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Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
1
Design and fabrication of seat belt-controlled hand
brake system with ignition control
M.Saravanakumar1, S.Prakash1, Nidhin S Kumar2, B V Gautham2,
Bijoy Mathew2
1Assistant Professor, Department of Mechanical Engineering, Aarupadai Veedu
Institute of Technology, VMRF, Chennai.
2UG Students, Department of Mechanical Engineering, Aarupadai Veedu Institute of
Technology, VMRF, Chennai
E-mail: sarov003@gmail.com
Abstract. Either link or bar linkage is utilized in a hand slowing mechanism to interface the
different segments together. The general pattern is to utilize a link for vehicles and vans,
and bars just for substantial business vehicles. We don't change any unique frameworks
that are remembered for the vehicle however we incorporate some additional segments into
it. As a result of that process changes occurs in the whole safety systems in it. This
progression will help the travelers just as the driver to guarantee security while beginning
the vehicle from the underlying point itself. In this endeavor a rack and pinion strategy
changes over the vertically dropping improvement of the seat strap catch as it is chopped
down into rotating development. It is then transmitted to an apparatus joined to the base of
the hand brake through a pole. The rigging is associated with a rack. The flat development
of the rack is changed over to vertical development used to bolt or discharge the discharge
switch of the handbrake switch. Additionally, with the assistance of press switch we can
control the start on and off procedure. The LED pointers associated with this press switch
will give exact situation of hand brake. Henceforth we can undoubtedly control it and start
the vehicle. Rack and pinion has been in presence since the improvement of designing. It is
one the most significant and basic segment utilized in building.
We are utilizing rack and pinion component to the hand stopping mechanism to bolt
hand brake until the safety belt is locked in. The slowing down power is produced
legitimately at each wheel by elite electrical engines and vehicle the executives, that region
unit constrained by an ECU. The electronic hand brake replaces the conventional
handbrake. It's worked by a switch inside the middle reassure. The mechanical gadget hand
brake gives the ensuing edges over the conventional handbrake: simple use-the hand brake
is applied absolutely regardless of the quality of the main impetus. Wellbeing the electrical
hand brake applies precisely once the key is off from the start.
Key Words: Smart handbrake, Automobile, Conventional, Automatic.
1. Introduction
Conventional hand brake feat involves the human interference. While not pull or pushing the
switch, the hand brake won't work. Also, generally as a result of negligence or in emergency
conditions, we humans have a tendency to usually forget to use parking brakes. This could bring
about moving of auto just if there should arise an occurrence of slants and crash with various
vehicles in leave [1]. Consistent improvements in dynamic wellbeing and upgrades with
connection to the dependableness and extravagance of activity imply that mechanical
handbrakes are continuously being supplanted via programmed mechanical gadget frameworks
In this project a rack and pinion arrangement convert the vertically downward
movement of the seatbelt hook as it is clipped down into rotating motion. It is then transmitted
to a gear attached to the base of the hand brake through a shaft [2]. The gear is connected to a
rack. The horizontal movement of the rack is converted to vertical movement used to lock or
release the release switch of the handbrake lever. Also, with the help of press switch we can
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
2
control the ignition on and off process. The LED indicators connected with this press switch will
give accurate position of hand brake. Hence, we can easily control it and start the vehicle [3-4].
Rack and pinion has been around since engineering grew. This is one of the most basic
and important components used in engineering. A rack and pinion are a type of linear actuator
comprising a pair of gears that transform rotational movement into linear movement. A circular
gear called "the pinion" engages teeth on a linear "gear" bar called "the rack"; rotational motion
applied to the pinion causes the rack to move relative to the pinion, thereby translating the
rotational motion of the pinion into linear motion.
We are using rack and pinion mechanism to the hand brake system to lock hand brake
until the seat belt is engaged. This new safety feature resists any vehicle owner to not drive a
vehicle without wearing a seat belt [5-6]. In India many safety features like ABS, airbag is an
additional feature. We want to pay more money to get these features, and yes luxuries vehicles
have them but the common man has to take the risk not having them and also many of them are
ignorant of safety in vehicles. Now in basic model cars which most of us can afford, only
seatbelt is the safety feature available. So, putting them on is most important while in driving
[7].
2. Objectives
1. To develop automation unit to reduce human manual interaction.
2. To make use of seatbelt mandatory.
3. Prevent damage of the engine due human error.
4. Make the system available at low cost.
5. To maintain the correctness in hand brake operation in case of hand brake is not fully remove
or lock in case of emergency braking system action
3. Problem statement
Handbrake (Parking brake) is the mechanism used for well-being in the car. The traditional
machine works by manually operating the handbrake lever. Under this setting, the brakes
remain connected even while the car is going because of manual blunders. This condition
causes safety hazards which may cause damage the system components. During travel on the
steep slope in upward direction, if the vehicle accidently goes into neutral or engine stops, the
tendency of the vehicle is roll backwards; here we need the downhill locker. It is compulsory for
the driver to wear safety belt or wellbeing however it is regularly ignored and may demonstrate
deadly if vehicle meets with a mishap.
4. Work methodology
Either cable or rod linkage is used in a hand brake system to link the various components
together. The general trend is to use a cable for cars and vans, and rods only for heavy duty
commercial vehicles. We don’t change any original systems that are included in the vehicle but
we include some extra components into it. As a result of that process changes occurs in the
whole safety systems in it. These changes will help the passengers as well as the driver to ensure
safety while starting the vehicle from the initial point itself.
Figure 1 Fabrication of seatbelt frame
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
3
4.1 fabrication and working
Figure 1, shows the fabrication of seatbelt frame, first the rack is attached to the bottom of the
seatbelt buckle such that the vertical movement of the rack can be obtained.
4.2 Hand Brake or Parking Brake
While the foot-slowing mechanism retards or stops a moving vehicle, the hand stopping
mechanism forestalls the vehicle moving once it is left. Since the hand-slowing mechanism
might be in activity for exceptionally prolonged stretch of time period, a linkage instrument
separate from that of the water driven foot-brake circuit is introduced. Stopping brakes are
commonly given uniquely on the back-street wheels.
4.3 Pull-twist Handgrip Lever.
This course of action utilizes a roundabout draw bar with ratchet teeth cut on one side.
Two pawls draw in these teeth. A peg, embedded close to the lower end of, as far as possible the
free bend development to around 90 degrees. For applying the stopping brake, the handgrip is
curved to move the wrench teeth from the pawls. This activity causes the pawl edges to interact
with the smooth surface bit of the draw-bar. At the point when the bar is pulled out
4.4 Pull-press-button Hand-Lever (Light-duty).
This development, the most well-known sort at present, utilizes a hand-switch. One finish
of the hand switch is associated straightforwardly to the brake link while the opposite end
shapes the handgrip, with a discharge press button. This switch is turned on a wrench section.
At the point when the driver pulls up the switch arm, the spring-stacked pawl slides over the
fastener teeth causing most extreme link pressure. Now the switch is discharged, and the
vehicle leave pulls up the hand switch somewhat
5. Results and Discussion
The design and fabrication of Seatbelt Controlled hand braking system with ignition control is a
simple and cost effective is majorly focused on the automotive safety study and practice of
design, construction, equipment and regulation to minimize the occurrence and consequences
of traffic collisions involving motor vehicles. Road traffic safety more broadly includes roadway
design.
One of the first formal academic studies into improving motor vehicle safety was by Cornell
Aeronautical Laboratory of Buffalo, New York. The main purpose is analyzed with this work is
the crucial importance of seat belts and padded dashboards. However, the primary vector of
traffic-related deaths and injuries is the disproportionate mass and velocity of an automobile
compared to that of the predominant victim, the pedestrian.
5.1 Pinion and rack on seatbelt side
1. Outer diameter of pinion = 37mm
2. Outer circle circumference of the pinion = 116.23mm
3. Movement of rack = 13mm
4. Therefore, length of rack = 75mm
5. Number of teeth on pinion = 22
6. Number of teeth required on rack = 15
7. Module = 2
8. For 13 mm movement of rack the pinion rotates 40°
9. Number of teeth that comes in contact with gear = 5
10.Therefor actual number of teeth on rack = 15 (for safety).
5.2 Pinion and rack connected to handbrake
1. Length of rack = 75mm
2. Number of teeth comes in contact with rack = 5
3. Angle rotated by gear = 40°
4. Distance moved by rack = 13 mm
5.3 Dimensi0ns of shafts and hole
1. Diameter of shaft = 8mm
2. Length of shaft connected to handbrake = 65mm
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
4
3. Length of rectangular shaft = 60mm
4. Breadth of rectangular shaft = 12mm
5. Height of rectangular shaft = 10mm
6. Diameter of shaft connecting pinion = 8mm
7. Length of shaft connecting pinion = 60mm
8. Diameter of hole on handbrake = 8.5mm
5.4 Movement of rack
1. Movement of the seatbelt clip = 13mm
2. Vertical movement of rack = 13mm
3. Angle rotated by pinion = 40°
4. Horizontal movement of rack = 13mm
5.5 Calculation of shaft diameter
Torque T = d³
T =2000Nmm; τ = 30N/mm²
x30xd³ d = 6.97mm
Standard diameter = 8mm
5.6 Design of spur gear
Table 1 Design of spur gear procedure
step 1 Gear ratio i = �z1z2� i = 1
step2 Selection of material carbon steel
step3 Calculation of gear life � = �������
step4 Initial design torque [mt] [mt] = mt. k. kd
k. kd = 1.3(assume)
t= mt =
��
����
mt = 0.167× 10�n/mm
step5 Calculation of eeq, (σb), (σc)
eeq =2.15× 10�n/mm�
(σb)= �.�×����×�� × σ��
(σb) = 169.16n/mm�
(σc)= c�hrck�� =823.48/mm�
step6 Calculation of centre distance
(a) a ≥ (i + 1) ��0.74�
σc� × e[mt]iφ "#
a = 39.6mm
step7 Pinion and gear teeth (z1, z2) z1=22teeth
z2= i z1 =22teeth
Step 8 module (m) m= �$(%�&%�)
m = 1.8 ≈ 2
Step 9 Revision of centre distance a=m
%�&%�� �
a= 44mm
Step 10 calculation of b, d�, v, and φ�
1 φ = �$ , b= 13.2mm
2 d� = mz�, d� = 44mm
3 v = �*��
�
,v =0.02m/s
4 φ� = �$,, φ� = 0.3
Step 11 Selection of quality of gear “is quality 10 “, is selected
Step 12 Revised design torque[-/] [mt]=mt. k. kd [mt] = 0.242 × 10�n/mm
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
5
Step 13 check for bending stress
σ� = (i + 1)amby [mt] ≤ [σ�]
σ� = 90 n/mm�
design is safe
Step 14 Check for wear stress σ� = 0.74 i + 1a �i + 1i × b e × [mt]
≤ [σ�] σ� = 624.66n/mm�
design is safe
Table 1, shows the design of spur gear is safe. So, we can proceed the following design, for the
design of rack and pinion the diameter of the pinion, the pitch, module etc. has to be calculated.
The movement of the rack and the corresponding rotation of the pinion have to be calculated.
Now the movement of the pinion is transmitted to the second pinion which in turn rotates the
second rack that is used to lock the handbrake. First the rack is attached to the bottom of the
seatbelt buckle such that the vertical movement of the rack can be obtained; the vertical
movement of the rack rotates the pinion. The rotation of the pinion is transmitted to the second
pinion using a shaft. Now the rack connected to the second pinion moves horizontally.
A rod connected to the end of this rack is inserted top the handbrake and thus the handbrake is
locked into place. When the seatbelt clip is inserted the process is reversed and the hand brake
will be free to be engaged. The whole arrangement is mounted on a frame. The design of the
seatbelt clip is altered for easier working of the system. With the help of press switch we can
control the ignition system. The controlling will be indicated with the help of led lights.
6. Conclusions
Some have proposed that the number of deaths was influenced by the development of risk
compensation, which says that drivers adjust their behavior in response to the increased sense
of personal safety wearing a seat belt provides. In one trial subjects were asked to drive go-karts
around a track under various conditions. It was found that subjects who started driving
unbelted drove consistently faster when subsequently belted. Similarly, a study of habitual non
seat belt wearers driving in freeway conditions found evidence that they had adapted to seatbelt
use by adopting higher driving speeds and closer following distances.
References
[1] Rohit Khubalkar et.al., Apr 2019 Modification and Implementation of Automatic Hand Brake System
using Sensor, International Research Journal of Engineering and Technology (IRJET) Volume: 06
Issue: 04
[2] S. Thivagar, C. Nantha Kumar, Feb-2016 “Automatic Hand Brake System”, International Journal of
Engineering Research and General Science, Vol-04, Issue-01.
[3] Rohan E. Dalvi, Ramesh G. Sutar, Prashant H. Karke, Jitendra B. Satpute, May-2017 “Design and
Development of Hand Brake Release System”, Global Research and Development Journal for Engineering,
Vol-02, Issue-06.
[4] Telore Sanket, Mr. Shubham Dhikale, Mr. Pawar Kalpesh, Miss. Sayyed Shayka, Prof. Kshatriya
Vaibhav G., Jan-2017 “Seatbelt Activated Handbrake System”, International Journal of Innovations in
Engineering Sciences and Technology, Vol-03, Issue-01.
[5] Gokul Gopan, Gopikrishnan EJ, Gritto Joseph Cherian, Jacob Shibu Samuel, Sreejith R, April-
2017 “Development of Automatic Hand Brake System”, International Journal for Innovative Research in
Science & Technology|, Vol-03, Issue-11.
[6] Sachin S. Dharia, Sachin S. Bhopale, Prathmesh P. Kumbhar, Kedar S. Pathak, May-2016
“Advancements in Automatic Hand Brake System”, 4th International Conference on Science, Technology
and Management.
[7] Amit B. Maske, S. B Tuljapure, P. K Satav, July-2016 “Design & Analysis of Parking Brake System of
Car”, International Journal of Innovative Research in Science, Engineering and Technology, Vol-05,
Issue- 07.
Reproduced with permission of copyright owner. Further reproduction
prohibited without permission.
– MSEM9931011
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**## Design_and_fabrication_of_seat.pdf**
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
1
Design and fabrication of seat belt-controlled hand
brake system with ignition control
M.Saravanakumar1, S.Prakash1, Nidhin S Kumar2, B V Gautham2,
Bijoy Mathew2
1Assistant Professor, Department of Mechanical Engineering, Aarupadai Veedu
Institute of Technology, VMRF, Chennai.
2UG Students, Department of Mechanical Engineering, Aarupadai Veedu Institute of
Technology, VMRF, Chennai
E-mail: sarov003@gmail.com
Abstract. Either link or bar linkage is utilized in a hand slowing mechanism to interface the
different segments together. The general pattern is to utilize a link for vehicles and vans,
and bars just for substantial business vehicles. We don't change any unique frameworks
that are remembered for the vehicle however we incorporate some additional segments into
it. As a result of that process changes occurs in the whole safety systems in it. This
progression will help the travelers just as the driver to guarantee security while beginning
the vehicle from the underlying point itself. In this endeavor a rack and pinion strategy
changes over the vertically dropping improvement of the seat strap catch as it is chopped
down into rotating development. It is then transmitted to an apparatus joined to the base of
the hand brake through a pole. The rigging is associated with a rack. The flat development
of the rack is changed over to vertical development used to bolt or discharge the discharge
switch of the handbrake switch. Additionally, with the assistance of press switch we can
control the start on and off procedure. The LED pointers associated with this press switch
will give exact situation of hand brake. Henceforth we can undoubtedly control it and start
the vehicle. Rack and pinion has been in presence since the improvement of designing. It is
one the most significant and basic segment utilized in building.
We are utilizing rack and pinion component to the hand stopping mechanism to bolt
hand brake until the safety belt is locked in. The slowing down power is produced
legitimately at each wheel by elite electrical engines and vehicle the executives, that region
unit constrained by an ECU. The electronic hand brake replaces the conventional
handbrake. It's worked by a switch inside the middle reassure. The mechanical gadget hand
brake gives the ensuing edges over the conventional handbrake: simple use-the hand brake
is applied absolutely regardless of the quality of the main impetus. Wellbeing the electrical
hand brake applies precisely once the key is off from the start.
Key Words: Smart handbrake, Automobile, Conventional, Automatic.
1. Introduction
Conventional hand brake feat involves the human interference. While not pull or pushing the
switch, the hand brake won't work. Also, generally as a result of negligence or in emergency
conditions, we humans have a tendency to usually forget to use parking brakes. This could bring
about moving of auto just if there should arise an occurrence of slants and crash with various
vehicles in leave [1]. Consistent improvements in dynamic wellbeing and upgrades with
connection to the dependableness and extravagance of activity imply that mechanical
handbrakes are continuously being supplanted via programmed mechanical gadget frameworks
In this project a rack and pinion arrangement convert the vertically downward
movement of the seatbelt hook as it is clipped down into rotating motion. It is then transmitted
to a gear attached to the base of the hand brake through a shaft [2]. The gear is connected to a
rack. The horizontal movement of the rack is converted to vertical movement used to lock or
release the release switch of the handbrake lever. Also, with the help of press switch we can
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
2
control the ignition on and off process. The LED indicators connected with this press switch will
give accurate position of hand brake. Hence, we can easily control it and start the vehicle [3-4].
Rack and pinion has been around since engineering grew. This is one of the most basic
and important components used in engineering. A rack and pinion are a type of linear actuator
comprising a pair of gears that transform rotational movement into linear movement. A circular
gear called "the pinion" engages teeth on a linear "gear" bar called "the rack"; rotational motion
applied to the pinion causes the rack to move relative to the pinion, thereby translating the
rotational motion of the pinion into linear motion.
We are using rack and pinion mechanism to the hand brake system to lock hand brake
until the seat belt is engaged. This new safety feature resists any vehicle owner to not drive a
vehicle without wearing a seat belt [5-6]. In India many safety features like ABS, airbag is an
additional feature. We want to pay more money to get these features, and yes luxuries vehicles
have them but the common man has to take the risk not having them and also many of them are
ignorant of safety in vehicles. Now in basic model cars which most of us can afford, only
seatbelt is the safety feature available. So, putting them on is most important while in driving
[7].
2. Objectives
1. To develop automation unit to reduce human manual interaction.
2. To make use of seatbelt mandatory.
3. Prevent damage of the engine due human error.
4. Make the system available at low cost.
5. To maintain the correctness in hand brake operation in case of hand brake is not fully remove
or lock in case of emergency braking system action
3. Problem statement
Handbrake (Parking brake) is the mechanism used for well-being in the car. The traditional
machine works by manually operating the handbrake lever. Under this setting, the brakes
remain connected even while the car is going because of manual blunders. This condition
causes safety hazards which may cause damage the system components. During travel on the
steep slope in upward direction, if the vehicle accidently goes into neutral or engine stops, the
tendency of the vehicle is roll backwards; here we need the downhill locker. It is compulsory for
the driver to wear safety belt or wellbeing however it is regularly ignored and may demonstrate
deadly if vehicle meets with a mishap.
4. Work methodology
Either cable or rod linkage is used in a hand brake system to link the various components
together. The general trend is to use a cable for cars and vans, and rods only for heavy duty
commercial vehicles. We don’t change any original systems that are included in the vehicle but
we include some extra components into it. As a result of that process changes occurs in the
whole safety systems in it. These changes will help the passengers as well as the driver to ensure
safety while starting the vehicle from the initial point itself.
Figure 1 Fabrication of seatbelt frame
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
3
4.1 fabrication and working
Figure 1, shows the fabrication of seatbelt frame, first the rack is attached to the bottom of the
seatbelt buckle such that the vertical movement of the rack can be obtained.
4.2 Hand Brake or Parking Brake
While the foot-slowing mechanism retards or stops a moving vehicle, the hand stopping
mechanism forestalls the vehicle moving once it is left. Since the hand-slowing mechanism
might be in activity for exceptionally prolonged stretch of time period, a linkage instrument
separate from that of the water driven foot-brake circuit is introduced. Stopping brakes are
commonly given uniquely on the back-street wheels.
4.3 Pull-twist Handgrip Lever.
This course of action utilizes a roundabout draw bar with ratchet teeth cut on one side.
Two pawls draw in these teeth. A peg, embedded close to the lower end of, as far as possible the
free bend development to around 90 degrees. For applying the stopping brake, the handgrip is
curved to move the wrench teeth from the pawls. This activity causes the pawl edges to interact
with the smooth surface bit of the draw-bar. At the point when the bar is pulled out
4.4 Pull-press-button Hand-Lever (Light-duty).
This development, the most well-known sort at present, utilizes a hand-switch. One finish
of the hand switch is associated straightforwardly to the brake link while the opposite end
shapes the handgrip, with a discharge press button. This switch is turned on a wrench section.
At the point when the driver pulls up the switch arm, the spring-stacked pawl slides over the
fastener teeth causing most extreme link pressure. Now the switch is discharged, and the
vehicle leave pulls up the hand switch somewhat
5. Results and Discussion
The design and fabrication of Seatbelt Controlled hand braking system with ignition control is a
simple and cost effective is majorly focused on the automotive safety study and practice of
design, construction, equipment and regulation to minimize the occurrence and consequences
of traffic collisions involving motor vehicles. Road traffic safety more broadly includes roadway
design.
One of the first formal academic studies into improving motor vehicle safety was by Cornell
Aeronautical Laboratory of Buffalo, New York. The main purpose is analyzed with this work is
the crucial importance of seat belts and padded dashboards. However, the primary vector of
traffic-related deaths and injuries is the disproportionate mass and velocity of an automobile
compared to that of the predominant victim, the pedestrian.
5.1 Pinion and rack on seatbelt side
1. Outer diameter of pinion = 37mm
2. Outer circle circumference of the pinion = 116.23mm
3. Movement of rack = 13mm
4. Therefore, length of rack = 75mm
5. Number of teeth on pinion = 22
6. Number of teeth required on rack = 15
7. Module = 2
8. For 13 mm movement of rack the pinion rotates 40°
9. Number of teeth that comes in contact with gear = 5
10.Therefor actual number of teeth on rack = 15 (for safety).
5.2 Pinion and rack connected to handbrake
1. Length of rack = 75mm
2. Number of teeth comes in contact with rack = 5
3. Angle rotated by gear = 40°
4. Distance moved by rack = 13 mm
5.3 Dimensi0ns of shafts and hole
1. Diameter of shaft = 8mm
2. Length of shaft connected to handbrake = 65mm
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
4
3. Length of rectangular shaft = 60mm
4. Breadth of rectangular shaft = 12mm
5. Height of rectangular shaft = 10mm
6. Diameter of shaft connecting pinion = 8mm
7. Length of shaft connecting pinion = 60mm
8. Diameter of hole on handbrake = 8.5mm
5.4 Movement of rack
1. Movement of the seatbelt clip = 13mm
2. Vertical movement of rack = 13mm
3. Angle rotated by pinion = 40°
4. Horizontal movement of rack = 13mm
5.5 Calculation of shaft diameter
Torque T = d³
T =2000Nmm; τ = 30N/mm²
x30xd³ d = 6.97mm
Standard diameter = 8mm
5.6 Design of spur gear
Table 1 Design of spur gear procedure
step 1 Gear ratio i = �z1z2� i = 1
step2 Selection of material carbon steel
step3 Calculation of gear life � = �������
step4 Initial design torque [mt] [mt] = mt. k. kd
k. kd = 1.3(assume)
t= mt =
��
����
mt = 0.167× 10�n/mm
step5 Calculation of eeq, (σb), (σc)
eeq =2.15× 10�n/mm�
(σb)= �.�×����×�� × σ��
(σb) = 169.16n/mm�
(σc)= c�hrck�� =823.48/mm�
step6 Calculation of centre distance
(a) a ≥ (i + 1) ��0.74�
σc� × e[mt]iφ "#
a = 39.6mm
step7 Pinion and gear teeth (z1, z2) z1=22teeth
z2= i z1 =22teeth
Step 8 module (m) m= �$(%�&%�)
m = 1.8 ≈ 2
Step 9 Revision of centre distance a=m
%�&%�� �
a= 44mm
Step 10 calculation of b, d�, v, and φ�
1 φ = �$ , b= 13.2mm
2 d� = mz�, d� = 44mm
3 v = �*��
�
,v =0.02m/s
4 φ� = �$,, φ� = 0.3
Step 11 Selection of quality of gear “is quality 10 “, is selected
Step 12 Revised design torque[-/] [mt]=mt. k. kd [mt] = 0.242 × 10�n/mm
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
5
Step 13 check for bending stress
σ� = (i + 1)amby [mt] ≤ [σ�]
σ� = 90 n/mm�
design is safe
Step 14 Check for wear stress σ� = 0.74 i + 1a �i + 1i × b e × [mt]
≤ [σ�] σ� = 624.66n/mm�
design is safe
Table 1, shows the design of spur gear is safe. So, we can proceed the following design, for the
design of rack and pinion the diameter of the pinion, the pitch, module etc. has to be calculated.
The movement of the rack and the corresponding rotation of the pinion have to be calculated.
Now the movement of the pinion is transmitted to the second pinion which in turn rotates the
second rack that is used to lock the handbrake. First the rack is attached to the bottom of the
seatbelt buckle such that the vertical movement of the rack can be obtained; the vertical
movement of the rack rotates the pinion. The rotation of the pinion is transmitted to the second
pinion using a shaft. Now the rack connected to the second pinion moves horizontally.
A rod connected to the end of this rack is inserted top the handbrake and thus the handbrake is
locked into place. When the seatbelt clip is inserted the process is reversed and the hand brake
will be free to be engaged. The whole arrangement is mounted on a frame. The design of the
seatbelt clip is altered for easier working of the system. With the help of press switch we can
control the ignition system. The controlling will be indicated with the help of led lights.
6. Conclusions
Some have proposed that the number of deaths was influenced by the development of risk
compensation, which says that drivers adjust their behavior in response to the increased sense
of personal safety wearing a seat belt provides. In one trial subjects were asked to drive go-karts
around a track under various conditions. It was found that subjects who started driving
unbelted drove consistently faster when subsequently belted. Similarly, a study of habitual non
seat belt wearers driving in freeway conditions found evidence that they had adapted to seatbelt
use by adopting higher driving speeds and closer following distances.
References
[1] Rohit Khubalkar et.al., Apr 2019 Modification and Implementation of Automatic Hand Brake System
using Sensor, International Research Journal of Engineering and Technology (IRJET) Volume: 06
Issue: 04
[2] S. Thivagar, C. Nantha Kumar, Feb-2016 “Automatic Hand Brake System”, International Journal of
Engineering Research and General Science, Vol-04, Issue-01.
[3] Rohan E. Dalvi, Ramesh G. Sutar, Prashant H. Karke, Jitendra B. Satpute, May-2017 “Design and
Development of Hand Brake Release System”, Global Research and Development Journal for Engineering,
Vol-02, Issue-06.
[4] Telore Sanket, Mr. Shubham Dhikale, Mr. Pawar Kalpesh, Miss. Sayyed Shayka, Prof. Kshatriya
Vaibhav G., Jan-2017 “Seatbelt Activated Handbrake System”, International Journal of Innovations in
Engineering Sciences and Technology, Vol-03, Issue-01.
[5] Gokul Gopan, Gopikrishnan EJ, Gritto Joseph Cherian, Jacob Shibu Samuel, Sreejith R, April-
2017 “Development of Automatic Hand Brake System”, International Journal for Innovative Research in
Science & Technology|, Vol-03, Issue-11.
[6] Sachin S. Dharia, Sachin S. Bhopale, Prathmesh P. Kumbhar, Kedar S. Pathak, May-2016
“Advancements in Automatic Hand Brake System”, 4th International Conference on Science, Technology
and Management.
[7] Amit B. Maske, S. B Tuljapure, P. K Satav, July-2016 “Design & Analysis of Parking Brake System of
Car”, International Journal of Innovative Research in Science, Engineering and Technology, Vol-05,
Issue- 07.
Reproduced with permission of copyright owner. Further reproduction
prohibited without permission.
– MSEM9931011
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Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
1
Design and fabrication of seat belt-controlled hand
brake system with ignition control
M.Saravanakumar1, S.Prakash1, Nidhin S Kumar2, B V Gautham2,
Bijoy Mathew2
1Assistant Professor, Department of Mechanical Engineering, Aarupadai Veedu
Institute of Technology, VMRF, Chennai.
2UG Students, Department of Mechanical Engineering, Aarupadai Veedu Institute of
Technology, VMRF, Chennai
E-mail: sarov003@gmail.com
Abstract. Either link or bar linkage is utilized in a hand slowing mechanism to interface the
different segments together. The general pattern is to utilize a link for vehicles and vans,
and bars just for substantial business vehicles. We don't change any unique frameworks
that are remembered for the vehicle however we incorporate some additional segments into
it. As a result of that process changes occurs in the whole safety systems in it. This
progression will help the travelers just as the driver to guarantee security while beginning
the vehicle from the underlying point itself. In this endeavor a rack and pinion strategy
changes over the vertically dropping improvement of the seat strap catch as it is chopped
down into rotating development. It is then transmitted to an apparatus joined to the base of
the hand brake through a pole. The rigging is associated with a rack. The flat development
of the rack is changed over to vertical development used to bolt or discharge the discharge
switch of the handbrake switch. Additionally, with the assistance of press switch we can
control the start on and off procedure. The LED pointers associated with this press switch
will give exact situation of hand brake. Henceforth we can undoubtedly control it and start
the vehicle. Rack and pinion has been in presence since the improvement of designing. It is
one the most significant and basic segment utilized in building.
We are utilizing rack and pinion component to the hand stopping mechanism to bolt
hand brake until the safety belt is locked in. The slowing down power is produced
legitimately at each wheel by elite electrical engines and vehicle the executives, that region
unit constrained by an ECU. The electronic hand brake replaces the conventional
handbrake. It's worked by a switch inside the middle reassure. The mechanical gadget hand
brake gives the ensuing edges over the conventional handbrake: simple use-the hand brake
is applied absolutely regardless of the quality of the main impetus. Wellbeing the electrical
hand brake applies precisely once the key is off from the start.
Key Words: Smart handbrake, Automobile, Conventional, Automatic.
1. Introduction
Conventional hand brake feat involves the human interference. While not pull or pushing the
switch, the hand brake won't work. Also, generally as a result of negligence or in emergency
conditions, we humans have a tendency to usually forget to use parking brakes. This could bring
about moving of auto just if there should arise an occurrence of slants and crash with various
vehicles in leave [1]. Consistent improvements in dynamic wellbeing and upgrades with
connection to the dependableness and extravagance of activity imply that mechanical
handbrakes are continuously being supplanted via programmed mechanical gadget frameworks
In this project a rack and pinion arrangement convert the vertically downward
movement of the seatbelt hook as it is clipped down into rotating motion. It is then transmitted
to a gear attached to the base of the hand brake through a shaft [2]. The gear is connected to a
rack. The horizontal movement of the rack is converted to vertical movement used to lock or
release the release switch of the handbrake lever. Also, with the help of press switch we can
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
2
control the ignition on and off process. The LED indicators connected with this press switch will
give accurate position of hand brake. Hence, we can easily control it and start the vehicle [3-4].
Rack and pinion has been around since engineering grew. This is one of the most basic
and important components used in engineering. A rack and pinion are a type of linear actuator
comprising a pair of gears that transform rotational movement into linear movement. A circular
gear called "the pinion" engages teeth on a linear "gear" bar called "the rack"; rotational motion
applied to the pinion causes the rack to move relative to the pinion, thereby translating the
rotational motion of the pinion into linear motion.
We are using rack and pinion mechanism to the hand brake system to lock hand brake
until the seat belt is engaged. This new safety feature resists any vehicle owner to not drive a
vehicle without wearing a seat belt [5-6]. In India many safety features like ABS, airbag is an
additional feature. We want to pay more money to get these features, and yes luxuries vehicles
have them but the common man has to take the risk not having them and also many of them are
ignorant of safety in vehicles. Now in basic model cars which most of us can afford, only
seatbelt is the safety feature available. So, putting them on is most important while in driving
[7].
2. Objectives
1. To develop automation unit to reduce human manual interaction.
2. To make use of seatbelt mandatory.
3. Prevent damage of the engine due human error.
4. Make the system available at low cost.
5. To maintain the correctness in hand brake operation in case of hand brake is not fully remove
or lock in case of emergency braking system action
3. Problem statement
Handbrake (Parking brake) is the mechanism used for well-being in the car. The traditional
machine works by manually operating the handbrake lever. Under this setting, the brakes
remain connected even while the car is going because of manual blunders. This condition
causes safety hazards which may cause damage the system components. During travel on the
steep slope in upward direction, if the vehicle accidently goes into neutral or engine stops, the
tendency of the vehicle is roll backwards; here we need the downhill locker. It is compulsory for
the driver to wear safety belt or wellbeing however it is regularly ignored and may demonstrate
deadly if vehicle meets with a mishap.
4. Work methodology
Either cable or rod linkage is used in a hand brake system to link the various components
together. The general trend is to use a cable for cars and vans, and rods only for heavy duty
commercial vehicles. We don’t change any original systems that are included in the vehicle but
we include some extra components into it. As a result of that process changes occurs in the
whole safety systems in it. These changes will help the passengers as well as the driver to ensure
safety while starting the vehicle from the initial point itself.
Figure 1 Fabrication of seatbelt frame
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
3
4.1 fabrication and working
Figure 1, shows the fabrication of seatbelt frame, first the rack is attached to the bottom of the
seatbelt buckle such that the vertical movement of the rack can be obtained.
4.2 Hand Brake or Parking Brake
While the foot-slowing mechanism retards or stops a moving vehicle, the hand stopping
mechanism forestalls the vehicle moving once it is left. Since the hand-slowing mechanism
might be in activity for exceptionally prolonged stretch of time period, a linkage instrument
separate from that of the water driven foot-brake circuit is introduced. Stopping brakes are
commonly given uniquely on the back-street wheels.
4.3 Pull-twist Handgrip Lever.
This course of action utilizes a roundabout draw bar with ratchet teeth cut on one side.
Two pawls draw in these teeth. A peg, embedded close to the lower end of, as far as possible the
free bend development to around 90 degrees. For applying the stopping brake, the handgrip is
curved to move the wrench teeth from the pawls. This activity causes the pawl edges to interact
with the smooth surface bit of the draw-bar. At the point when the bar is pulled out
4.4 Pull-press-button Hand-Lever (Light-duty).
This development, the most well-known sort at present, utilizes a hand-switch. One finish
of the hand switch is associated straightforwardly to the brake link while the opposite end
shapes the handgrip, with a discharge press button. This switch is turned on a wrench section.
At the point when the driver pulls up the switch arm, the spring-stacked pawl slides over the
fastener teeth causing most extreme link pressure. Now the switch is discharged, and the
vehicle leave pulls up the hand switch somewhat
5. Results and Discussion
The design and fabrication of Seatbelt Controlled hand braking system with ignition control is a
simple and cost effective is majorly focused on the automotive safety study and practice of
design, construction, equipment and regulation to minimize the occurrence and consequences
of traffic collisions involving motor vehicles. Road traffic safety more broadly includes roadway
design.
One of the first formal academic studies into improving motor vehicle safety was by Cornell
Aeronautical Laboratory of Buffalo, New York. The main purpose is analyzed with this work is
the crucial importance of seat belts and padded dashboards. However, the primary vector of
traffic-related deaths and injuries is the disproportionate mass and velocity of an automobile
compared to that of the predominant victim, the pedestrian.
5.1 Pinion and rack on seatbelt side
1. Outer diameter of pinion = 37mm
2. Outer circle circumference of the pinion = 116.23mm
3. Movement of rack = 13mm
4. Therefore, length of rack = 75mm
5. Number of teeth on pinion = 22
6. Number of teeth required on rack = 15
7. Module = 2
8. For 13 mm movement of rack the pinion rotates 40°
9. Number of teeth that comes in contact with gear = 5
10.Therefor actual number of teeth on rack = 15 (for safety).
5.2 Pinion and rack connected to handbrake
1. Length of rack = 75mm
2. Number of teeth comes in contact with rack = 5
3. Angle rotated by gear = 40°
4. Distance moved by rack = 13 mm
5.3 Dimensi0ns of shafts and hole
1. Diameter of shaft = 8mm
2. Length of shaft connected to handbrake = 65mm
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
4
3. Length of rectangular shaft = 60mm
4. Breadth of rectangular shaft = 12mm
5. Height of rectangular shaft = 10mm
6. Diameter of shaft connecting pinion = 8mm
7. Length of shaft connecting pinion = 60mm
8. Diameter of hole on handbrake = 8.5mm
5.4 Movement of rack
1. Movement of the seatbelt clip = 13mm
2. Vertical movement of rack = 13mm
3. Angle rotated by pinion = 40°
4. Horizontal movement of rack = 13mm
5.5 Calculation of shaft diameter
Torque T = d³
T =2000Nmm; τ = 30N/mm²
x30xd³ d = 6.97mm
Standard diameter = 8mm
5.6 Design of spur gear
Table 1 Design of spur gear procedure
step 1 Gear ratio i = �z1z2� i = 1
step2 Selection of material carbon steel
step3 Calculation of gear life � = �������
step4 Initial design torque [mt] [mt] = mt. k. kd
k. kd = 1.3(assume)
t= mt =
��
����
mt = 0.167× 10�n/mm
step5 Calculation of eeq, (σb), (σc)
eeq =2.15× 10�n/mm�
(σb)= �.�×����×�� × σ��
(σb) = 169.16n/mm�
(σc)= c�hrck�� =823.48/mm�
step6 Calculation of centre distance
(a) a ≥ (i + 1) ��0.74�
σc� × e[mt]iφ "#
a = 39.6mm
step7 Pinion and gear teeth (z1, z2) z1=22teeth
z2= i z1 =22teeth
Step 8 module (m) m= �$(%�&%�)
m = 1.8 ≈ 2
Step 9 Revision of centre distance a=m
%�&%�� �
a= 44mm
Step 10 calculation of b, d�, v, and φ�
1 φ = �$ , b= 13.2mm
2 d� = mz�, d� = 44mm
3 v = �*��
�
,v =0.02m/s
4 φ� = �$,, φ� = 0.3
Step 11 Selection of quality of gear “is quality 10 “, is selected
Step 12 Revised design torque[-/] [mt]=mt. k. kd [mt] = 0.242 × 10�n/mm
ICMECE 2020
IOP Conf. Series: Materials Science and Engineering 993 (2020) 012011
IOP Publishing
doi:10.1088/1757-899X/993/1/012011
5
Step 13 check for bending stress
σ� = (i + 1)amby [mt] ≤ [σ�]
σ� = 90 n/mm�
design is safe
Step 14 Check for wear stress σ� = 0.74 i + 1a �i + 1i × b e × [mt]
≤ [σ�] σ� = 624.66n/mm�
design is safe
Table 1, shows the design of spur gear is safe. So, we can proceed the following design, for the
design of rack and pinion the diameter of the pinion, the pitch, module etc. has to be calculated.
The movement of the rack and the corresponding rotation of the pinion have to be calculated.
Now the movement of the pinion is transmitted to the second pinion which in turn rotates the
second rack that is used to lock the handbrake. First the rack is attached to the bottom of the
seatbelt buckle such that the vertical movement of the rack can be obtained; the vertical
movement of the rack rotates the pinion. The rotation of the pinion is transmitted to the second
pinion using a shaft. Now the rack connected to the second pinion moves horizontally.
A rod connected to the end of this rack is inserted top the handbrake and thus the handbrake is
locked into place. When the seatbelt clip is inserted the process is reversed and the hand brake
will be free to be engaged. The whole arrangement is mounted on a frame. The design of the
seatbelt clip is altered for easier working of the system. With the help of press switch we can
control the ignition system. The controlling will be indicated with the help of led lights.
6. Conclusions
Some have proposed that the number of deaths was influenced by the development of risk
compensation, which says that drivers adjust their behavior in response to the increased sense
of personal safety wearing a seat belt provides. In one trial subjects were asked to drive go-karts
around a track under various conditions. It was found that subjects who started driving
unbelted drove consistently faster when subsequently belted. Similarly, a study of habitual non
seat belt wearers driving in freeway conditions found evidence that they had adapted to seatbelt
use by adopting higher driving speeds and closer following distances.
References
[1] Rohit Khubalkar et.al., Apr 2019 Modification and Implementation of Automatic Hand Brake System
using Sensor, International Research Journal of Engineering and Technology (IRJET) Volume: 06
Issue: 04
[2] S. Thivagar, C. Nantha Kumar, Feb-2016 “Automatic Hand Brake System”, International Journal of
Engineering Research and General Science, Vol-04, Issue-01.
[3] Rohan E. Dalvi, Ramesh G. Sutar, Prashant H. Karke, Jitendra B. Satpute, May-2017 “Design and
Development of Hand Brake Release System”, Global Research and Development Journal for Engineering,
Vol-02, Issue-06.
[4] Telore Sanket, Mr. Shubham Dhikale, Mr. Pawar Kalpesh, Miss. Sayyed Shayka, Prof. Kshatriya
Vaibhav G., Jan-2017 “Seatbelt Activated Handbrake System”, International Journal of Innovations in
Engineering Sciences and Technology, Vol-03, Issue-01.
[5] Gokul Gopan, Gopikrishnan EJ, Gritto Joseph Cherian, Jacob Shibu Samuel, Sreejith R, April-
2017 “Development of Automatic Hand Brake System”, International Journal for Innovative Research in
Science & Technology|, Vol-03, Issue-11.
[6] Sachin S. Dharia, Sachin S. Bhopale, Prathmesh P. Kumbhar, Kedar S. Pathak, May-2016
“Advancements in Automatic Hand Brake System”, 4th International Conference on Science, Technology
and Management.
[7] Amit B. Maske, S. B Tuljapure, P. K Satav, July-2016 “Design & Analysis of Parking Brake System of
Car”, International Journal of Innovative Research in Science, Engineering and Technology, Vol-05,
Issue- 07.
Reproduced with permission of copyright owner. Further reproduction
prohibited without permission.
– MSEM9931011
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