Introduction

Brake Failure indicator

Background:

Though the world is getting modernized, we have to face so many problems. One of such problems is accidents. One of the thing that everyone tried to avoid is while traveling is accidents, and sometimes it is inevitable. Now- a-days we can see accidents in every nook and corner of the world. It results in the death of thousands of lives. With the population ever climbing there are more vehicles than ever on road , which means there is a higher livelihood of the brakes giving out.

In foreign countries they take remedial measures for the prevention of accidents but our country like India takes less action against the prevention of accidents. One common cause for accidents is brake failure. Accidents may occur due to brake failure. In such a situation my project brake failure indicator plays an important role in controlling accidents.

Brake failure indicator circuit is a circuit that constantly monitors the condition of brake. The sensor which is attached to the circuit get the chance of a brake failure by monitoring the brake switch and reminds you of the condition of brake every time when the brake is applied.

Most vehicles retain some degree of control over the brakes even if the main system doesn’t work and most vehicles have two braking systems. One acting as back up system. Even though brake failure is relatively rare along with tire blowouts, brake failure is actually one of the top cause of accidents involving trucks and larger vehicles. The most common cause is that there is a leak in the brake line, master cylinders or wheel cylinders . All of these things can cause the brake failure. In order to solve this problem, I choose the ‘Brake failure indicator’ as my project.
Rationale:

There are many precautions that should be undertaken while using a vehicle. The brake failure indicator circuit is a combination of various products like LED, piezo buzzer, sensor etc and it is capable to avoid accidents . This is the major benefit of this project. Since it works automatically, it is very easy to use.

Even though the existing products are capable to indicate accidents , but it can only indicate brake failure or failure of electric circuit , when the brake is applied. But my product senses the chance of brake failure by monitoring the brake switch and reminds you of the condition of brake every time, when the brake is applied. Several specific issues can help contribute to brake failure. Some problems include hydraulic lines not being attached properly and overheating brakes, which can damage brake pads or rotors.

If you are traveling in a vehicle in the state of Connecticut and got in an accident contact a Connecticut vehicle accident lawyer to being prosecuting whoever was responsible . when the driver brakes they are actually pushing a plunger into the master cylinder, which in turn pushes brake fluid through tubes and hoses to brake all the moving units in the vehicle.

So many other devices are there to predict brake failure like united states patent 3711827 , united states patent 3914734 , etc . the united states patent 3711827 is a self test incorporated to determine if the warning light is operated properly. But my project can indicate brake failure and the function of the brake whenever the brake is applied and it is less expensive compared to other products.


Objectives:

The main objective of this project is to avoid accidents.
The specific objectives of this project were ,


 To save life.


 To avoid small number of accidents involving trains and boats caused by brake failure .


 To measure the change in hydrolytic pressure.


 To indicate the failure of brake switch .


 It can control all the moving units in the vehicle.


 It can measure fluid leakage.


 To connect the audio visual indicator with a sensor.


 To measure the fluid breaking pressure.


 To identify whether the brake is working or not.

Scope:

The brake failure indicator circuit is designed for avoiding accidents due to brake failure. If you can grasp the necessary force and the durability that brakes require to stop tones of moving metal , you can understand how brake malfunctions can occur. So many things can cause brake failure . There are something that we all take for granted , the brake on our vehicles. Though the brake failure indicator is applicable it has so many limitations.

• The circuit will work only in vehicles with negative grounding.


• The brake switch is fluid operated and doesn’t function if the fluid pressure drops to leakage.

• It is very unusual for a vehicle to suffer total failure of the braking system.


Though it has so many limitations , this equipment is very effective to detect brake failure and it will find great scope in future.


Product Description

Brake failure indicator is a device used to avoid accidents and it gives an early indication of brake failure . Of all the system that make up a vehicle , the brake system might just be important. If a force is exerted on the piston putting pressure on the fluid confined in the left hand container , the fluid is forced out through the narrow tube at the bottom and into the right hand container , exerting a force on the second piston , forcing it to move upward. The circuit can be assembled on any general purpose PCB or perforated board. The audio visual indicator is silver in colour. It is connected on the right side of stearing. One LED is red in colour and the other LED is green in colour. It is rectangular in shape .The main constituent parts of an indicator are:

• Pressure sensor.

• LED

• Diode

• Resistor

• Capacitor

• Buzzer

1. Pressure sensor

A pressure sensor measures the pressure , typically of gases and liquids. Pressure is an expression of force required to stop a fluid from expanding and is usually. In brake failure indicator system , the pressure sensor is used to detect the severe pressure drop in the brake pedal . The pressure sensor is rectangular in shape. The use of pressure sensor is used to detect the fluid leakage with the help of pressure change.

2. LED

A light emitting diode is a semiconductor diode that emits light when the electric current is applied in the forward direction of the device, as in the simple LED circuit. The effect is a form of electroluminescence where incoherent and narrow spectrum light is emitted from p-n junction. LED’s are widely used as indicator lights on electronic devices and increasingly in higher power applications such as flashlights and area light . the colour of emitted light depends on the composition and condition of semiconductor material used and infrared , visible or ultraviolet .In brake failure indicator , the LED is used for 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 the brake fails, the red LED glows and the buzzer stops beeping.


3. Diode

A diode is a device that permits current flow predominantly in only one direction. Most semiconductor diodes are made from germanium or silicon. A diode has two leads , an anode and a cathode . The cathode is often marked by a band at one end is the lead by which conventional current leaves the diode when forward biased . There are several types of diode , each with features that suits a particular job. In brake failure indicator , the inverting input is connected to the brake switch through diode and resistor . It receives a higher voltage when the brake is applied.


4. Resistor

A resistor is a component that offers electrical resistance to the current flow in an electrical circuit . It is this property that is used to limit the current to a specific value in a circuit .The resistors are of different types. Some common types are carbon composition resistors , carbon film resistors , metal film resistor , metal oxides resistors and wire- wound resistors . The inverting is connected to the brake switch through a resistor . In the brake failure indicator seven resistors are used for the complete functioning of the device.

5. Capacitor

A Capacitor is a circuit that can store energy in the form of electric charge . simple capacitors consists of two plates made of metal and are separated by a non-conducting material or dielectric . When the voltage is applied to the plates of a capacitor , one plate becomes positive charged and other negative . Increasingly the area of the plates , decreasing their separation , or by changing the dielectric can increase the capacity of the device for storing electric charge . To a certain extent , capacitors are like very leaky rechargeable batteries . In the brake failure indicator the capacitor is used for providing ripple free regulated supply to the inverting input of IC . Actually seven capacitors are used for this circuit.

6. Buzzer

A buzzer or beeper is a signaling device usually electronic . These devices are used in automobiles , household appliances such as microwave oven . It consists of a number of switches or sensors connected to a control unit that determines if and which button pushed or a present time has lapsed , sounds a warning in the form of a intermittent buzzing or beeping sound . Buzzer or beeper are output transducers converting electrical energy into sound.

hey contain an internal oscillator to produce the sound which is set at about 400 Hz for buzzers and about 3KHz for beepers. In brake failure indicator, when the brake is applied the green LED blinks and the buzzer beeps for one second and if the brake fails, the buzzer stops beeping. Thus the buzzer function as an indicator of brake failure.


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 piezobuzzer beeps for around one second if the brake system is intact. If brake fails the red LED glows and the buzzer stops beeping.

The circuit will work only in vehicles with negative grounding. It also gives an indication of brake switch failure.

In hydraulic brake systems of vehicles, a brake switch is mounted on the brake cylinder to operate the rear brake lamps. The brake switch is fluid operated and doesn’t function if the fluid pressure due to leakage. The fluid leakage cannot be detected easily unless there is a severe pressure drop in the brake pedal. This circuit senser the chance of brake failure by monitoring the brake switch and reminds you of condition of brake every time the brake is applied.

The circuit comprises of IC’s, seven resistors, seven capacitors, two LED, Two diodes and a buzzer. The circuit uses an op-amp (IC 2) as voltage comparator and timer in nonostable configuration for alarm. IC 2 senses the voltage level across, the brake switch.

Its non – inverting input gets half the supply voltage through potential divider resistors R3 and R4 of 10 Kilo – ohms each. The inverting input of IC2 is connected to brake switch through diode DI, ICI and resistor R2. It receives a high voltage when the brake is applied.

Normally, when the brake is not applied, the output of IC2 remains high and the red LED glows. Resistor R1 is used for the input stability of IC2. ICI and CI provide a ripple-free regulated supply to the inverting input of IC2.

IC3 is wired as a monostable to give pulse output of one second. Timing elements RT and C4 make the output high for one second to activate the buzzer and LED2. Usually the trigger pin of IC3 is high due to R6 and the buzzer and LED2 remains off.

When 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 red LED. When there is a pressure drop in the brake system due to leakage, the pressure sensor works LED1 remains ‘on’ and the buzzer does not sound when the brake is applied.

The circuit can be assembled on any general purpose PCB or perforated board. The circuit can be powered form the vehicle’s battery.

The circuit requires well-regulated power supply to avoid unwated triggering while the battery is charging from the dynamo. IC4 , C6 and C7 provide regulated 12V to the circuit.

The power supply should be taken from the ignition switch and the circuit ground be clamped to the vehicles body. A bicolour LED can be used in place of LED1 and LED2 if desired.

Instructions to use:-

• Always use to the vehicles with negative grounding.

• Keep the sensor attached to the brake switch.

• Always keep the buzzer tone high

• Check the level of fluid leakage regularly.


Product Testing

In order to detect the efficiency and its working of Brake failure indicator, several tests were conducted. Before releasing it as a new product into the market, every product undergo testing. So product testing is essential to verify the working of the product. The test should be decided inorder to verify whether the product satisfied all the objectives. With the help of speed test, we can verify the different levels of speed.

In order to detect the effect of petrol level on this device, the petrol level testing is also conducted. The condition of brake is also detected with the help of another methods. Therefore, with the help of this tests, we find out whether the “Brake Failure Indicator’ is working properly or NOT.

Speed Testing


With the help of this test, we can conform that the bake failure indicator is working in all the above conditions. This test was under taken to check the working of brake switch as well as brake failure indicator. From this testing, we find out that whether the speed is high or low, the brake failure indicator is working in all condition. It is working at even low speed also. So from speed test we can conform that it is working properly.

Petrol level Testing

From the above test, we can conform that the level of petrol does not cause any problem to the condition of brake. Thus the brake failure indicator worked properly at all conditions

CONCLUSION

The main aim of my project was to develop a Brake failure indicator (BFI), which is used to avoid accidents due to brake failure.

The other objectives of the project were:-

• To identify the failure of brake switch.

• To indicate the pressure drop.

• To measure the change in hydrolytic pressure

• To sense the fluid leakage.

• To connect the audio visual indicator with a sensor

• To measure the fluid breaking pressure

• To avoid small number of accidents involving trains and boats caused by brake failure.

Most of the project objectives were successfully met. The Brake failure indicator is able to use for avoiding accidents. The brake failure indicator is more powerful when compared with the existing ones. Its efficiency is test at various conditions. The test ensures that the Brake failure indicator is working properly.


Reference

• www.Electronics for you .com
• Brake failure indicator system
• Fundamentals of physics by Prof. R Pillai
• Vas publications
• Fundamentals of electronics by Mehta
• Brake failure indicator@yahoo.com
• Circuit labs, www.google.com
• en.wikipedia.org
• www.bmwmoa.org
• www.volvofocums.com