Air Brake PROJECT REPORT

8/18/2019 Air Brake PROJECT REPORT

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FABRICATION OF PNEUMATIC BRAKING SYSTEM

Submitted in the partial fulfillment of the requirement for the award of

“DIPLOMA IN MECHANICAL ENGINEERING ”

SUBMITTED BY:

1. G.K. MANIGANDAN 4. J. DHANAJEYAN

2. B. KARTHIKEYAN 5. D. DURAIVEL

3. P. BALASUBRAMANI 6. L. PRABHU

Under guidance of

Mr. V.K. RAJENDRAN,M.E.

MA!" #$%&'

DEPARTMENT OF MECHANICAL ENGINEERING

A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 6!2 !3


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A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 6!2 !3

BONAFIDE CERTIFICATE

Thi( i( to certif) that thi( *ro+ect wor, on

- FABRICATION OF PNEUMATIC BRAKING SYSTEM "

(ubmitted b) ........ .....' eg' /o' .....

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING

Thi( i( the bonafide record of wor, carried out b) him under

our (uper0i(ion during the )ear #$%&

Submitted for the 1i0a20oce e3am held on .....''

"EAD 45 T"E DE*ATME/T *46E!T 7UIDE

I/TE/A8 E9AMI/E E9TE/A8 E9AMI/E


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ACKNO#LEDGEMENT


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ACKNOWLEDGEMENT

At the out(et we would li,e to empha(i;e our (incere than,( to the *rincipal Mr.

R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement and 0aluable ad0ice'

we than, our E(quired "ead of Department Mr R. RAJKUMAR, A.M.I.E,

M.E., for pre(enting hi( felicitation( on u('


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CONTENTS


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CONTENTS

!hapter /o' TIT8E

%' I/T4DU!TI4/

#' SY/4*SIS

?'


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INTRODUCTION


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ABSTRACT


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ABSTRAC

The aim i( to de(ign and de0elop a control ()(tem ba(ed on brea,ing ()(tem of an

AI controlled (afel) automoti0e wheel bra,ing ()(tem'

'

The control 0al0e which direct( the air to the double acting c)linder for

brea,ing control' Thi( bra,ing action( i( implemented In our pro+ect we ha0e to appl)

thi( bra,ing ()(tem in one wheel a( a model'


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CHAPTER – 1


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DESCRIPTION OF BRAKE

SYSTEM

CHAPTER – 1

DESCRIPTION OF BRAKE SSTEM

1.1 INTRODUCTION

1.1 INTRODUCTION


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Bra,e( are one of the mo(t important control component( of the 0ehicle' The) are

required to (top the 0ehicle within the (malle(t po((ible di(tance and thi( i( done b)

con0erting the ,inetic energ) of the wheel( into the heat energ) which i( di((ipated into

the atmo(phere'

T!"#$ %& 'r()#$ '($#* %+ #-h%* %& (-/(-0%+

%' Mechanical bra,e(

#' ")draulic bra,e(

?' Electric and electronic bra,e(

' 1acuum bra,e(' Air bra,e(

T!"#$ %& 'r()#$ '($#* %+ (""20(-0%+

%' Drum bra,e(

#' Di(c bra,e(

?' *ar,ing Bra,e(

1.3 DRUM BRAKES

The modern automobile drum bra,e wa( in0ented in %$# b) 8oui( enault

though a le(( 2 (ophi(ticated drum bra,e had been u(ed b) Ma)bach a )ear earlier' In the

fir(t drum bra,e( the (hoe( were mechanicall) operated with le0er( and rod( or cable('

5rom the mid2%?$( the (hoe( were operated with oil pre((ure in a (mall wheel c)linder

and pi(ton( though (ome 0ehicle( continued with purel)2mechanical ()(tem( for

decade(' Some de(ign( ha0e two wheel c)linder('


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The (hoe( in drum bra,e( are (ub+ect to wear and the bra,e( needed to be ad+u(ted

regularl) until the introduction of (elf ad+u(ting drum bra,e( in the %$(' In the %&$(

and %C$( bra,e drum( on the front wheel of car( were graduall) replaced with di(c

bra,e( and now practicall) all car( u(e di(c bra,e( on the front wheel( with man)

offering di(c bra,e( on all wheel(' "owe0er drum bra,e( are (till often u(ed for

handbra,e( a( it ha( pro0ed 0er) difficult to de(ign a di(c bra,e (uitable for holding a

car when it i( not in u(e' Moreo0er it i( 0er) ea() to fit a drum handbra,e in(ide a di(c

bra,e (o that one unit (er0e( for both footbra,e and handbra,e'

Earl) t)pe bra,e (hoe( contained a(be(to('


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8i,e the di(c pad( bra,e (hoe( con(i(t of a (teel (hoe with the friction material or

lining ri0eted or bonded to it' Al(o li,e di(c pad( the lining( e0entuall) wear out and

mu(t be replaced' If the lining( are allowed to wear through to the bare metal (hoe the)

will cau(e (e0ere damage to the bra,e drum'

1.3.3 BACKING PLATE

The bac,ing plate i( what hold( e0er)thing together' It attache( to the a3le and

form( a (olid (urface for the wheel c)linder bra,e (hoe( and a((orted hardware' It rarel)

cau(e( an) problem('

1.3.4 BRAKE DRUM

Bra,e drum( are made of iron and ha0e a machined (urface on the in(ide where

the (hoe( ma,e contact' 6u(t a( with di(c rotor( bra,e drum( will (how (ign( of wear a(

the bra,e lining( (eat them(el0e( again(t the machined (urface of the drum'


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with the drum'


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The par,ing bra,e =a','a' emergenc) bra,e> ()(tem control( the rear bra,e(

through a (erie( of (teel cable( that are connected to either a hand le0er or a foot pedal'

The idea i( that the ()(tem i( full) mechanical and completel) b) pa((e( the h)draulic

()(tem (o that the 0ehicle can be brought to a (top e0en if there i( a total bra,e failure'

In drum bra,e( the cable pull( on a le0er mounted in the rear bra,e and i( directl)

connected to the bra,e (hoe(' Thi( ha( the effect of b) pa((ing the wheel c)linder and

controlling the bra,e( directl)'

%' Support plate

#' *ar, bra,e (hoe(

?' Equali;er

' Spring(

' "old down clip(

&' Ad+u(ter

Di(c bra,e( on the rear wheel( add additional complication for par,ing bra,e ()(tem('There are two main de(ign( for adding a mechanical par,ing bra,e to rear di(c bra,e('

The fir(t t)pe u(e( the e3i(ting rear wheel caliper and add( a le0er attached to a

mechanical cor,(crew de0ice in(ide the caliper pi(ton'


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4n car( with automatic tran(mi((ion( the par,ing bra,e i( rarel) u(ed' Thi( can cau(e

a couple of problem(' The bigge(t problem i( that the bra,e cable( tend to get corroded

and e0entuall) (i;e up cau(ing the par,ing bra,e to become inoperati0e' B) u(ing the

par,ing bra,e from time to time the cable( (ta) clean and functional' Another problem

come( from the fact that the (elf ad+u(ting mechani(m on certain bra,e ()(tem( u(e( the

par,ing bra,e actuation to ad+u(t the bra,e(' If the par,ing bra,e i( ne0er u(ed then the

bra,e( ne0er get ad+u(ted'

1.5 DISC BRAKES

1.5.1 INTRODUCTION

Di(c bra,e( con(i(t of a metal di(c attached to the wheel hub that rotate( with the

wheel' !aliper( are attached to the frame or for, along with pad( that (quee;e together

on the di(c' Such bra,e( ha0e been (ucce((full) u(ed on motorc)cle( for decade( and

been the principal choice there' The di(c bra,e i( a lot li,e the bra,e( on bic)cle' Bic)cle

bra,e( ha0e a caliper which (quee;e( the bra,e pad( again(t the wheel' In a di(c bra,ethe bra,e pad( (quee;e the rotor in(tead of the wheel and the force i( tran(mitted

h)draulicall) in(tead of through a cable' 5riction between the pad( and the di(c (low(

the di(c down'

1.5.3 CONSTRUCTION

THEOR OF CONVENTIONAL HDRAULIC DISC BRAKE

A Di(c bra,e u(e( a flat round di(c or rotor attached to the wheel hub

in(tead of a drum' Bra,e pad( are po(itioned on the oppo(ite (ide( of the rotor and are


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mounted in the bra,e caliper' The caliper contain( the h)draulic pi(ton u(ed to appl) the

(hoe( and to tran(mit the bra,ing force( from the (hoe( to the (u(pen(ion member('

All di(c bra,e( are non energi;ed non (er0o bra,e(G lining pre((ure i( directl)

proportional to bra,e pedal pre((ure'

!entrifugal force will throw the contaminant( off the rotor' A di(c bra,e will ha0e much

cooler operation than drum bra,e( becau(e of increa(ed area that i( e3po(ed to the air

flowing pa(t it'

All modern automoti0e bra,e ()(tem u(e( a h)draulic ()(tem to tran(mit the

application force( from the bra,e pedal to the bra,e (hoe('

The bra,eH( h)draulic ()(tem begin( at the ma(ter c)linder' The ma(ter c)linder i(

ba(icall) a pi(ton t)pe h)draulic pump operated b) the bra,e pedal' A( bra,e pedal i(

pu(hed bra,e fluid i( pumped to the caliper or wheel c)linder pi(ton' Thi( fluid pu(he(

on the pi(ton( which pu(h the bra,e (hoe( again(t the rotor'

%.5.4 ADVANTAGES OF DISC BRAKES OVER DRUM BRAKES

In ca(e of di(c bra,e( the friction( (urface i( directl) e3po(ed to the cooling air (o

the heat di((ipation i( much ea(ier in di(c bra,e than drum bra,e('

The frictional (urface in ca(e of di(c bra,e( are flat when compared to cur0ed

(urface of drum bra,e( thi( mean in di(c bra,e( there i( uniform wear'

5rictional pad material i( not (ub+ected to an) bending thereb) increa(ing the

range of material( from which to choo(e the (uitable one'


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The de(ign of di(c bra,e( i( (uch that there i( no lo(( efficienc) due to e3pan(ion

a( the ()(tem become( hot e3pan(ion of drum of internall) e3panded (hoe t)pe(

if bra,e tend( to mo0e the friction (urface apart cau(ing a lo(( of effecti0e pedal

tra0el on the friction (urface( (lightl) without tending to increa(e the clearance'

Di(c bra,e weigh le(( than their con0entional drum t)pe counterpart a (a0ing

appro3imatel) #$J being po((ible'

Di(c bra,e ha( a better anti fade characteri(tic( than drum bra,e('

1.5. DISADVANTAGES

An) lea,age( of h)draulic fluid lead( to bra,e failure

Air bubble( if an) got trapped in the h)draulic circuit will re(ult i( bra,e failure'

Sufficient le0el of bra,e fluid (hould alwa)( be maintained all the time

")draulic di(c bra,e( u(uall) require relati0el) (peciali;ed tool( to bleed the

bra,e ()(tem('

epair( on the trail are difficult to perform wherea( mechanical di(c bra,e( rarel)

fail completel)'


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!on(idering the abo0e mentioned ad0antage( and (uperior nature of di(c bra,e( we

decided to choo(e modification( in di(c bra,e( to ma,e it much (impler and more

effecti0e and cheaper de(ign'

1.6 HDRAULIC VS MECHANICAL

Two main di(c bra,e ()(tem( e3i(t: h)draulic and mechanical =cable2actuated>'

Mechanical di(c bra,e( =which are almo(t alwa)( le(( e3pen(i0e than h)draulic> ha0e

le(( modulation than h)draulic di(c bra,e ()(tem( and (ince the cable i( u(uall) open to

the out(ide mechanical di(c bra,e tend to pic, up (mall bit( of dirt and grit in the cable

line( when ridden in har(h terrain' ")draulic di(c ra,e( u(e fluid from a re(er0oir

pu(hed through a ho(e to actuate the pi(ton( in the di(c caliper that then actuate the

pad(' ")draulic di(c bra,e ()(tem( generall) ,eep contaminant( out better' "owe0er

(ince h)draulic di(c bra,e( u(uall) require relati0el) (peciali;ed tool( to bleed the bra,e

()(tem( repair( on the trail are difficult to perform wherea( mechanical di(c bra,e(

rarel) fail completel)' ")draulic di(c bra,e( occa(ionall) require bleeding of the bra,e

line( to remo0e air bubble(' There are two t)pe( of bra,e fluid u(ed in di(c bra,e( toda):mineral oil and D4T fluid' Mineral oil i( generall) inert and while D4T ha( a higher

boiling point it i( ,nown to be corro(i0e to frame paint' The two are generall) not

interchangeable a( the different fluid( ma) cau(e (eal( to (well or be corroded' Al(o the

h)draulic fluid ma) boil on (teep continuou( down hill(' Thi( i( due to heat building up

in the di(c and pad( and can cau(e the bra,e to lo(e it( abilit) to tran(mit force through

incompre((ible fluid( (ince (ome of it ha( become a ga( which i( compre((ible' To

a0oid thi( problem #$? mm = inch> diameter di(c rotor( ha0e become common on

downhill bi,e(' 8arge( rotor( di((ipate heat more quic,l) and ha0e a larger amount of

ma(( to ab(orb heat' 5or the(e rea(on( one mu(t weigh the ad0antage( and

di(ad0antage( of u(ing a h)draulic ()(tem 0er(u( a mechanical ()(tem'


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4ur de(ign i( mainl) focu(ed to a0oid the abo0e mentioned di(ad0antage( b)

entirel) new and inno0ati0e ()(tem for di(c bra,e(' The main concept of our pro+ect i(

deri0ed from electronic wedge bar,ing ()(tem' and few important outline of the E


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CHAPTER - 2

AIR BRAKING SYSTEM


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FABRICATION OF THE

PROJECT

FABRICATION OF THE PROJECT

This project consists of

1)DCV system


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2)Pneumatic actuator unit

3)Two wheeler (TVS MOPED)

2.PNEUMATIC ACTUATOR UNIT;

The brake lever is connected to the double acting cylinder which is

controlled by the 5/2 way solenoid operated directional control valve.

This cylinder has 12mm dia and 25mm stroke length.


To fabricate this brake set up a TVS CHAMP two wheeler moped is

arranged.


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WORKING PRINCIPLE


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WORKING PRINCIPLE

This project consists of

1)AIR control system

2)Pneumatic actuator unit



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2.5.1. ADVANTAGES


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2.5.1. ADVANTAGES

%' Bra,e co(t will be le((

#' 5ree from wear ad+u(tment(

?' 8e(( power con(umption

' 8e(( (,ill technician( i( (ufficient to operate

' In(tallation i( (implified 0er) much


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Increased safety: improvement in maneuverability and stability of the

vehicle

More room and less weight: fewer components result in savings in terms

of space and weight

Flexibility and ease of maintenance

DISADVANTAGES

%' /eed (eparate air tan,


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#' Thi( bra,e ()(tem i( co(tlier one'

?' Addition co(t i( required to in(tall thi( ()(tem to four wheeler


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APPLICATIONS


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APPLICATIONS

%' 5our wheeler application

#' It i( al(o implemented in two wheeler


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DESCRIPTION OF

PNEUMATIC COMPONENTS


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DESCRIPTION OF PNEUMATIC COMPONENTS

%' Double acting air c)linder with pi(ton arrangement'

#' Spool 0al0e =# po(ition port( 0al0e>

?' *neumatic fitting(

a' Bul, head union

b' 5le3ible ho(e(

c' Air compre((or(

DOUBLE ACTING AIR CLINDER WITH PISTON ARRANGEMENT

It con(i(t( of a pi(ton in(ide a c)lindrical hou(ing called a barrel' Attached to one

end of the pi(ton i( a rod which the rod end ha( one port' Thi( rod end port i( u(ed for

entrance of air and e3tend( out(ide one end of the c)linder' At another end i( a port for

e3it of air'

Double acting c)linder can be e3tended and retracted pneumaticall)' The (malle(t

bore (i;e of a double acting c)linder i( % %K inch' The pi(ton which i( made of ductile

Iron contain( u2cup pac,ing to (eal again(t lea,age


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between the pi(ton and barrel' The port( are located in the end cap( which are (ecured

to the barrel b) bolt( and nut('

SPOOL VALVE

The (pool i( rod in K# 0alue( (o that K# 0al0e i( called -(pool

0al0e' It u(ed to change the path of flow of air'

DIRECTING CONTROL VALVES

A direction control 0al0e i( u(ed to change the direction of airflow a( and when

required b) the ()(tem for re0er(ing the machine tool de0ice(' A direction control 0al0e

ma) be cla((ified according to the con(truction of the internal mo0ing part( a(

%' otar) (pool T)pe'

#' Sliding Spool T)pe'

?' Solenoid operated 0al0e(


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SOLENOID OPERATED VALVES

Solenoid 0al0e( are electromechanical de0ice( li,e rela)( and contractor(' A

(olenoid 0al0e i( u(ed to obtain mechanical mo0ement in machiner) b) utili;ing fluid or

air pre((ure' The fluid or air pre((ure i( applied to the c)linder pi(ton through a 0al0e

operated b) a c)lindrical electrical coil' The electrical coil along with it( frame and

plunger i( ,nown a( the (olenoid and the a((embl) of (olenoid and mechanical 0al0e i(

,nown a( (olenoid 0al0e' The (olenoid 0al0e i( thu( another important

electromechanical de0ice u(ed in control of machine(' Solenoid 0al0e( are of two t)pe(

%' Single (olenoid (pring return operating 0al0e=K#>

#' Double (olenoid operating 0al0e'

In fig % i( (hown a (ingle (olenoid (pring return 0al0e in it( de2energi;ed condition' The

()mbol for the (olenoid and the return are al(o (hown' The (olenoid 0al0e i( (hown

connected to the c)linder to help reader( under(tand

the (olenoid 0al0e action' In the de energi;ed condition the plunger and the 0al0e (pool

po(ition a( (hown in figure %'


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In thi( po(ition of (pool port * i( connected to port A and port B i( connected to tan, or

e3hau(t =i'e' atmo(phere> if air i( u(ed' Spring pre((ure =S> ,eep( the (pool in thi(

condition

a( long a( the coil

i( de

energi;ed' 5luid pre((ure from port * through port A i( applied to the left (ide of the

c)linder pi(ton' Thu( the c)linder pi(ton mo0e( in the right direction' /ow

when the (olenoid coil i( energi;ed plunger i( attracted and it pu(he( the (pool again(t

(pring pre((ure'

The new po(ition of plunger and (pool are (hown in fig #'

K#


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In thi( po(ition of (pool port A get( connected to tan, and port * get( connected to port

B' Thu( pre((ure i( applied to the c)linder pi(ton from right and mo0e( the pi(ton rod to

the left' At the (ame time fluid in the other (ide i( drained out to the tan,' will mo0e the (pool to it( original

po(ition a( (hown in figure %' Thu( normall) when the (olenoid coil i( de energi;ed the

pi(ton rod remain( e3tended'


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PNEUMATIC

$ITTING


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PNEUMATIC FITTINGS

There are no nut( to tighten the tube to the fitting( a( in the con0entional t)pe of

metallic fitting(' The tube i( connected to the fitting b) a (imple pu(h en(uring lea,

proof connection and can be relea(ed b) pre((ing the cap and doe( not require an)

(pecial tooling li,e (panner to connect =or> di(connect the tube from the fitting'

SPECIFICATION OF THE FITTING

Bod) Material 2 *la(tic

!ollectKThread /ipple 2 Bra((

Seal 2 /itrate ubber

5luid U(ed 2 Air

Ma3' 4perating *re((ure 2 C Bar

Tolerance on 4D of the tube( 2 ± % mm

Min'


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FLE8IBLE HOSES

The *neumatic ho(e( which i( u(ed when pneumatic component( (uch a(

actuator( are (ub+ected to mo0ement' "o(e i( fabricated in la)er of

Ela(tomer or ()nthetic rubber which permit( operation at high pre((ure' The (tandard

out(ide diameter of tubing i( %K%& inch' If the ho(e i( (ub+ected to rubbing it (hould be

enca(ed in a protecti0e (lee0e'


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CONCLUSION


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CONCLUSION

Bydoing this mini project we were able to understand the importance of

Coordination between the various departments in an manufacturing unit

This brake system offers ample scope for improvement By providing

intermittent force at the brake plate. One of the major aims to achieve is that

when the operator sees a brake force , that he needs to know immediately

strike him, implying that the designs simple and easily understandable. Such

was the case with AIR brake system. AIR Brake system are hailed as the

greatest mechanical contrivance.


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REFERENCE

Henry Hartmann, Mat1in Shautt, Antonio Pascucci, Bernd Gombert.

"eBrake® - the mechatronic wedge brake", SAE Technical Paper Series,

paper No. 2002-01-2582, 6pp, 2002.

“Automotive Braking System” , by Thomas W. birch.

“Automotive Engineering Fundamentals” by Richard Stone, Jeffrey K.

Ball

Siigmar Micke, Richard E. Thompson, Bernd-Holger Roehling (1990).

The introduction of Air DiscBrakes for Trucks end Buses in Europe, SAE

Technical Paper series, paper No. 902203.

Richard Roberts, Bernd Gombert, Hemy Hartmann, Dittmar Lange, &

Martin Schautt."Testing the Mechatronic Wedge Brake", SAE Technical

Paper Series, paper No.2004-0 1-2766, 9 pp, 2004.


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The investigation of disc brake mechanisms. - Minsk Automotive Plant,

1999. -lIp.

COST ESTIMATION


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COST ESTIMATION

%' BA@E SYSTEM 22222222222222222 #$$$'$$

#' AI !Y8I/DE %%$$'$$

?' K#


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LLLLLLLLLLLLLLL

PHOTO VIEW


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PHOTO VIEW

Documents

Air Brake PROJECT REPORT