Design and fabrication of heavy vehicles emergency braking system using auxiliary braking system

Chan, Ding Hau (2024) Design and fabrication of heavy vehicles emergency braking system using auxiliary braking system. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Air brakes also referred to as compressed air brake systems, represent a friction braking mechanism utilized in vehicles. They rely on compressed air exerting pressure on a piston to activate the brake pads, thereby halting the vehicle's motion. These braking systems find extensive use in large, heavy-duty vehicles (HDV), particularly those with multiple trailers interconnected within the braking setup. Examples of vehicles employing air brakes include trucks, buses, trailers, semi-trailers, and even diesel and gasoline engine-powered vehicles According to Royal Malaysia Police (RMP), a few 40,000 incidents occurred that include heavy-duty vehicles. (MIROS,2022) Numerous variables influence the likelihood of heavy-duty vehicle collisions. Heavy-duty vehicle brake fading is a significant element in the incidents. Heavy-duty vehicle conventional braking systems may be efficient in normal circumstances, but in an emergency, things like brake fade, load, and longer stopping distances could prevent them from offering the required response time or stopping force. Therefore, we proposed system integrates auxiliary braking methods, including engine braking and exhaust braking, each selected for their effectiveness and reliability under various operational conditions. The proposed system incorporates key components, including an Arduino Mega 2560 microcontroller, a pressure transducer, servo motors, and MATLAB Simulink software and TruckSim for simulation. Simulations conducted under unladen, half-laden, and fully laden scenarios demonstrated significant improvements in braking performance, including reduced stopping distances and consistent deceleration rates. The system's rapid response time and adaptability to diverse operational challenges further validate its effectiveness. This work aligns with contemporary advancements in auxiliary braking technologies, emphasizing their potential to address safety challenges in heavy-duty vehicles. The findings pave the way for further research and real-world application of integrated braking systems, contributing to improved road safety standards for heavy vehicles.

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