International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
Fabrication and Modification of Hand Brake and Clutch Assemblies to
avoid unnecessary wear and tear of Brake Liners
Vinayak V. Chettier1, Shantanu S. Chilgar2, Charles Edward3
1BE,Department of Mechanical Engineering, JSPM’s Imperial College of Engineering, Pune
2BE,Department of Mechanical Engineering, JSPM’s Imperial College of Engineering, Pune
3Asst. Professor, Dept. of Mechanical Engineering, JSPM’s Imperial College of Engineering, Pune, India
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Abstract - The technological advancements in engagement lever. This linkage will disengage the clutch
automobile sector has paved the way to some from the flywheel whenever parking brake is engaged. This
innovations related to safety and braking of an will not let the vehicle move forward when the parking
brake is in engaged position, as any power produced by the
automobile. But such system when employed in any
engine will not be transmitted to the gearbox, as the clutch
automobile, costs up to some extent. Hence, a system will be disengaged from the engine.
which works with less operating and input cost is
needed. This research is based on developing such system
which helps in improving brake liner's life using simple 1.1 Parking brake: It is a latching brake used to hold the
and manipulating arrangements. Mechanical input used vehicle stationary when the vehicle is not in use. It is
while applying hand brake, the clutch is disengaged from engaged/disengaged using a hand lever. When the lever
the flywheel. This would not allow the automobile to is pulled up, the brakes
move forward until the hand brake is disengaged. Hand 1.2 Clutch: A Clutch is a machine member used to connect
brake disengagement will engage the clutch with the driving shaft to a driven shaft, so that the driven
flywheel and the vehicle will move forward. This process shaft may be started or stopped at any time, without
is carried out using as simple arrangement which is the stopping the driving shaft. A clutch thus provides an
proposed work of the project. interruptible connection between two rotating shafts.
Clutches allow a high inertia load to be started with a
small power. Clutches are also used extensively in
Key Words: Hand brake, brake liners wear, Clutch plate production machinery of all types.
1.INTRODUCTION 1.3 Parking Brake: It is a latching brake usually used to
keep the vehicle stationary. It can also be used as an
emergency brake in case of a failure of primary brakes.
Parking Brake is the lever brake arrangement in a
vehicle used to hold the vehicle in stationary position when
1.4 Hand Brake Equalizer: It is a component which is
parked. At times, due to human error, this lever is not
used to divide the single hand brake lever motion
disengaged before driving. This leads to the continuous
towards two rear wheels brakes.
brakes’ engagement inside the brake drum while the vehicle
being driven. Continuous engagement of brake liner with the
brake drum while the drum constantly rotating with the
wheels, causes friction between the liners and the drum. The
friction causes large temperature increase and wear of the
brake liner surface. This could’ve been avoided if the parking
brake lever was disengaged before the vehicle being driven.
Clutch of a vehicle is a friction material used in
transmission system to engage and disengage engine from
the gearbox. It is operated by an actuation lever provided
over bell housing. This actuation lever can be actuated using
hand levers (in two wheelers) and foot pedals (in four Fig 1. Hand Brake Equalizer.
wheelers).
1.5 Clutch: While clutch assembly is a system which is used
The following paper is an attempt to avoid temperature
to disengage the power/torque from engine to
increase and wear of the brake liners. It is a demonstration
gearbox/transmission system.
of a linkage connected from brake liner to the clutch
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4433
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
1.6 Proposed System: Using the above two systems, the 2. CONSTRUCTION & WORKING
proposed system is fabricated. This system will
disengage the clutch from the flywheel and the vehicle Construction:
will not move forward and will subsequently increase L- angle beams are welded together to construct a
liner's life if vehicle is not driven forward when parking rectangular frame of (1000x600x600) mm. It is provided
brake is engaged. with reinforcement angles to support the load at 450mm
from the top. Bell housing which consists of the clutch
2. Literature Review: assembly (Flywheel-Clutch Plate-Diaphragm Spring) is
mounted on the frame. Hand brake lever is mounted on the
Heinz Heisler [1] in his book explaining various advanced corner or the frame. One end of the clutch cable is connected
system employed in any automobile has provided some to the hand brake and the other is connected to the clutch
information about hand brake system. When the hand brake actuation lever, alongside the primary clutch cable on the
lever is applied, the cable pulls the hand lever inward, bell housing. A MS rod of 22mm is connected to the clutch
causing it to react against the strut. As it tilts it forces the assembly which acts as the output shaft.
trailing shoe outwards to the drum. At the same time the A 0.375W, 1375 rpm DC motor is mounted at the
strut is forced in the opposite direction against the sector lower part of the frame using supports from the
lever. reinforcement angles. A solid MS rod is welded to the
flywheel and mounted on the top reinforcements of the
frame and the end of shaft is supported using a 22/62 ball
bearing. This MS rod is mounted with a pulley of ID 22 mm
and OD 50.8 mm at 150mm from the bearing end. This rod
acts as the input shaft connected to the flywheel. The pulley
on this shaft will be connected to the motor shaft using a V-
belt. Construction layout of the demonstration is shown.
Fig 2. Demonstration Layout.
Fig 2. Linkage from Hand Brake lever to the Brakes [2]
Working:
V.B. Bhandari (2008) [2] explained in his experiment that The proposed idea is demonstrated by mounting
Diaphragm spring is a flat, spring-steel disc compressed hand brake and clutch assemblies on a frame and linking
between the cover and pressure plate that, when pushed by both the assemblies using a simple four-wheeler clutch
the release bearing, engages and disengages the clutch. cable. It demonstrates the process when the hand brake is
engaged (pulled up), it will disengage the flywheel from rest
Prof. K. Gopinath et. al[3], has stated some useful of the transmission.
calculations formulae for calculation of temperature rise in The motor is run and the rotary output from the
the brake liners during parking condition. This transaction motor is transmitted to the input shaft and it rotates, the
also includes solved examples of such calculations of clutch assembly rotates along with it as the flywheel being
temperature rise in the liners. connected to the shaft. As soon as the hand brake lever is
engaged (pulled up), the clutch is disengaged from the
flywheel and the output shaft from the clutch assembly stops
rotating. In short, the DC motor acts as the engine of the
vehicle and the shaft connected to the flywheel acts as the
crank shaft.
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4434
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
Fig 4. Equalizer adjustment.
The above figure shows an adjustment in real
practice which helps obtain three outputs. Two
equalizers are used in above adjustment. Input from
hand brake is transmitted from Equalizer 1 to two
cables (outputs), the right-side brake and left side brake,
(in usual practice). Another equalizer, Equalizer 2 is
connected to the left side brake cable. Equalizer 2, then
transmits the input in two more outputs, one can be
used in order to carry out the proposed system and the
other will be connected to the left side brake. One input
and requirement of three outputs can thus be fulfilled,
when, the proposed idea is taken up for actual use.
Fig 3. Actual demonstrating model.
4. CONCLUSIONS
3. EQUALIZER PROBLEM Using the demonstrative model, it was concluded
that the clutch is properly and completely disengaged from
the flywheel, using hand brake actuations. There are no
problems in primary workings of the clutch and hand brake.
This disengagement does not allow the vehicle to move
forward until the hand brake is disengaged. In actual
practice, there will be a need of connecting just a clutch cable
from the hand brake to the clutch actuation lever and a slight
modification of hand brake equalizer connections.
Advantages:
Fig 3. Actual hand brake system 1. The unnecessary wear and tear of brake liners
Above illustration shows the hand brake system in is avoided, when engaged while the vehicle is
actual. When the hand brake is pulled up the motion is driven.
transmitted to the brakes through a component called the 2. Cost effective method to save brake lining
equalizer. But the equalizer has two one input and two materials from wearing out quickly.
outputs. In the proposed system, there is a need for a third 3. Saves the brake liners from temperature rise
output, which is to be connected to the clutch. due constant friction with the brake drum.
In order to overcome this problem, there are two
options viz.,
1. To design an equalizer which has one input and REFERENCES
three outputs
2. The manipulation shown below: [1] Heinz Heisler, "Advanced Vehicle Technology", 2nd Ed.,
Reed Educational and Professional Publishing Ltd, 2001
[2] V.B. Bhandari, "Design of Machine Elements", 2008, Tata
McGrew Hill Publications..
[3] Prof. K.Gopinath, Prof. M.M.Mayuram, "Machine
Design", Indian Institute of Technology, Madras.
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4435
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
BIOGRAPHIES
Vinayak Vishvanath Chettier, a
student pursuing Bachelor’s in
Engineering from JSPM’s College of
Engieering, Pune.
Shantanu Shahaji Chilgar, student
pursuing Bachelor’s in Engineering
from JSPM’s Imperial College of
Engineering, Pune
Charles Edward, Assistant
Professor in JSPM’s Imperial
College of Engineering, Pune.
Project Guide to the proposed idea.
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 4436
