Ignition Switch operated hand brake

1. A Project Stage-I Report on
IGNITION SWITCH OPERATED
HAND BRAKE
By
Mr. Nehe Onkar Mr. More Kailas
Mr. Ahire Dipak Mr. Mahajan Pritam
Prof. N. B. Ahire
Bhujbal Knowledge City
MET’s Institute of Engineering
Department of Mechanical Engineering
[2020-21]

2. Bhujbal Knowledge City
MET’s Institute of Engineering
Department of Mechanical Engineering
C E R T I F I C A T E
This is to certify that Mr. (Nehe onkar dinkar), has successfully
completed the Project Stage – I entitled “(Ignition switch operated
hand brake )” under my supervision, in the partial fulfilment of
Bachelor of Engineering - Mechanical Engineering of University of
Pune.
Date: 23/04/2021
Place: Nashik
Guide’s Name Examiner
Prof. N. B. Ahire
Dr. M. P. Ray Dr. V. P. Wani
Head of the Department Principal

3. CHAPTER 1
INTRODUCTION
The Automatic Parking System is one of the most efficient
hand braking system over the conventional systemWhen parking
is on ground level many people only select a gear (i.e. handbrake
release).If parking on hilly or street slope with only gear results
in car.rolling and damaging car or other property. insurance
company.in some country for ex. In Germany are not required to
pay for damages. Nearly 400 die a day in road mishaps during
this year stated by report Ministry of Road Transport and
Highway. Last year also witnessed the highest number of
accidents on the roads, at 5,01,423 or 1,374 a day, according to
the data compiled and released by the Ministry of Road
Transportand Highways The ministry’s report blamed
irresponsible driving for most (77 per cent) accidents. With
69,059 accidents, Tamil Nadu witnessed the largest number of
road accidents in 2015 and including it, 12 states reported 86.7
per cent of the accidents in the year.Maharashtra witnessed the
second highest accidents at 63,805. From above figures we can
say that the main problem faced by society is casuality in road
accidents

4. 1.1 Problem Statement
Automobile are the major part of human life for transportation.
As the transportation comes the safety to passenger comes. The
braking is one of the most important thing while driving. Due to
the improper timing of braking and the man made mistake while
braking the number of accident causes. To reduce these accident
this project deals with the automation in braking system.
1.2 Objectives
Objective of project is enhance the performance of handbrake
system to reduce human efforts and to avoid accidental condition.
1.3 Scope
As the automobile is one of the most rising sector this project
can have very good advantages over the accidental safety. Also
there will be no much compromise with toomuch money and the
money we invest in system will give the very beneficial output
for safety of passenger.
1.4 Methodology
A worm is a toothed gear that can be thought of as a sector
gear with an infinitely large radius of curvature. Torque can be
converted to linear force by
meshing a worm with a worm gear; the worm wheel turns; the
worm moves in a straight line. Such a mechanism is used in
automobiles to convert the rotation of the steering wheel into the

5. left-to-right motion of the tie rod(s).Linear actuation is used to
engage the hand brake lever and disengagement is done by spring
tension
1.5 Organization of Project
The report is organized as per the sequence of work done.
Chapter 1 : Describes the Introduction, Problem statement,
Objective, Scope, Methodology.
Chapter 2 : Describes the brief literature review on the
work done by different researchers
Chapter 3 : Describes the Design analysis and Concept.
Chapter 4 : Describes the Working of components.
Chapter 5 : Braking Condition, component of specification ,
sequence of operation
Chapter 6 : Observation , Practical Calculation, System weight.

6. CHAPTER 2
LITERATURE REVIEV
Mohd RazmiIshak ,etal(24 August 2016). This paper
attempts to establish validated parking brake model in order to
predict its torque performance with the aim to avoid vehicle roll
away phenomena from the parked condition.
S.Thivagar, et al(January-February, 2016). In our project,
hand brake is actuated with the help of rack and pinion and
proximity sensor based on some conditions. Sensors sense and
provides signal to the circuit board which directly drives the
motor. The rack and pinion gets activated and lifts the hand and
disengages with the help of push lock and spring tension. In
future, this could be developing by adding some of the additional
features and also automatic hand brake will be used in all types
of automobiles at low cost.
Prof: Wakchaur P.B ,Prof: Borkar B.R(April 2013). The
most common use for a parking brake is to keep the vehicle
motionless when it is parked. Parking brakes have a ratchet
locking mechanism that will keep them engaged until a release
button is pressed
Sachin S. Dharia, et al (may 2016). Automatic hand brake
release mechanism is beneficial for operator‟s safety by reducing
accident chances as well as disengaging chances of braking. This
system can also be used in commercial cars for ease of operating

7. as well for reducing cost purpose. The working is quite simple
and doesn‟t require any extra effort to operator or driver.
Steven Becker,Robson Forensic Inc.(April 08, 2013). While the
purpose of this study could not address state driver's manuals and
vehicle operator manuals being right or wrong in requiring that
vehicles with automation.

8. CHAPTER 3
3.1 DESIGN ANALYSIS
Brakes are one of the most important safety systems in a
motor vehicle. The main functions of brakes system are
todecelerate the vehicle, to maintain the vehicle’s speed during
downhill operation and finally to park the vehiclestationary either
on a flat or slope road condition. The first two functions are
related to the service brakes, while the lastfunction is referred to
the secondary or parking brakes. Conventional parking brake
actuation involves the humaninterference. Without pulling or
pushing the lever, the parking brake will not work. Also,
sometimes due to negligenceor in emergency conditions, we
humans often forget to apply parking brakes. This may lead to
rolling of vehicle in caseof slopes and collision with other
vehicles in parking area. Constant enhancements in active safety
and improvementswith respect to the reliability and comfort of
operation mean that mechanical handbrakes are increasingly
beinged replaced by new other systems and this giving birth to
new ideas of parking brake techniques.

9. Fig.3.1 Conventional Parking Brake System
A traditional handbrake is very simple by pulling the lever up;
you are pulling two cables which run to each of the rear brakes.
By adding tension to these cables, this in turn causes the pads (or
‘shoes’ for cars with drum brakes) to squeeze against the discs (or
drums) to hold the rear wheels firmly in place.
Some cars with disc brakes have separate handbrake drum-brake
shoes or even a separate disc-brake caliper for the handbrake.Later
electronic parking brake replaces this mechanical system with an
electrical one. By pressing the switch, motors on each brake caliper
squeeze the pads into the disc. We are trying to make hand brake
mechanism even simpler using worm and worm wheel.
3.2 Design Concept
The analysis of traditional system is done then by studying
its drawback the new modified automatic parking brake system is
designed. A new parking brake system involves a 12 v dc motor,
spur gear and worm gear. A power and torque from the motor is

10. transmitted to spur gear and worm gear an worm gear works as a
anti lock mechanism and at output shaft of worm gear cable wire
is attached and at that cable wounds two times to the out shaft and
thus cable wire is get locked and thus the parking brake is applied.
As a result the mechanical hand brake is eliminated and we get
more space at the front side of the drivers cabin and thus the
problem of required force of pushing and pulling hand brake is
totally eliminated by this new parking brake system.
Fig. 3.2. Design of Modified Hand Brake
A worm is a toothed gear that can be thought of as a sector gear with an
infinitely large radius of curvature. Torque can be converted to linear
force by meshing a worm with a worm wheel. Such a mechanism is used
in automobiles to convert the rotation of the steering wheel into the left-
to-right motion of the tie rod(s).Linear actuation is used to engage the
hand brake lever and disengagement is done by spring tension

11. Analytical Method
In Analytical method design of various components and their related
calculations required are calculated and carried out as follows. Design
of various components or parts of new designed parking brake system,
which includes. Design of spur gear, Design of worm gear and selection
of proper dc motor, Design of output shaft. As per from the industries
data required condition, The complete two stage or complete system
should be fitted in a one frame and it should compact & feasible in size,
The whole system should be fitted in compact box, which has size of
200×200×100 mm.
Hand Brake should be applied in 1 sec & in this cable wire travel
distance should not exceed 60 mm and load required to apply brakes is
222 N.
We know
F= T/D
Torque = Force × Distance
T = F × d ………………d = 2r
Here material used is steel case carburized
We have
Shear stress τ = 115 N/mm²
As taken F.O.S = 2
Shear stress allowance τ = 115/2 = 57.5 N/mm²

12. We have,
T =
π τ d3
16
F × D =
𝜋 𝜏 𝑑3
16
F × 2r =
π τ 2𝑟 ×2𝑟 ×2𝑟
16
…………………….d = 2r
r = 2.21716 mm
d = 2r = 2 × 2.21716
d = 4.43432 mm
We take diameter as 10mm for more safety purpose
➢ Considering output shaft diameter & Cable wire length = 60 mm
d =10mm and r = 5mm
• We have circumference of circle
= 2πr
= 2 x π x 5 = 31.4 ……………………………in 1 revolution
= 2 × 31.4 ………………………Because the cable wire wound around
the shaft 2 times
= 62.8 ………………………..in 1 sec
This satisfies the required condition of the company that cable wire
travel distance should not exceed 60 mm.

13. Total distance travel = 60 mm
For 2 revolution in sec,
2×60 = 120 R.P.M
Thus we get required speed at the output shaft 120 R.P.M
The Out shaft diameter of Motor is 10 mm.
Table.1 Input / Output values
Input
(12v motor)
Output
Motor Power = 0.35 kw Speed of out Shaft = 120
r.p.m
Speed of Motor = 7000
r.p.m
Therefore now we have Input speed & output speed
• Input speed = 7000 R.P.M
• Output speed = 120 R.P.M
∴ Speed Ratio = Input speed / Output speed
= 7000 / 120
= 58.33

14. 1:58….Gear Ratio for this speed reduction is required
Now the whole system is divided In two stage, If the speed reduction
not be reduced, Then going for three stage, Four stage if essential.
3.2 Proposed design system:
Fig.2 3d model of complete assembly of new parking
brake designed system
3.3 Design of Spur Gear
➢ 1st
Stage
Choosing spur gear,
Module m = 1mm
Numbers of teeth on pinion Tp =18mm
Pressure angle ∅ = 20º
By calculating we get required dimensions of spur gear as in the table
3.1

15. Table 2. Gear Terminology (Dimension)
Dg = 60 mm Dp = 20 mm
Tg = 54 Tp = 18
G.R = 3 m = 1 mm
The material selected for spur gear and properties is selected from
standard table
• Material for spur gear:- Structural steel
• Ultimate tensile strength (𝜎𝑢𝑡) = 460 N/mm² or MPa.
The allowable static stress() for steel gear is approximately one third
of ultimate tensile strength (𝜎𝑢𝑡) i.e.
𝜎0=
𝜎𝑢𝑡
3
=
460
3
= 153.33 N/mm² or MPa.
But in our case as both the pinion and gear is made up of same
material structural steel, The static allowable stress from the material
(𝜎𝑢𝑡),
We have,
𝜎0𝑝 = 153.33 N/mm² & = 153.33 N/mm²
∴ Now using the Lewis equation for the pinion, we get tangential
tooth load acting on the tooth (or beam strength of the tooth)
WTP = (σ0p× Cv) b ×π m × yp =
(153.33× 0.29040) 10.545 × π × 1×
0.1033
WTP= 152.280 N.
The tangential component ( WT) induces a bending stress which
tends to break the tooth. As the radial component (WR) induces a
compressive stress of relatively small magnitude, Therefore its effect
on the tooth may be neglected. Hence the bending stress is used as
the basis for design calculations.
• The bending stress on the pinion can be find out by following
formula

16. .
𝜎𝑏𝑝 =
𝑊𝑇
𝑏×𝑚×𝑗
=
152.380
10.545×1.11×0.34404
= 37.8389 N/mm²
(j) Geometry factor = 0.34404 is
taken from standard table
• Torque acting on the pinion
Tp =
𝑃 × 60
2 ×𝜋 ×𝑁𝑝
=
350 ×60
2 × 𝜋 ×7000
= 477.4648 N-mm
• Torque acting on the gear
Tg =
𝑃 ×60
2 × 𝜋 × 𝑁𝑔
=
350 ×60
2 × 𝜋 ×2333.33
= 1432.3969 N-mm
• Tangential load acting on the gear tooth ( 𝑊𝑇𝑔)
= (σ× Cv) b × m × Yg = (153.33× 0.29040) 10.545 × π × 1×
0.13711
= 202.2520 N
• The bending stress on the gear.
𝜎𝑏𝑔 =
𝑊𝑇
𝑏×𝑚×𝑗
=
202.25037
10.545×1.11×0.34404
= 50.2239 N/mm2
3.4 Design of worm gear
• 2nd
Stage
Now,
We have,
Input speed from the motor = 7000 r.p.m

17. Gear ratio of spur gear = 3
∴ Speed ratio =
𝐼𝑛𝑝𝑢𝑡 𝑆𝑝𝑒𝑒𝑑
𝑂𝑢𝑡𝑝𝑢𝑡 𝑆𝑝𝑒𝑒𝑑
3 =
7000
𝑂𝑢𝑡𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑
Output speed = 2333.33 r.p.m. i.e. the speed of gear (Ng).
This output speed from gear shaft is transmitted to worm as an input
speed. Therefore from input and output speed we get required gear
ratio for worm gear is 19.4
• 20° normal pressure angle worm gear is assumed for which the lead
angle should not exceed 25° (Table 5.6) and Z2 mimimum is 21
(Table 5.7).
• Allowing 6° lead per thread of the worm, the worm could have 4
or less teeth. Z1 = 4 or quadruple threaded worm is assumed
• Assuming module m is 2 mm.
• Necessary data is taken from the standard table.
➢ Choosing phosphor bronze for the worm gear and heat
treated C45 steel for the worm,
The phosphor bronze is widely used for worm gears in order to
reduce wear of the worms which will be excessive with cast iron or
steel.
The allowable static stress (𝜎0) = 84 MPa is taken from standard table.

18. By calculating we get required dimensions of worm gear as in the
table 3
Table 3. Worm Gear Terminology (Dimension)
Diameter of worm (Dw) =
16.0712 mm
Diameter of worm gear (Dg ) =
154.95 mm
Numbers of teeth on worm
(Z1)= 4
Numbers of teeth on worm gear
(Z2)= 78
G.R = 19.44 m = 2 mm
• Torque acting on the worm
TW =
𝑃×60
2×𝜋×𝑁𝑤
=
350×60
2×𝜋×2333.33
= 1432.3965 N-mm
• Tangential force acting on the worm
WTW =
𝑇𝑊
𝐷𝑊
2
⁄
=
1432.396
16.0712
2
⁄
= 178.256 N
• Torque acting on worm gear
Tg =
𝑃×60
2×𝜋×𝑁𝑔
=
350×60
2×𝜋×120
= 27852.110 N-mm
• Tangential force acting on the worm gear
WTg =
𝑇𝑔
𝐷𝑔
2
⁄
=
27852.1150
154.95
2
⁄
= 358.0538

19. FEA OF DIFFERENT PARTS OF NEW DESIGNED SYSTEM
After doing all mathematical analytical calculations, designing
and checking for safe design, In Simulation method 3d modeling
(CATIA V5) and Analysis (ANSYS workbench) of following
components is done based on which experimental method is carried
out.
➢ Geometry:- Gear Mesh
The geometry spur gear (bigger gear) is modeled in CATIA V5 as
per the dimensions calculated and designed safely in analytical
method and imported 3d model of gear from CATIA V5 in ANSYS
workbench for analysis purpose, The meshing properties of gear &
its nodes and elements is shown below

20. Fix support Load
The fix support is applied at the shaft hole of the gear along whole
periphery at the inner side of the gear & the load is applied on the
tooth of the gear
Results: Gear by applying load Equivalent stress
Total deformation
The results getting from ANSYS by applying force of 202.25 N on
the tooth, we get results of equivalent stress and total deformation
and answer are validated with Allowable static stress (σ0) is taken out
from standard properties of material selected Structural steel

21. Equivalent stress = 86.21 N/mm²
From ANSYS
Allowable static stress σ0=153.33
N/mm²
From Standard table of properties
of material
From above results we get total deformation of the tooth to the next
tooth of the worm gear and also gives equivalent stress of maximum
stress and minimum stress as shown in the images above, And by
validating with the material allowable static stress we can say the
design is safe and now we can go for manufacturing purposes.
➢ Geometry:- worm worm gear
The 3d model of worm n worm gear is created in CATIA V5 and
imported in ANSYS workbench for Analysis purpose.

22. Fix support load
The fix support is applied at one end of the worm shaft of the along
whole periphery at the outer side of the worm shaft & the load is
applied on the tooth of the worm as shown.
Results: worm by applying load Equivalent stress
Total deformation
The results getting from ANSYS by applying force of 178.26 N on
the tooth, we get results of equivalent stress and total deformation
and answer are validated with Allowable static stress (σ0) is taken out
from standard properties of material selected.

23. Equivalent stress = 17.924
N/mm²
From ANSYS
Allowable static stress σ0=
153.33 N/mm²
From Standard table of properties
of material
Fix support worm gear
gear tooth load on worm
The fix support is applied at the shaft hole of the worm gear along
whole periphery at the inner side of the gear & the load is applied on
the tooth of the worm gear

24. Results: worm gear by applying load Equivalent stress
Total deformation
The results getting from ANSYS by applying force of 358.18 N on the
tooth, we get results of equivalent stress and total deformation and
answer are validated with Allowable static stress (σ0) is taken out from
standard properties of material selected phosphor bronze. The results
are obtained are mentioned in the below table.
Equivalent stress = 50.423
N/mm²
From ANSYS
Allowable static stress σ0 = 84
N/mm²
From Standard table of properties
of material

25. CHAPTER 4
SYSTEM COMPONENTS
4.1 Electric Circuit Design:
For the Automatic Parking Brake system electrical signal
switching is very important. The signal which are taken for the
operation of system are alternator signal for inactuate the
handbrake and signal of battery check lamp.
Fig. 4.1 Electrical Circuit for Automatic Parking system
As per the signal condition relay unit swaps the current to
pinion motor and the operation of handbrake performs. The
manual switch can perform operation at any condition for
emergency as circuit has tendency to avoid signal from alternator.

26. 4.2 Relays:
Fig. 4.2 Electrical Relay
Relays are the electrically operated switch. Many relays use an
electromagnet to mechanically operate a switch, but other
operating principals are also used such as solid state relays.
Relays are used where it is necessary to control a circuit by low
power signal (with complete electrical isolation between control
unit and controlled circuits).We are using the rcelays for
switching the motor ON or OFF. For making automatic hand
brake system more efficient, these relays should be operated
perfectly in all driving and climatic Conditions

27. 4.3 Spring
Fig.4.3spring
Extension springs are attached at both ends of the components.
When these components move apart, the spring tries to bring them
together again. Extension spring absorbs and store energy as well
as creates a resistance to a pulling force. It initial tension
thatdetermines how tightly together an extension spring is coiled.
The spring is interlinked with hand brake lever at center to the
base to make the disengagement easier.

28. 4.4 Motor
Fig.4.4 Motor
A DC relies on the fact that like magnet poles attract each
other. A coil of wire with a current running through it generates
an electromagnetic field aligned with the center of the coil. The
motor is used to drive the worm wheel which drives the worm so
that circular motion occurs. The source of current is obtained
from the 12 v dc battery from the car.

29. 4.5Worm and worm wheel mechanism:
The two elements are also called the worm screw and worm
wheel. Theterminology is often confused by imprecise use of the
term worm gearto refer to theworm, the worm gear, or the worm
drive as a unit.Like other gear arrangements, a worm drive can
reduce rotational speed or transmithigher torque. A worm is an
example of a screw, one of the six simple machines.One of the
major advantages of worm gear drive units are that they can
transformation in 90 degrees.

30. Fig.4.5 worm and wheel mechanism
A gearbox designed using a worm and worm-wheel is
considerably smaller than one made from plain spur gears, and
has its drive axes at 90° to each other. With a single start worm,
for each 360° turn of the worm, the worm-wheel advances only
one tooth of the gear wheel. Therefore, regardless of the worm's
size (sensible engineering limits notwithstanding), the gear ratio

31. is the "sizeof the worm wheel - to - 1". Given a single start worm,
a 20 tooth worm wheel reduces the speed by the ratio of 20:1.
With spur gears, a gear of 12 teeth must match with a 240 tooth
gear to achieve the same 20:1 ratio. Therefore, if the diametrical
pitch (DP) of each gear is the same, then, in terms of the physical
size of the 240 tooth gear to that of the 20 tooth gear, the worm
arrangement is considerably smaller in volum
4.6 Manual Control Switch:-
• To control the hand brake in driving situation the and push
down pullswitch is provided
• This is the switch which is use in pull direction to engage
and push direction to disengage handbrake.
• This is the switch which is use in pull direction to engage
and push direction to disengage handbrake.

32. Fig.4.6 Manual Control Switch

33. CHAPTER 5
BRAKING CONDITION
Car Alternato
r
Ignition Handbra
ke
Rest Off Off Engaged
Running On On Disngage
d
Running
(suddenly
Engine
stopped)
Off On Engaged
Vehicle
running
Manual sw
operated
On On
Engaged
/
disengag
ed
Table 5.0 Braking Condition

34. 5.1. COMPONENT SPECIFICATION
1.Motor Specification:
Rated Voltage: 12 Volt
DC. Starting Voltage:
13.5±0.2V. Operating
Voltage Range: 10-15V.
Test Temperature:25±5°c.
Speed:
65±RPM.
Current:5A.
Torque≥25m
.
2. Relay N/O,N/C 12V, 5Pin.
3. Limit Switch (Heavy door durable switch). (push to cut)
4. M6 Nut & Bolts 10 nos. with Washer (MS).
5. L clamp (SS) 2 nos.
6. Push to On/Off Switch.
7. Harness wire Dia. 0.5 sq.mm. Length 7m.

35. CONCLUSION
This project deals with hand brake actuation with the help
of worm and worm wheel and Signal based on some conditions.
Limit Switch and provides signal to the circuit board which
directly drives the motor. The worm and worm wheel gets
activated and lifts the hand and disengages with the help of push
lock and spring tension.

36. REFERENCE
❖ MohdRazmiIshak , Abd Rahim Abu Bakar , Ali Belhocine ,
Jamaludin Mohd Taib ,Wan Zaidi Wan Omar a
“Brake torque analysis of fully mechanical parking brake
system: Theoretical and experimental approach” (24 August
2016)
❖ S.Thivagar, C. Nantha Kumar
“International Journal of Engineering Research and General
Science Volume 4, Issue 1, January-February, 2016 ISSN
2091-2730”
❖ Prof: Wakchaure P.B ,Prof: Borkar B.R
“International Journal of Scientific and Research
Publications, Volume 3, Issue 4, April 2013 ISSN 2250-
3153”
❖ Sachin S. Dharia, Sachin S. Bhopale, Prathmesh P.
Kumbhar, Kedar S. Pathak “Advancements in Automatic
Hand Brake System”(may 2016)
❖ Steven Becker, Robson Forensic Inc.
“SAE International by Steven Becker, Monday, April 08, 2013”

37. 37