AUTOMATIC BRAKING SYSTEM IN HILL STATION VEHICLES

INTRODUCTION
These mechanisms give a solution for the general issue of descending or rolling back of the
vehicle, while starting motion uphill in forward or reverse direction in various ways. The
issue is encountered by employing the devices like freewheel, roller clutch or ratchet-pawl
mechanism in different-different manners and locations within the gearbox. The issue is
discussed here considering uphill motion in forward direction. Uphill motion in the reverse
direction also has the similar issue. Ratchet and pawl mechanism is used in many applications
effectively where the one side power transmission is required for example in (i) Giant wheel-
It is the large wheel used in the amusement parks to rotate along the horizontal axis to rotate
in one direction while carrying the number of passengers. (ii)Clocks- where the hands rotate
in clockwise directions only.(iii) Baffle gates- in the entrances of many buildings which
rotates about vertical axis in one direction.(iv) Shaping Machines – in the crank and slotted
arm. In the hill station, the most common problem to the drivers isto park their cars in the
slope and to start up the car. While waiting in the traffic , the cars have to move on step by
step very slowly, this situation is a difficult one for the drivers to make their car not to roll
back in the slope. So the mechanism has to be developed to stop the vehicle from rolling back
and it should not stop the vehicle in accelerating forwards. This function can be achieved by
using the ratchet and pawl mechanism. The ratchet and pawl has to be designed and has to be
fit in the front drive shaft in case of the front drive vehicles.
General issue
when a person drives uphill in forward direction on an inclined path / hilly terrain, when he
tries to commence the motion, here comes the issue of managing three pedals / foot-levers
using two feet. Initially, the person keeps on pressing the brake pedal using right foot in order
to prevent the backward motion due to self-weight of vehicle on inclination and presses
clutch pedal using left foot to shift the gears, further, he fixes any of the forward gear, say the
lower most – 1st gear, now the clutch pedal is to be slowly released and the engine is to be
accelerated by pressing the accelerator pedal to start motion simultaneously. At this instant,
the left foot of the person is busy with guiding the clutch pedal. As the person tries to press
the accelerator pedal, he removes right foot from the brake pedal. The moment he releases the
brake pedal, the vehicle descends backward under the influence of self-weight due to
inclination, which is undesired and may cause accidents. To overcome this issue, generally,
people use to take the help of the hand-brake and drives without fully or partially releasing
the hand-brake, which is not the exact remedy for the problem.
“Anti-Roll Back Device for Motor Vehicles”, the mechanism invented in 1993, it was
developed by installing two additional gears on the lobs on a plate. One of them meshes with
clutch dog of lower most gear (1st gear) and other meshes with the intermediate gear of
reverse gear, for restricting their motion in one desired direction only [3]. The gear, which is
installed separately comprises of freewheel / roller clutch within it. The mechanism is
installed on an additional shaft. Shortcomings: K. It does not work with all the gears. Its
application is limited to the lowest gear and the reverse gear. L. An additional sliding mesh
mechanism will be involved. M. Additional shafts and lobs are required. “Hill Holder Control
Apparatus for Vehicle”, the mechanism invented in 2003, it was developed by employing an
additional clutch within the gearbox termed as secondary clutch [3]. An additional couple of
gears is kept always meshed up between the countershaft and the driven splined shaft of a
constant mesh gearbox. This additional gear rotates under the guidance of secondary clutch,
which is operated by an electronic controller, sensors and controlling the hydraulic pressure
of the actuators. Shortcomings: N. It employs electronic controller, sensors and actuators,
which makes it less reliable in comparison to mechanical mechanisms. O. Expensive. P. The
secondary clutch releases the additional gear after a predetermined time frame decided by the
electronic circuit, i.e., it deactivates after a stipulated time.

BEARING

A bearing is a device to permit constrained relative motion between two parts, typically
rotation or linear movement. Bearings may be classified broadly according to the motions
they allow and according to their principle of operation.
Major types

Common motions include linear/axial and rotary/radial. A linear bearing allows motion along
a straight line, for example a drawer being pulled out and pushed in. A rotary bearing or
thrust bearing allows motion about a center, such as a wheel on an axle or a spindle through a
housing. Common kinds of rotary motion include both one-direction rotation and oscillation
where the motion only goes through part of a revolution, such as with a hinge. Other kinds of
bearings include spherical bearings such as ball joints which are used in car suspensions and
some computer mice.

Bearing friction

Low friction bearings are often important for efficiency, to reduce wear and to facilitate high
speeds. Essentially, a bearing can reduce friction by virtue of its shape, by its material, or by
introducing and containing a fluid between surfaces.

 By shape, gains advantage usually by using spheres or rollers.

 By material, exploits the nature of the bearing material used. (An example would be
using plastics that have low surface friction.)
 By fluid, exploits the low viscosity of a layer of fluid, such as a lubricant or as a
pressurised medium to keep the two solid parts from touching.
 By fields, exploits electromagnetic fields, such as magnetic fields, to keep solid parts
from touching.

Combinations of these, can even be employed with the same bearing. An example of this is
where the cage is made of plastic, and it separates the rollers/balls, which reduce friction by
their shape and finish.

PRINCIPLES OF OPERATION
There are at least six common principles of
operation:

 sliding bearings, usually called "bushes", "bushings", "journal bearings", "sleeve

bearings", "rifle bearings", or "plain bearings"
 rolling-element bearings such as ball bearings and roller bearings
 jewel bearings, in which the load is carried by rolling the axle slightly off-center
 fluid bearings, in which the load is carried by a gas or liquid
 magnetic bearings, in which the load is carried by a magnetic field
 flexure bearings, in which the motion is supported by a load element which bends.

Load bearing and performance capacities

Bearings vary greatly over the forces and speeds that they can support.

Forces can be radial, axial (thrust bearings) or moments perpendicular to the main axis.

The maximum speeds that rotational bearings can support also vary, generally performance is
defined in terms of the product 'DN' where D is the diameter (often in mm) of the bearing and
N is the rotation rate in revolutions per minute.
History and development

An early type of linear bearing was an arrangement of tree trunks laid down under sleds. This
technology may date as far back as the construction of the Pyramids of Giza, though there is
no definitive evidence. Modern linear bearings use a similar principle, sometimes with balls
in place of rollers.

The first plain and rolling-element bearings were wood, but ceramic, sapphire or glass can be
used, and steel, bronze, other metals, and plastic (e.g., nylon, polyoxymethylene, teflon, and
UHMWPE) are all common today. Indeed, stone was even used in various forms. Think of
the "jeweled pocket watch", which incorporated stones to reduce frictional loads, and allow a
smoother running watch. Of course, with older, mechanical timepieces, the smoother the
operating properties, then the higher the accuracy and value. Wooden bearings can still be
seen today in old water mills where the water has implications for cooling and lubrication.

Rotary bearings are required for many applications, from heavy-duty use in vehicle axles and
machine shafts, to precision clock parts. The simplest rotary bearing is the sleeve bearing,
which is just a cylinder inserted between the wheel and its axle. This was followed by the
roller bearing, in which the sleeve was replaced by a number of cylindrical rollers. Each
roller behaves as an individual wheel. The first practical caged-roller bearing was invented in
the mid-1740s by horologist John Harrison for his H3 marine timekeeper. This used the
bearing for a very limited oscillating motion but Harrison also used a similar bearing in a
truly rotary application in a contemporaneous regulator clock.

An early example of a wooden ball bearing (see rolling-element bearing), supporting a

rotating table, was retrieved from the remains of the Roman Nemi ships in Lake Nemi, Italy.
The wrecks were dated to 40 AD. Leonardo da Vinci is said to have described a type of ball
bearing around the year 1500. One of the issues with ball bearings is that they can rub against
each other, causing additional friction, but this can be prevented by enclosing the balls in a
cage. The captured, or caged, ball bearing was originally described by Galileo in the 1600s.
The mounting of bearings into a set was not accomplished for many years after that. The first
patent for a ball race was by Philip Vaughan of Carmarthen in 1794.
Friedrich Fischer's idea from the year 1883 for milling and grinding balls of equal size and
exact roundness by means of a suitable production machine formed the foundation for
creation of an independent bearing industry.

BALL BEARING

A ball bearing is a common type of rolling-element bearing, a kind of bearing.

The term ball bearing to mechanical engineers usually means a bearing assembly which uses
spherical bearing balls as the rolling elements. To laypeople the term often means an
individual ball for a bearing assembly. The remainder of this entry uses the term ball for the
individual component and "ball bearing" or just "bearing" for the assembly.

Ball bearings typically support both axial and radial loads and can tolerate some
misalignment of the inner and outer races. Also, balls are relatively easy to make cheaply
compared to other kinds of rolling elements. Ball bearings tend to have lower load capacity
for their size than other kinds of rolling-element bearings due to the smaller contact area that
spherical shapes provide.

Although Leonardo da Vinci has been credited with the discovery of the principle behind the
mechanics of ball bearings, the first patent was taken out by Philip Vaughn, a Welsh carriage-
maker, in 1791, and ball bearings were found on the Roman Nemi ships constructed in about
40 A.D..

COMMON DESIGNS

There are several common designs of ball bearings, each offering various tradeoffs.

Radial

A radial ball bearing uses axially symmetric inner and outer races that are shaped so a radial
load passes radially through the bearing. Most radial designs also support modest axial loads;
however, large axial loading tends to separate the bearings.
Angular contact

An angular contact ball bearing uses axially asymmetric races. An angular load passes in a
straight line through the bearing, whereas a radial load takes an oblique path that tends to
separate the races axially. So the angle of contact on the inner race is the same as that on the
outer race. Angular contact bearings allow 'combined loads' (loading in both the radial and
axial directions) and the contact angle of the bearing should be matched to the relative
proportions of each. The larger the contact angle (typically in the range 10 to 45 degrees), the
higher the axial load supported, but the lower the radial load. In high speed applications, such
as turbines, jet engines, dentistry equipment, the centrifugal forces generated by the balls will
change the contact angle at the inner and outer race. Ceramics such as silicon nitride are now
regularly used in such applications due to its low density (40% of steel - and so significantly
reduced centrifugal force), its ability to function in high temperature environments, and the
fact that it tends to wear in a similar way to bearing steel (rather than cracking or shattering
like glass or porcelain).

Most bicycles use angular-contact bearings in the headsets because the forces on these
bearings are in both the radial and axial direction. The angular-contact bearing is able to
withstand such a combined load, as well as small misalignments which often occurs, due to
the flexibility of the front fork.

Axial

An axial ball bearing uses side-by-side races. An axial load is transmitted directly through the
bearing, while a radial load is poorly-supported, tends to separate the races, and anything
other than a small radial load is likely to damage the bearing.

Deep-groove

A deep-groove radial bearing is one in which the race dimensions are close to the dimensions
of the balls that run in it. Deep-groove bearings have higher load ratings for their size than
shallow-groove , but are also less tolerant of misalignment of the inner and outer races. A
misaligned shallow-groove bearing may support a larger load than a similar deep-groove
bearing with similar misalignment.
Turning is the process used to produce cylindrical components in a lathe. It can be done

manually, or using a CNC machine.

When turning, a piece of material (wood, metal, etc.) is rotated and a cutting tool is traversed

along 2 axes of motion to produce precise diameters and depths. Turning can be either on the

outside of the cylinder or on the inside (also known as boring) to produce tubular components

to various geometries.

Turning can be performed manually on what are known as conventional machines with center

lathes which are not computerized. In this case, they require constant supervision.

Alternatively, they may be done using automatic lathes (auto lathes) operated by skilled

tradesmen called machinists (or fitter and turners). Modern practice is moving towards the

use of CNC controls such as a CNC turning center.

Facing is a related term. It involves moving the cutting tool across the face (or end) of the

workpiece and is performed by the operation of the topslide, as distinct from the longitudinal

feed (turning). It is commonly associated with the use of a lathe although it may be used in

relation to vertical boring mills or similar operations.

The bits of waste metal from turning operations are known as chips. In some locales they

may be known as turnings or swarf although swarf is generally applied to the waste from

grinders.
DRILLING

DRILL

A drill (from Dutch Drillen) is a tool with a rotating drill bit used for drilling holes in

various materials. Drills are commonly used in woodworking and metalworking.

The drill bit is gripped by a chuck at one end of the drill, and is pressed against the

target material and rotated. The tip of the drill bit does the work of cutting into the target

material, slicing off thin shavings (twist drills or auger bits) or grinding off small particles

(oil drilling).

TAP AND DIE

Taps and dies are cutting tools used to create screw threads in solid substances

including, but not limited to, metal, wood, and plastic. A tap is used to cut the female portion

of the mating pair (e.g. a nut). A die is used to cut the male portion of the mating pair (e.g. a

bolt). Other than pipes, it is more common to create the hole into which a bolt is screwed than

to create the item that is screwed into a hole. Thus, taps are often more commonly available.

The process of cutting the threads in a hole is called "tapping" the hole.

The die cuts a thread on a preformed cylindrical rod, which creates a male threaded

piece which functions like a bolt.

WELDING

Welding is a fabrication process that joins materials, usually metals or thermoplastics,

by causing coalescence. This is often done by melting the work pieces and adding a filler

material to form a pool of molten material that cools to become a strong joint, with pressure

sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast

with soldering and brazing, which involve melting a lower-melting-point material between

the workpieces to form a bond between them, without melting the work pieces.

ARC WELDING

Many different energy sources can be used for welding, including a gas flame, an

electric arc, a laser, an electron beam, friction, and ultrasound. While often an industrial

process, welding can be done in many different environments, including open air, underwater

and in space. Regardless of location, however, welding remains dangerous, and precautions

must be taken to avoid burns, electric shock, poisonous fumes, and overexposure to

ultraviolet light.

WELDING PROCESSES

These processes use a welding power supply to create and maintain an electric arc

between an electrode and the base material to melt metals at the welding point. They can use

either direct (DC) or alternating (AC) current, and consumable or non-consumable electrodes.

The welding region is sometimes protected by some type of inert or semi-inert gas, known as

a shielding gas, and filler material is sometimes used as well.

A valid comparison of shaft vs. chain drives can only be made if both bikes use the same type
of gearing, whether single-speed or with an internal gear system. Most of the advantages
claimed for a shaft drive can be realized by using a fully-enclosed chain case.

Bicycles typically employ more torque but at much lower rotational speed than motorcycles
and cars This mitigates against shaft drive as the shafts must be large to cope with the torque,
which adds to their mass. This is particularly noticeable when pedaling hard, when there can
be noticeable torsional springing in the drivetrain.
II. LITRATURE SURVEY
A. Anti-creep and hill holder brake system Cook George suggested a hill holder mechanism
holds the vehicle in slope for 2 seconds by using the brake pressure. A device operable in a
transmission of a vehicle for substantially preventing vehicular rollback on an incline,
comprising: a shaft rotatable which is supported in a transmission housing; a gear selectively
connected for common rotation with the shaft, wherein the gear is rotatable in a first rotary
direction and a second rotary direction.
B. Improved release mechanism for a hill holder device William kent utilized a load sensor
connected with a wheel brake to sense a change in wheel braking torque and communicate
responsively with a mechanical brake control device. If a car is stopped on an incline while
the motor is still running, there's a good chance that some kind of hill-start control will be
needed. A sensor that detects an incline of more than a certain amount, three degrees or more,
can send a signal to the hill-start control indicating that the vehicle has the potential to start
rolling. The disadvantage of incline detection is that sometimes a car maybe on an incline
without needing the hill-start control - for instance, when a tire slips into a pothole

C. Improved release mechanism for a hill holder device Grzegorz Janiszewski stated that the
use of piston cylinder device, controlled by an electronic unit which is coupled to a hydraulic
pressure system and acts on the brake pedal for two seconds.

D. Release mechanism for a hill holder device William K. Messersmith used the load cell
with electrical control for braking system. But it requires continuous electric energy for the
production and display of signals. It also requires an amplification circuit for the generation
of output display because the signals produced by the gauge itself are of very much low
voltage almost in milli-volts. In a vehicle having a clutch pedal and a brake pedal, a hill
holder device is utilized to maintain the brake pedal in the applied position so that the vehicle
operator's foot is free to operate the accelerator pedal. A mechanical brake control device
may be disposed between the clutch and brake pedals, with the clutch pedal connected by a
linkage to the brake control device so that release of the clutch pedal will cause deactivation
of the brake control device and result in release of the brake pedal from the applied position.
The release mechanism should be usable with either a mechanical brake control device or a
braking assistance servo-motor system.
E. Vehicle transmission hill holder Alvin H. Berger used a one-way clutch when engaged it
prevents rolling of the vehicle. A device operable in a transmission for substantially
preventing vehicular rollback on an incline includes a shaft, a gear, a one-way clutch, and a
pawl member. The gear is selectively connected for common rotation with the shaft. The gear
is rotatable in a first rotary direction and a second rotary direction. The one-way clutch has an
inner race and an outer race, where the inner race is connected to the gear and the outer race
has an outer surface having a plurality of engaging teeth. The pawl member has a first end
and a second end, where the first end is pivotal mounted to a transmission housing. The
second end of the pawl has a first angled portion configured to release and engage at least one
of the plurality of engaging teeth of the outer race as the outer race rotates in the second
rotary direction.
LITERATURE REVIEW
Heretofore, a lot of work is done to encounter or prevent this issue of rolling back of vehicles.
Different scientist and researchers gave different remedies. Significant among them are: “No-
Roll Back Device”, the mechanism invented in 1934, it was developed by installing a device
like ball type freewheel or roller-clutch on the shaft which gets connected to the propeller
shaft, which extends to the differential [1]. Shortcomings: A. The device works in one
direction only. It will not restrict the rolling back when the vehicle moves uphill in reverse
direction. B. For driving the vehicle in reverse direction, it requires manual deactivation of
the device. C. To change the direction of motion, every time it requires activation or
deactivation of the device manually. “No-Roll Back Brake for Automobile”, the mechanism
invented in 1938, it was developed by installing a “cramping” member normally entirely free
and out of the engagement with the operating devices while the driving shaft is in the
rotation, but instantly operable on a reverse movement such as is imparted to the shaft when
the vehicle would tend to back down a hill or a grade when the clutch is released or when
stalled [2]. Shortcomings: D. Once this mechanism came into action for stopping the roll
back, it stops the propeller shaft, extending from the gear box to differential box, like brake
shoe action in the brake drum. To release the propeller shaft for motion further, it requires a
lever to be guided manually. E. This mechanism requires its deactivation manually, to allow
reverse direction motion of the vehicle. F. Once this mechanism got deactivated for reverse
direction motion, it needs to be re-activated manually, i.e., it requires manual assurance to get
it re-activate again. G. It does not work while the vehicle is moving uphill in reverse
direction. “No-Roll Back Mechanism”, the mechanism invented in 1939, it was developed by
installing the devices like freewheel, ratchet-pawl or roller clutch on the driven (output) shaft
of sliding mesh gearbox, to restrict its rotation in one direction only [4]. This mechanism was
made in such a way that it deactivates when the reverse gear is applied. Shortcomings: H. It
does not work while the vehicle is moving uphill in reverse direction. I. Once this mechanism
got deactivated, it does not get re-activate, unless the top gear is applied, i.e., it requires
manual assurance to get it re-activate again. J. This mechanism cannot be installed in the
constant mesh gearbox.

DESIGN AND DRAWING

Any device that prevents a car from rolling backward on a hill when the brake pedal is
released can be called a hill holder. The earliest hill holders were used in horse-drawn
carriages and early horseless carriages. They were often home-made or made by a local
blacksmith. These early hill holders were little more than a heavy iron weight with a spike or
other sharp end that could be quickly dropped behind a wheel when the need arose,
preventing the vehicle from rolling backward.

Hill-Holder is a name for the mechanism invented by Wagner Electric and manufactured by
Bendix Brake Company in South Bend, Indiana. Studebaker[1] and many other carmakers
offered the device as either optional or standard equipment for many years. It is a device that
holds the brake until the clutch is at the friction point, making it easier to start up hills from a
stop in manual transmission automobiles. It was first introduced in 1936 as an option for
the Studebaker President. By 1937 the device, called "NoRoL" by Bendix, was available on
Hudson, Nash and many other cars. Another name for the mechanism is a hill hold
control (HHC).

RATCHET MECHANISM
A ratchet is a mechanical device that allows continuous linear or rotary motion in only one
direction while preventing motion in the opposite direction. Ratchets are widely used in
machinery and tools. Though something of a misnomer, "ratchet" is also often used to refer to
ratcheting socket wrenches, a common tool with a ratcheting handle.

A ratchet consists of a round gear (see Figure 1) or linear rack with teeth, and a pivoting,
spring-loaded finger called a pawl that engages the teeth. The teeth are uniform
but asymmetrical, with each tooth having a moderate slope on one edge and a much steeper
slope on the other edge.

When the teeth are moving in the unrestricted (i.e., forward) direction (see Figure 2), the
pawl easily slides up and over the gently sloped edges of the teeth, with a spring forcing it
(often with an audible 'click') into the depression between the teeth as it passes the tip of each
tooth. When the teeth move in the opposite (backward) direction, however, the pawl will
catch against the steeply sloped edge of the first tooth it encounters, thereby locking it against
the tooth and preventing any further motion in that direction.

The ratchet and pawl mechanism allows motion in one direction but locks it in the other
direction. In this sense it acts in the same way as a diode in an electrical circuit or a check
value in a water pipe. The ratchet and pawl was often used with a winch or windlass, a
horizontal drum with a rope or cable attached, which allowed the rope to be wound onto the
cylinder but prevented the cylinder from unwinding the rope.

Reuleaux was fascinated with ratchet mechanisms and designed several different models to
illustrate the different motions and uses of the ratchet. In his machine design book The
Constructor (1893), he defined the ratchet in the similar way as Leonardo da Vinci;
"The object of the ratchet is to check the action of certain portions of a machine and so
modify an otherwise continuous motion into some intermittent form."
NEED FOR AUTOMATION
Automation can be achieved through computers, hydraulics, pneumatics, robotics,
etc., of these sources, pneumatics form an attractive medium for low cost automation.

The main advantages of all pneumatic systems are economy and simplicity.
Automation plays an important role in mass production.

Nowadays almost all the manufacturing process is being atomized in order to deliver
the products at a faster rate.The manufacturing operation is being atomized for the following
reasons.

 To achieve mass production

 To reduce man power
 To increase the efficiency of the plant
 To reduce the work load
 To reduce the production cost
 To reduce the production time
 To reduce the material handling
 To reduce the fatigue of workers
 To achieve good product quality
 Less maintenance

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are discussed below.

PROPERTIES
The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied
Can be weight, surface finish, rigidity, ability to withstand environmental attack from
chemicals, service life, reliability etc.
 The following four types of principle properties of materials decisively affect their
selection
 Physical
 Mechanical
 From manufacturing point of view
 Chemical
The various physical properties concerned are melting point, thermal
Conductivity, specific heat, coefficient of thermal expansion, specific gravity, electrical
conductivity, magnetic purposes etc.
The various Mechanical properties Concerned are strength in tensile,
Compressive shear, bending, torsional and buckling load, fatigue resistance, impact
resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness, wear resistance
and sliding properties.

The various properties concerned from the manufacturing point of view are,
 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.

MANUFACTURING CASE
Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of special
materials.
QUALITY REQUIRED
This generally affects the manufacturing process and ultimately the material. For
example, it would never be desirable to go casting of a less number of components which can
be fabricated much more economically by welding or hand forging the steel.

AVAILABILITY OF MATERIAL
 Some materials may be scarce or in short supply, it then becomes obligatory for the
designer to use some other material which though may not be a perfect substitute for the
material designed. The delivery of materials and the delivery date of product should also be
kept in mind.
SPACE CONSIDERATION
Sometimes high strength materials have to be selected because the forces involved are high
and space limitations are there.

COST
As in any other problem, in selection of material the cost of material plays an
important part and should not be ignored.
Some times factors like scrap utilization, appearance, and non-maintenance of the
designed part are involved in the selection of proper materials.

COST ESTIMATION

MATERIAL COST

S.No DESCRIPTION QTY MATERIAL AMOUN

T (Rs)
 1 RATCHET WHEEL 1 M.S 500

2 SPUR GEAR 1 M.S 500

3 FLOW CONTROL VALVE 1 ALUMINUM 500

4 WELDING NOZZLE 1 M.S 250

5 CONTROL UNIT 1 ELECTRONIC 800

6 PU TUBES 5 POLYURETHANE 200

meter

7 BASE 1 M.S 250

8 BASE UP PLATE 1 M.S 1660

Total 4660

LABOUR COST

LABOUR WORK QTY AMOUNT

FABRICATION MEN 2000

ASSEMBLY WORKS WORK

 COST ESTIMATION

MATERIAL COST
Material cost = 4660

LABOUR COST
Lathe, drilling, welding, drilling, gas cutting cost
Labour cost = 2000

TOTAL COST
Total cost = Material Cost +Labour Cost
= 4660 + 2000
Total cost for this project = Rs. 6660
RESEARCH GAP
The greatest disadvantage of hill holder mechanism is that it can hold the vehicle in the slope
for just two to three seconds. Though it avoids rolling back, the driver has to be alert. Besides
this, the system is expensive. These shortcomings are identified in hill holder mechanism and
the following problems are faced by the driver while the vehicle is driven in hill roads

Most of the drivers face difficulties while operating the brake, clutch and accelerator
simultaneously while driving the car in hill roads.
(Fig.1)

Figure 1: Schematic representation of operating the brake, clutch and accelerator

simultaneously

(ii) It is not advisable to use the hand brakes while the car is moving in forward movement.

Working Principle

In this work, Ratchet and Pawl mechanism is identified to arrest the backward motion to the
car. The ratchet is placed in the front drive shaft and the Pawl is fitted with the frame. When
the vehicle is moved in the hill road, the lever has to make the pawl to touch the ratchet. If the
vehicle tends to move backward direction, the pawl would stop the ratchet to move Counter
Clock-wise direction with respect to front wheel.
As the vehicle is in neutral position, the pawl engaged the ratchet and the vehicle did not
move in backward direction. So the hand brakes need not to be applied. When the vehicle is
in moving condition, the engagement between the ratchet and pawl is detached. The present
invention includes a standard Reverse Braking system in hill station vehicles. It is a
mechanical and electronics based device which provides skid free and steer ability while
braking. Usually, there is no other source to stop the movement when the hill station vehicle
is in reverse direction, this leads to skidding of the vehicle. Reverse braking system provides
a gear arrangement in the wheels, and a lever arrangement with one end of the lever is
attached to the wheel and other end is set between the teeth of the gear. When the wheel is
in normal direction the lever allows the gear to run along with the wheel, but when the wheel
is in reverse direction the lever set between the gear stops the movement of the gear which
tends to stop the rotation of the wheel. Thus the movement of the hill station vehicle is
stopped.

DESIGN OF RATCHET AND PAWL

The mechanism is designed for the different loading conditions. The circumference of the
front drive shaft of this car is measured and the diameter is determined as 23.89mm. The
weight and Torque of the car are 1060 Kg and 190N-m, respectively.
SLOPE OF THE ROAD:
Eg.The steepest road in India is ZOJI PASS in KASHMIR and the angle of inclination of the
road is found to be 21.80 degrees. The percentage slope there is about 40 %.

The fabricated mechanism is fitted in drive shaft for testing experimentally to check whether
the functionality has been achieved (Figure 5). The hand driven lever is turned in forward
direction, similar to forward motion of the car, the pawl does not stop the ratchet to rotate.
The hand lever is turned in opposite direction similar to the reverse motion of the car in the
hill road, and the pawl stops the rotation of the ratchet. So, the drive shaft and the wheels did
not rotate. Therefore the reverse motion of the wheels is arrested. The same can be achieved
if this model is fitted in the car. This will be the case while fitting this mechanism in the drive
shaft of the car. When it has been done the car cannot move in reverse direction in the slope
as the pawl locks the ratchet.

Advantages
Safe and secured journey on th inclined road Simple mechanical arrangement.
Disadvantages
Connecting the ratchet wheel to the front wheel hub is expensive.
CONCLUSION
Thus the mechanism can stop the vehicle from rolling back in hill roads. This would be more
helpful for the drivers to drive their cars comfortably in hilly roads and he can take off the car
in the uphill without rolling back the car.
REFERNCES:
[1] T.J. Prabu-Design ofTransmission system,
[2] Transport Research Wing, “Road Accidents in India”, Ministry of Road Transport and
Highways, India, 2011.
[3] The New In-Depth, At-the-Scene, Accident Investigation Database in India by
N.Rameshkrishnan, A. Sathyakumar, S. Balakumar, A. M. Hassan, R. Rajaraman, J.
Padmanaban.
[4] Mahesh shahapuri-Anti-roll back system for manual transmission vehicles (WO
2013024491 A2)
[5] Cook George -Anti creep and hill holder brake system (US 2938611 A)
[6] William kent-Improved release mechanism for a hill holder device.
[7] Grzegorz Janiszewski-Improved release mechanism for a hill holder device.
[8] William K. Messersmith-Release mechanism for a hill holder device.
[9] Alvin H. Berger-Vehicle transmission hill holder.