross product,
θ is the angle between the force vector and the lever arm vector.
The length of the lever arm is particularly important; choosing this length appropriately lies behind the operation of levers, pulleys, gears, and most other simple machines involving a mechanical advantage. The SI unit for torque is the newton metre (N·m). For more on the units of torque.
Figure 4.9: Example of Torque
4.9.1 The torque (T) required is:
To select the proper motor, we must consider the “worst case scenario”, where the robot is not only on an incline, but accelerating up it.
Note now that all forces (F) are along the x and y axes. We balance the forces in the x-direction:
Inserting the equation for torque above, and the equation for mgx, we obtain:
Rearrange the equation to isolate T:
This torque value represents the total torque required to accelerate the robot up an
incline. However, this value must be divided by the total number (N) of drive wheels
to obtain the torque needed for each drive motor. Note that we do not consider the
total number of passive wheels as they have no effect on the torque required to move
the object aside from adding weight.
CHAPTER V
CONCLUSION AND RECOMMENDATION
5.1 CONCLUSION
Generated from the project, hoped that this will show and demonstrate a new
system was introduced. The prototype was created to show that the system design to
avoid violations of the right to withdraw from the current back to reduce the rate of
accidents often occur among drivers less attentive while driving a vehicle.
Planning costs incurred is one aspect that is quite important in this project. As
a result of the planning and implementation of projects correctly and systematically
minimize the cost of the project without defacing project produced. Studies of
purchased components can reduce production costs by purchasing capital goods and
components that are correct and accurate.
Workshop work involved in this project is the production of welding, drilling,
measuring, grinding and cutting. In this work, the machines used are as welding
machines, drilling machines, grinding machines, metal cutting machines, tools and
other workshop. Almost all of these projects involve the use of iron.
Analysis and findings that have been conducted show that this ideal
Emergency Brake Reverse applied to vehicles to improve safety.
Overall, many aspects of which have been collected from the projects that
have been implemented. In addition, it is hoped that this project will meet the needs
of the automotive field (PSMZA). With production of Emergency Brake Reverse
could help in some way to develop technology in the automotive field in the future.
5.2 RECOMMENDATION
Since this project capable of commercialized to the market then some
suggestions made for improvement of the market place, the improvements that
should be done is:
1) Using a better drive mechanism
Mechanism to pull the brake pedal needs to be more neat and safe. It should
be designed so that if anything goes wrong in the system, it will not have a
problem to be serviced or replaced.
2) Creating a special type of motor that is smaller and stronger
In further increase the current strength of the braking process, the type of
power window motor cannot provide a guaranteed strength. Therefore, a
special motor should be built to be the driving force for this system. The
construction should be small and strong to pull the brake pedal.
5.3 Rujukan
5.3.1 Rujukan Daripada Buku
Panduan Penulisan Laporan Projek Pelajar Semester Akhir, Politeknik
Sultan Mizan Zainal Abidin,2013.
5.3.2 Rujukan Daripada Internet
http://en.wikipedia.org/wiki/Torque.
http://en.wikipedia.org/wiki/Force