Improved Braking System of a Motor Assisted Pedal

Rickshaw

Meghdeepa Choudhury 11.02.08.010

Anindya Roy 11.02.08.021

Md. Tajul Islam 11.02.08.054

Mechanical Engineering Program

Department of Mechanical and Production Engineering

Ahsanullah University of Science and Technology

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 CONTENT
Chapters: Page no.:

1. Introduction.5-13
1.1. Braking principle....5-7
1.2. Classification of brakes..8-11
1.3. Braking system of motor assisted pedal rickshaw.................................................12-13
2. Design..14-16
2.1. Computer Aided Design14
2.1. Parts design14-15
2.2. Assembly16
3. Manufacturing.17-23
3.1. Disc brake...17-18
3.2. Properties of friction materials...18
3.3. Material selection...19
3.4. Mechanical components.19-21
3.5. Structural construction........21-23
4. Working methodology and Applications...24-29
4.1. Working methodology....24
4.2. Required data......25
4.3. Experimental phenomenon..26-28
4.4. Experimental data.. .28-29
4.5. Limitations ..29
4.6. Applications 29
5. Conclusion and Future recommendation....30

Appendices....31

Bibliography..32

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 Approved by:

Dr. Md. Shahnewaz Bhuiyan

Assistant professor

Mechanical and Production Engineering Department, AUST

Abhishek Kumar Ghosh

Lecturer

Mechanical and Production Engineering Department, AUST

Md. Jubayer Hossain

Lecturer

Mechanical and Production Engineering Department, AUST

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 Acknowledgement

This research project would not have been possible without the support of many people. We wish
to express our gratitude to our respected teachers Dr. Md. Shahnewaz Bhuiyan, Abhishek Kumar
Ghosh, Md. Jubayer Hossain who were abundantly helpful and offered invaluable assistance,
support and guidance. We do also express our indebtedness to Dr. Dewan Hasan Ahmed for
encouraging our project with his mesmerizing ideas. We are highly grateful to our institution and
authority for granting us this project and thus allowing us explore our eligibility.

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Chapter-1
Introduction
Most cities in Bangladesh have very high air and noise pollution caused by transport vehicles
especially petrol/diesel-powered three-wheelers. An improved and electric cycle rickshaw can
provide a non-polluting and very silent transport system for urban and rural areas of the country.
However, the existing breaking systems are obsolete, there are only front breaks & while going
down the hill at high speed breaking produces a catapult effect. This project explores some
possible options for a better braking system of electric cycle rickshaw and the documents the
design and fabrication of a back wheel braking system from a test setup analysis.

1.1. Braking principle

The brake system converts the kinetic energy of the moving vehicle into heat. The brake
engineer has two challenges:

Create enough deceleration to stop the car as quickly as the driver wishes, without
exceeding the drivers comfort level with regard to pedal effort or hand lever.

Manage the resulting heat energy so as not to damage the brake system or the rest of the
vehicle.

The total braking force required can simply be calculated using Newtons Second Law:

F = Mag ; Where,

F = Total braking force (N)

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M = Total vehicle mass (kg)

a = Deceleration (g units)

g = Acceleration due to gravity (N/m2)

Braking limits:

o Force:

Force limit means the driver pushes as hard as possible with his foot and the vehicle cant stop
any quicker

o Deflection:
Deflection limit is reached as the brake pedal stops at the floor or stop. This means the pedal is
moving too far to get maximum efficiency from the brakes. A deflection limit can be
eliminated by design changes such as stiffening the pedal-support structure, increasing master-
cylinder size, installing stiffer brake hoses, changing to stiffer calipers, or other modifications.
Maintenance can eliminate a deflection limit if air is trapped in the brake lines.

o Wear:
Wear limit won't happen when brakes are new. However, if friction material is worn excessively,
it may be worn out just when one needs the brakes most such as the end of a long race. Wear
limits can be eliminated or reduced by changing linings, using larger brakes or by dissipating
heat.

o Temperature:
Brakes cannot absorb the full power of an engine continuously without some time to cool. When
the temperature limit is reached, one can reach a force limit, deflection limit, or greatly increase
the wear at the same time. Other things can happen, too, such as complete destruction of the

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brakes or total collapse of a structural part. Excessive temperature is a common cause of brake
problems.

o Tire traction:

If brakes are properly designed and maintained, and don't get too hot, the only stopping limit is
tire traction. If one tries to stop quicker than the traction limit allows, the wheels lock up and the
tires skid. The traction limit is always the limit with good brakes, but it can be increased through
correct adjustment of brake balance.

Brake linings:

The output of any brake is directly related to the coefficient of friction () between the
lining and the disc or drum.
The challenge is knowing what the instantaneous value of is during any given stop.

Stopping distance:

Does not Depend on: Does Depend on:

Type of brakes Tire to road friction

Size of brakes Vehicle balance

Skill of driver

System Reaction
Time

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1.2. Classification of brakes:

On the basis of the type of mechanical brake:

Band brakes, the simplest brake configuration, have a metal band lined with heat and wear
resistant friction material.
Drum brakes, which are commonly used on automobile rear wheels, work when shoes
press against a spinning surface called a drum.
Disc brakes are constructed of brake pads, a caliper, and a rotor. During operation, the
brake pads are squeezed against the rotor.
Cone brakes are made with a cup and a cone, which is lined with heat and wear resistant
material. During actuation, the cone is pressed against the mating cup surface.

Fig. 1.2 (a)

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 Fig. 1.2 (b)

On the Basis of Method of Actuation:

Foot brake (also called service brake) operated by foot pedal.

Hand brake it is also called parking brake operated by hand

On the Basis of Mode of Operation:

Mechanical brakes: The brake pedal operates cables or rods that apply the brakes when the
pedal is pushed.

Hydraulic brakes: In a hydraulically actuated system, the cables or rods of the mechanical
system are replaced by fluid-filled lines and hoses. The brake pedal linkage operates a piston
in a master cylinder to pressurize the fluid inside the lines and hoses. Fluid pressure in each
fluid cylinder forces the friction material against the drum or rotor.

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 Fig: 1.2 Hydraulic braking system

Air brakes: Air brakes are applied by the pressure of compressed air. Air pressure applies
force on brakes shoes through suitable linkages to operate brakes. An air compressor is used
to compress air. This compressor is run by engine power.

Fig: 1.2 (d) Air brake

Vacuum brakes: Vacuum brakes are a piston or a diaphragm operating in a cylinder. For
application of brakes one side of piston is subjected to atmospheric pressure while the other
is applied vacuum by exhausting air from this side. A force acts on the piston due to
difference of pressure. This force is used to operate brake through suitable linkages.

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 Electric brakes: In electrical brakes an electromagnet is used to actuate a cam to expand the
brake shoes. The electromagnet is energized by the current flowing from the battery. When
flow of current is stopped the cam and brake shoes return to their original position and brakes
are disengaged. Electric brakes are not used in automobiles as service brakes.

On the Basis of Action on Front or Rear Wheels:

Front-wheel brakes
Rear-wheel brakes.

On the Basis of Method of Application of Braking Contact:

Internally expanding brakes

Externally contracting brakes.

Fig: 1.2(e)

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1.3. Braking system of motor assisted pedal rickshaw:

Either of mechanical or hydraulic brakes can be used in such rickshaw. In a hydraulic braking
system, the leading advantages are: equal braking action on all wheels, increased braking force,
low wear rate of brake linings, flexibility of brake linings and increased mechanical advantage.
On the other hand, the whole braking system fails due to leakage of fluid from brake linings and
presence of air inside the tubings ruins the whole system. So as to facilitate the lessening of
manufacturing cost and easy maintenance, mechanical braking system is found more convenient
than hydraulic braking for a rickshaw.

In this project, disc-brake or drum -brake at the back is adapted skillfully for a cycle rickshaw.
Normal rickshaws have their brakes fitted on the front wheel; but this has some disadvantages as
the rickshaw has a tendency to upturn if brakes are applied suddenly, especially when travelling
fast as the puller might lose control of the vehicle.

Fig. 1.3(a)

In a normal rickshaw simple metal-flats are used to absorb the bumps. We added a spring along
with a metal flat in a slightly different manner and this has improved shock qualities.
Disc brakes are generally considered superior to drum brakes for several reasons. First, they
dissipate heat better (brakes work by converting motion energy to heat energy). Under severe

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usage, such as repeated hard stops or riding the brakes down a long incline, disc brakes take
longer to lose effectiveness (a condition known as brake fade). Disc brakes also perform better in
wet weather, because centrifugal force tends to fling water off the brake disc and keep it dry,
whereas drum brakes will collect some water on the inside surface where the brake shoes contact
the drums. Hence, a disc brake is fitted at the rear wheels shaft of the vehicle.

Fig: 1.3(b)

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Chapter 2:

Design

2.1 Computer Aided Design: Computer-aided design (CAD) is the use of computer
systems to assist in the creation, modification, analysis, or optimization of a design. CAD
software is used to increase productivity of the designer, improve the quality of design, improve
communications through documentation, and to create a database for manufacturing. There are
many types of software which are used in engineering field. We use Solid Works version 2011 to
design our project.

2.2. Parts Design:

Fig: 2.2(a) V-rod Fig: 2.2(b) Chassis

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Fig: 2.2Disc

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2.3 Assembly

Fig: 2.3(a) assembly

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Chapter-3

Manufacturing

3.1. Disc brake:

A flat metal disc is the rotor with a rubbing material on each side
Friction materials are inside the caliper which surround the rotor
Disc brake friction material one on each side of the rotor is called a brake pad, puck
or lining

Characteristics of disk brakes include the following

Main advantage of disc brakes is their resistance to wear as the discs remain cool even after
repeated brake applications.

Brake pads are easily replaceable.

The condition of brake pads can be checked without much dismantling of brake system.
More force is needed be applied as the brakes are not self emerging.

Pad wear is more.

Hand brakes are not effective if disc brakes are used in rear wheels. (Hand brakes are better with
mechanical brakes).

3.2. Properties of friction material:

It should have high coefficient of friction with minimum fading. In other words, the
coefficient of friction should remain constant with change in temperature.
It should have low wear rate.
It should have high heat resistance.

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 It should have high heat dissipation capacity.
It should have adequate mechanical strength.
It should not be affected by moisture and oil.

Fig: 3.2

3.3. Material selection:

Gray Cast Iron:
wear resistant,
hard,
good heat absorption and
good heat dissipation.

3.4. Mechanical components

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The mechanical components used for the construction of the machine part are:

Rear wheel shaft

Hand lever
Free wheels

Fig: 3.4(a)

Disc

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 Fig: 3.4(b) Reference disc of disc brake

Spring

Fig: 3.4 Spring

Bush

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 Fig: 3.4(d) Bush

Fig: 3.4(e) Bearing

Bearing
Caliper
Brake shoe
Hand lever

3.5. Structure construction

o The normal rear axle used in existing motor rickshaw is collected.
o The disc of required size is made by turning method using lathe machine.
o By the method of drilling- holes are made in the disc which are useful for heat rejection
due to heat formation while braking.
o The brake shoes used in present cars is cut to give the desired shape and size .
o The brake caliper with spring is made using lathe machine.
o The brake shoe is pasted with brake caliper.
o As the brake shoe material, asbestos is selected and used.

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Fig:3.5(a)

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Fig: 3.5(b)

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Chapter-4

Working methodology and Applications

4.1. Working methodology

A disc brake slows rotation of the wheel by the friction caused by pushing brake pads against a
brake disc with a set of calipers. The brake disc is connected to the axle. To stop the wheel,
friction material in the form of brake pads, mounted on a device called a brake caliper, is forced
mechanically. Friction causes the disc and attached wheel to slow or stop. Brakes convert motion
to heat, and if the brakes get too hot, they become less effective, a phenomenon known as brake
fade.

Disc brake has no self-servo effect and its braking force is always proportional to the pressure
placed on the brake pad by the braking system via any brake servo, braking pedal or lever. This
tends to give the driver better feel to avoid impending lockup.

Following sequences of operations activates the brake:

Applied force on the brake lever or pedal force force transmitted through mechanical linkages

Brake calipers gripped

Stopping disc rotation through frictional force

Stopping shaft rotation

Rear wheel rotation stops

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4.2. Required data:
Clamping Force (Fn) is the force pressing each brake pad against the disc.

Braking Force (Fb) is the tangential friction force acting between the brake pads and disc.
Fb= 2 . . Fn
Where: is the coefficient of friction between the pad and the disc (a nominal value of 0.4 is
assumed for fully conditioned pads of standard material).

Braking Torque (Tb) is the moment of braking force about the center of rotation.
Tb = Fb . re
Where re is the effective disc radius.

In order to provide a consistent controlled performance of a brake it is also important to check

the power dissipated during a stop. This affects the condition of the brake pads. To calculate the
power dissipation it is necessary to calculate the total energy absorbed during the stop, estimated
as follows:

Kinetic energy (KE) = J . m2/ 2 (Joules)

Where, m = Maximum disc speed [rad/sec]
In the case of external loads further allowance should also be made for the change in potential
energy of the system. For example in the case of a hoist this is determined by how far the load
drops during the braking cycle. The mean power dissipated is therefore given by:

Mean power dissipation = KE / tb (Watts)

This is usually converted to what is termed the Mean Specific Power Dissipation (kW/cm2) for
evaluation of performance, i.e. the mean power dissipation is divided by the pad area.

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4.3. Experimental phenomenon:
A calculation has been made to check the braking power or efficiency of the disc brake
constructed. An experiment has been made to detect the time required to stop the vehicle
after application of the brake, which is the main matter of concern to a brake engineer.
Following procedures have been followed during the experiment.

A battery rickshaw is hired for the test analysis.

The rear wheels of the rickshaw are taken off from the axle.
The prevailing axle in replaced by the constructed axle with brake of our
experiment.
A connection is made between the axles free wheel and the motors free wheel by
using a chain.
Motors power is switched on.
By flexible adjustment, the disc is placed and fitted in required position.
Brake is pressed by hand lever.
The time required to pause the motion was noted down via a stop watch
Gradual successive readings were taken for both high and low speeds of the motor
The readings were noted down.

Fig: 4.3(a)

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 Fig: 4.3(b)

Fig: 4.3

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 Fig: 4.3(d)

4.4. Experimental data:

Braking time for high speed of motor:

48
50
52
50
51

All measurements are in milli second.

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 Braking time for low speed of motor:
28
30
29
31
30

All units are in milli second.

4.5. Limitations:
In this experiment, we were unable to perform road test and failed to achieve the
deceleration value of the vehicle
We were not able to use fresh mechanical components for the construction of the
machine part.
Due to unavailability of time and resource, it was not possible to measure the braking
torque using a dynamometer

4.6. Applications

This project can be applied as follows.

This study has resulted in the design and development of a pedal assisted front wheel
braking mechanism along with back wheel braking while motor in use.
It will help reduce accidents due to upturn
It can be actuated both by hand brake or pedal brake.
Present estimates are that such modification will add Tk. 6000/- to the previous sum
of 50,000/-
Such a rickshaw can serve as a safer mean of transportation for urban and rural
middle class and hence can fill an important niche in this segment of the market.

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Chapter-5

Conclusion and Future recommendation

Conclusion

A disc brake of thickness 0.9 cm and diameter 15.24 cm has been fitted to the rear wheel shaft at
a flexible distance. As per experimental results, the time required to brake was found to be 50 ms
for high speed of motor and 30 ms for low speed of motor.

Future recommendation

This project can be preceded further with the following objectives-

Creating better options to resist accidents due to Gyro Torque.

Using electrical means of braking instead of hand lever or pedal
Road test
Trial and error
Perfection

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 Appendices

Weight of rickshaw without battery = 100 kg

No. of batteries =8

Weight of each battery = 7 kg

Estimated weight of rickshaw including 2

passengers and the driver = 150 kg

Time of brake for high speed of motor Time of brake for low speed of motor

48ms 28ms
50ms 30ms
52ms 29ms
50ms 31ms
51ms 30ms

Cost estimation
Construction 2200/-
without disc and
calllipers
Disc brake with 2500/-
caliper
Road test 400/-

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 Bibliography

1. Theory of machines- R.S. Khurmi

2. Brake handbook
3. An Introduction to braking systems- DaimlerChrysler
4. Engineering Inspirations- Peters blog
5. http://cars.about.com/od/thingsyouneedtoknow/a/discvsdrum.htm
6. http://www.globalspec.com/learnmore/motion_controls/clutches_brakes/mechanic
al_brakes
7. Module-design of books-Kharagpur
8. ICME11-RT-032 pdf
9. http://nariphaltan.org/research/renewable-energy/mobility/
10. http://www.nariphaltan.org/att42.htm

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