ARUSHA TECHNICAL COLLEGE

JUNCTION OF MOSHI - ARUSHA AND NAIROBI ROAD

P. O.BOX 296, ARUSHA - TANZANIA
TELEPHONE; +255- 27-2503040 /2502076, FAX:+255-27-2548337
WEBSITE: http://www.atc.ac.tz,E-MAIL:[email protected]

AUTOMOTIVE ENGINEERING DEPARTMENT

ORDINARY DIPLOMA IN AUTO ELECTRIC ENGINEERING PROGRAMME
N.T.A LEVEL 06
PROJECT TITLE: DESIGN AND FABRICATION OF EMERGENCY BRAKE SYSTEM IN
FOUR WHEEL DRIVE
PRESENTED BY: JANETH ELPHAS 19010102019
RAMADHANI KALEYA 20010112040
INNOCENT KIMATH 20010112021

SUPERVISOR NAMES: Dr. PETER MASHINGO

Eng. CASTORY MKUMBA
Sir: DENIS MATIKO

PROJECT COORDINATOR: Eng. SEBA MAGINGA

2022/2023
 CERTIFICATION

The undersigned certifies that they have accept project proposal and here by recommend for
acceptance by ARUSHA TECHNICAL COLLEGE(ATC) a project entitled “DESIGN AND
FABRICATION OF EMERGENCY BRAKE SYSTEM”. Partial fulfillment of the requirement
for the ordinary diploma in Auto-electric and Electronic Engineering in ATC under NACTE act.

Dr. Peter Mashingo

Signature…………….
Date……………….
Eng. Castory Mkumba
Signature…………….
Date………………….
Denis Matiko
Signature…………….
Date …………………

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 DECLARATION
We hereby declare the project work entitle “DESIGN AND FABRICATION OF
EMERGENCEY BRAKE SYSTEM” Submitted to the Arusha Technical Collage Department of
Automotive Engineering, is record of an original work done by us under the guidance of our
supervisor and coordinator, and this project work is submitted in the fulfillment of the
requirement for the award of the Diploma in Auto-electrical and Electronic Engineering.

Name of students:
Ramadhani Kaleya 20010112040
Signature………………….
Innocent Baraka 20010112021
Signature…………………...,
Janeth Elphas 19010102019
Signature……………………..

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 DEDICATION

This project is dedicated to The Principle of ATC, Head of Automotive Engineering and my
fellow colleagues for their advice, co-operation, encouragement, love, sincere and help they
showed to us during the period of our study. GOD blesses you all.

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 ACKNOWLEDGEMENT

We are so grateful to those helped us directly or indirectly in preparing this valuable work. It
could be impossible to complete this work without their heartily assistance and encouragement.
However, it is difficult to mention all by their given names in this print of paper. First of all, We
would like to thank God Almighty for rewarding health and mental prowess necessary to
accomplish this task.
Secondly, We are highly indebted to our supervisors, for their voluntary effort to see us complete
this work regardless various challenges we faced. May almighty God be with them.
Thirdly, we would like to extend our sincerely thanks to the Arusha Technical College for
granted permission for proceeding with this project. Besides, we express our inner gratitude to all
Automotive Department staff for their unwavering support and guidance without forgetting all
respondents who contributed to this proposed project which are difficult to mention one after
another.
Fourth, we could feel guilty if we forget to thank our classmates for their support that enable the
success of this report at hand. They spared their time and agreed to participate in the project
proposal and report at hand. May almighty God reward them all.

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 ABSTRACT

This project work is about “Design and Fabrication of Emergence brake system” use of
innovative technology for the purpose of preventing accident happen in restricted road way. This
system based on intelligence or emergency control adopted in four wheel, with supportive of
sensor, micro controller, battery, warning light, wheel tire composition with the brake. The
related work on this system was synthesis, analyses, interpreted and critically evaluated and then
short summary was provided. By research in past project, substantive finding as well as
theoretical and methodological contribution. The best solution was provided for proposed a
system. The system like Anti-lock brake system, hand brake (emergency brake system). Journal
and books related to brake system and supportive of emergency system was review in order
consider the best and alternative solution for the accident avoidance. Literature review was a part
also taken under consideration, method of reaching a goal of project provided through data
collection, data analysis, circuit design, develop of source code, simulation, circuit
implementation was set up as technique or procedure to be followed in order to archive a goal of
this project. The success of intelligence (emergence) brake system will help the driver and road
user on avoidance of accident under different condition and vehicle maneuvering.

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 TABLE OF CONTENT

CERTIFICATION.....................................................................................................................i
DEDICATION........................................................................................................................iii
ACKNOWLEDGEMENT......................................................................................................iv
ABSTRACT.............................................................................................................................v
CHAPTER ONE............................................................................................................................1
1.0: Introduction............................................................................................................................1
1.1: Historical background....................................................................................................1
1.2: problem statement...........................................................................................................2
1.3: The objectives Of The Project........................................................................................2
1.3.1 The main objectives of the project...............................................................................2
1.3.2 The specific objectives of the project...........................................................................2
1.4: Significance of the project..............................................................................................3
CHAPTER TWO......................................................................................................................4
LITERATURE REVIEW.................................................................................................4
2.1: Introduction............................................................................................................................4
2.2: Existing system of brake........................................................................................................4
2.2.1 Design and Development of Hand Brake Release System.....................................................4
2.3: Proposed system.....................................................................................................................6
2.3.1 Description of Proposed System..........................................................................................6
ii. Control unit...............................................................................................................................7
iii. LED display system...........................................................................................................7
iv. Power supply.....................................................................................................................7
CHAPTER THREE...........................................................................................................8
3.1 Introduction..............................................................................................................................8
3.2: Project setup;............................................................................................................................8
3.2.1 Qualitative and quantitative collection...................................................................................8
3.2.2 Equipment/Accessories...........................................................................................................8

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3.2.3 Arduino UNO Source Code Programming.............................................................................9
3.2.4 Circuit design..........................................................................................................................9
3.2.5 Circuit implementation and prototype test.............................................................................9
CHAPTER FOUR..................................................................................................................10
4.0: Ideal budget............................................................................................................................10
CHAPTER FIVE....................................................................................................................11
5.0:The project schedule................................................................................................................11
References......................................................................................................................................12

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 CHAPTER ONE
1.0: Introduction
An emergency brake system is a reliable system which is used to detect if there is a risk of
collision of vehicle or with pedestrian by alert the driver through visual and detecting sound. The
system will monitor and control the application of brake with micro controller, based on the
detection pulse information.

1.1: Historical background

This chapter provides introductory information about the historical background of the project,
statement of the problem, aim of the project, significance and scope of the project. In earlier
1800’s the first mechanism to slow a vehicle momentum and prevent motion were tested, and
over 100 years later the brake system has evolved in to complex, device designed to adapt to
different road condition. From the early drum brake to modern day disk, the brake system
evolution has improved safety and reduce the risk of car crushes or collision. Under the form of
brake that existed over century, it hard to pinpoint the inventor of the original brake system,
however those designed system share common goals, to make possible for human to control
another vehicle, with goal to create safer condition, innovators over the years brought new
technologies to the braking system, improving on the original ideas. Development of brake
system is based on number of priorities of improving auto safety and efficiency, it was beginning
since 19th century, and continues today, the types of braking systems that have been used over
the years include:

Wooden block brakes, the earliest brake system applied the physical principles used to design
brakes today; however, the system consisted only of wooden blocks and a single lever used by
the driver to apply the brake. This form was used on vehicles with steel-rimmed wheels,
including horse-drawn vehicles and steam-driven automobiles.

Mechanical drum brakes, considered to be the foundation of the modern braking system, the
mechanical drum brake was developed in 1902 by French manufacturer Louis Renault, but had
been invented earlier by Gottlieb Daimler. Daimler had theorized that anchoring a cable-wrapped
drum to the vehicle’s chassis could be used to stop momentum, thus creating the first concept of
the drum brake

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Hydraulic brakes, in 1918, the concept of a four-wheel brake system using hydraulics was first
proposed by Malcolm Long head. The system used fluids to transfer force to the brake shoe
when a pedal was pressed. This braking system was adopted in nearly every vehicle by the late
1920’s.

Disc brakes, the disc brake was invented long before becoming popular. William Lancaster
patented the disc brake in 1902; the system was not popular until the auto industry began to
boom in the mid-20th century. The rise of disc brakes as a popular option is attributed to the
increasing weight and speed capabilities of vehicles, which caused hydraulic brakes to become
less efficient in distributing heat. The first system to use disc brakes integrated both disc and
hydraulic functions and was introduced in the Chrysler Imperial.

Anti-lock brakes, the anti-lock brake system, better known as ABS, was created to assist
previous braking systems to prevent the brakes from locking up while in use. ABS works by
sensing when a lock is about to occur and igniting a system of hydraulic valves to reduce the
pressure of a brake on a single wheel. The system revolutionized the way brake’s function and is
useful in providing more control for the modern days.

Such innovation has led to increase safety on road and few accidents, unfortunately brake can
still fail and car crushed are not always avoidable. This project proposes a very convenient
solution for maintained and control the brake system under difficult operation of the vehicle and
unpredictable situation.

1.2: problem statement

The primary brake system work through hydraulic system, handbrake system with a purpose to
slow or stop vehicle but effect and impact of accident still occur, this effect of accident can be
caused by the driver’s delaying in applying the brake or brake failing. The system that will be
installed will assist and help driver by monitor, detect the front condition and avoid collision to
overcome.

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 1.3: The objectives Of The Project
The objectives of this project are;
1.3.1 The main objectives of the project
The main objective of this project is to design and fabricate emergency(intelligence) brake
system in four-wheel drive
1.3.2 The specific objectives of the project
The following specific objective of this project;
i. To design a teaching module that will be helpful to continuous student.
ii. To manufacture the simple layout of the system.
iii. To make the model that will be stable and permanent last in time.

1.4: Significance of the project

The following are the significance of the project;
i. It increase means for practical studying.
ii. It increase knowledge among the student on how the actual system work.
iii. Emergency brake system prevent lock up and skidding even in slippery condition.
iv. Intelligence brake system coordinate the wheeler activity with sensor on each wheel that
regulate brake pressure as necessary, so the wheel operate in similar speed range.

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 CHAPTER TWO

LITERATURE REVIEW

2.1: Introduction
This chapter gives general overview of the system and conceptual frame work of study about
design and fabrication of emergence brake system in four-wheel drive.it describe the existing
system and it’s draw back that result the need of new proposed system.

2.2: Existing system of brake

2.2.1 Design and Development of Hand Brake Release System

This system provides a brand-new idea style of the electro mechanical parking brakes system
that has straightforward and cheap characteristics. The system deals with coming up with the
fabrication of Electro mechanical brake system. Mechanical device hand brake system conjointly
remarked as brake by-wire, replace typical early braking systems with a totally electrical part
system. This happens by replacement typical linkages with electrical motor-driven units. The
braking force is generated directly at every wheel by high performance electrical motors and
automobile management, that area unit controlled by an ECU. The electronic hand brake
replaces the traditional handbrake. It's operated by a switch within the center console. The
mechanical device hand brake provides the subsequent edges over the traditional handbrake:
easy use-the hand brake is applied totally no matter the strength of the driving force. Safety-the
electrical hand brake applies mechanically once the key is off from the ignition.

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2.2.2 Automatic emergency brake system
Automatic Emergency Braking (AEB) is a braking system which helps to apply brakes
automatically under the condition of emergency and helps to mitigate the severity of a crash.
This paper deals with the study of designing and working of automatic emergency braking
system using the various fundamentals of mechanical and electronics engineering. In this system
capacities proximity Sensors with the combined use of Stereo Cameras will detect an obstacle in
front of the vehicle and it will tell us the relative distance between the obstacle and the vehicle.
The ECU will then judge if an accident is likely to happen or not and the brakes will be applied
automatically under this system to reduce the impact of speed or mitigate the effects of head on
crashes, rear end crashes, right turn crashes and pedestrian crashes. Automatic Emergency
Braking (AEB) is an emerging form of Advanced Driver Assisted Systems (ADAS) which works
on the principle of electronically controlled Ultrasonic Sensors which analyze and sense the
speed of the Vehicle coming, and thus helps to apply AEB system into working. (Barry,2017).

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www.innovationdiscoveries space, this site describes the function operation and wiring
connection of this system
2.3: Proposed system
The emergency brake system initially use Ultrasonic sensor that transmit the ultrasonic waves in
range of frequency. If there’s any obstacle in the path, the ultrasonic waves gets reflected. This
reflected ultrasonic waves are received by the Ultrasonic sensor. The Ultrasonic sensor receives
the reflected ultrasonic waves and also the signals are passed to the micro controller which has a
timer circuit,this will inform the motor driver for stopping the voltage supplied and therefore the
brakes are applied.

In this automatic braking system , there’s a four wheel cart driving which rear wheels are being
motorized for drive wheel. The drive of the car is by switch and motor operated. One sensors are
used for front to avoiding damage to the car at the time of crash. The sensors used are a ultra
sonic sensor which might sense both metal and non-metal obstacles. Also one relays are used

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after the sensors which activate the braking motor when obstacles are sensed in forward
direction.

2.3.1 Description of Proposed System

The followings are the description of the proposed system as shown in figure 4.

LED DISPLAY

SUPPLY (9V)

MICROCONT MOTOR
ROLLER DRIVE
ULTRA
SONIC

MECHANICAL
BATTERY ARRANGEMENT
(12V) RELAY

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 i. Input devices
The sensors is used to provide to signals from the environment to control unit. Ultrasonic sensor
are used to detect the signal and converting in electrical form in such that control unit can
understand for processing.
ii. Control unit
The control unit use binary decoder to convert coded instructions into timing and control signals
that direct the operation of other units namely inputs and outputs devices. The control unit
receives signal from the sensors and process that signal to the desired format that can be
displayed and direct operations to output devices. Appropriate program was written and
uploaded to the control unit so as to operate according to requirements of system.
iii. LED display system
The system designed imposed with indicator lamp to show signal during the time sensor detect
the effect of obstacle, and its goes off if there is no bill heading.
iv. Power supply
The circuit is used for supplying power to the chicken rearing system, for operation of the
system. The circuit was providing low d.c voltages needed to operate in electronic devices and
a.c high voltage to operate ac devices.

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 CHAPTER THREE

METHODOLOGY
3.1 Introduction
This chapter explains various steps that will be taken in order to accomplish the project
objectives. This chapter describes in details project setup, equipment/accessories, circuit design
in Proteus, Proteus circuit programming and simulation, PCB layout, Arduino UNO source code
programming and prototyping as follows:

3.2: Project setup;

Project setup was involved on determination expectations and features of system for establishing
useful mechanism. Project setup was need collection and analysis of information from literature
review. This method involved analysis of collected information so as to avoid features creep and
ensuring the system will operate under condition as required for safety reason. Project setup was
accomplished through qualitative and quantitative data collection and analysis method as
explained hereunder.

3.2.1 Qualitative and quantitative collection

Methods were used for gathering of information from different sources like website, internet,
books, and other ideas from mechanics, fellow students and supervisor so as to have useful data
for proposed operated mechanism. Observation of the few past work to this mechanism were
involved and other area like electronic shops were involved for explaining, analyzing,
interpretations and categorized all requirements of the project and data collection. These methods
are tool for data analysis for setting up the project as expected. Qualitative and quantitative
methods allow exploration of concepts, electronics devices, test hypothesis and experience for
proposed system in more details.

3.2.2 Equipment/Accessories

Equipment was identified and analyzed so as to accomplish the proposed system designing. And
also, to have devices that meet requirements of project. The component specification was

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detailed, focusing on what the proposed system is to do, the specification of ultrasonic sensor,
motor driver, power supply, wheel drive, relay, motor, were collected and analyzed. Equipment
was selected based on requirement analysis in project and specification of components. Proteus
and Arduino program software technologies were used to designing the circuit for electrical and
electronic components connection.

3.2.3 Arduino UNO Source Code Programming

Arduino IDE software was used in the project to program source code and upload it to the
Arduino board of micro controller for interfacing and controlling of the circuit. The source code
programming was involved systematic procedure to achieve the goal. To start the Arduino IDE,
all programs should be installed and corrected inputs and outputs ports of micro controller should
be recognized as shown in schematic capture and interfaced with other peripherals.

3.2.4 Circuit design

The circuit design will base on information collected in order to meet the objective of the project.
This section will involve the physical layout of the circuit by using available and required
material resource. Different parts of this system after design will be simulated in order to observe
results of each part before implementing the complete circuit.

3.2.5 Circuit implementation and prototype test

Circuit implementation will involve the implementing of the circuit as a prototype designed
ready for the test.

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 CHAPTER FOUR

4.0: Ideal budget

NAME OF ITEM
ITE SPECIFICATION QUANTITY PRICE
M
NO.

1. Automobile 1 200,000/=
battery

2. Electric motor 1 260,000/=

3. Control switch 1 25,000/=

4. Arduino UNO 1 50,000/=

5. Ultra sonic sensor 1 35,000/=

6. Positive cable 1 22,000/=

7. Negative cable 1 20,000/=

8. Relay 1 20,000/=

9. Chain drive 1 45,000/=

10. Sprocket (key 2 90,000/=

way)

11. Frame 100,000/=

12. Wheel 4 160,000/=

13. Motor drive 1 70,000/=

14. Screw 5000/=

15. Light emitting 1 3000/=

diode(LED)

Total 1,105,000/=

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 CHAPTER FIVE

5.0:The project schedule

Activity SEMISTER 1 SEMISTER 2
Nov Dec Jan Feb April May June July
Project
proposal and
development
Literature
review
Modeling of
circuit
Material
selection and
calculation
design
Material
purchasing and
preparation
Developing of
the system
Testing of the
system
Presentation of
the system

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References

Andrews, M. (2014.). "Intelligent Braking Systems: Developments and Future Trends" . Cambridge, UK,:
Woodhead Publishing.
Bert Breuer, S. (2014). Brake Technology Handbook. Germany: Bosch.
Egardt, B. (2013). Advances in Automotive Control. London, UK: Springer.
Fridman, L. (2014). Advanced Vehicle Control Systems: Intelligent Driving and Control Systems.
London, UK: Springer.
G. Genta, T. ( 2019.). "Advanced Braking Systems and Control". Italy: Springer.
Houshmand, N. ( 2016). Modern Braking Systems. Tehran, Iran: Springer.
International, S. ( 2016). Automotive Braking Systems. Warrendale, USA: SAE International.
Lian, G. (2018). Intelligent Transport Systems and Control. Beijing, China: CRC Press.
Matsuda, T. ( 2016). Intelligent Brake Systems. Osaka, Japan: Springer.
Matsuda, T. (2016.). Intelligent Brake Systems. Osaka, Japan: Springer.

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