Design of an Ultrasonic-Based Brake Pad Wear Detection System for Automotive Applications
Ernest Yao Agbanyo
Department of Mechanical Engineering, Cape Coast Technical University, Cape Coast, Ghana.
Sherry Kwabla Amedorme *
Department of Mechanical and Automotive Technology Education, Akenten Appiah-Menka University of Skills Training and Entrepreneurial Development, Kumasi, Ghana.
*Author to whom correspondence should be addressed.
Abstract
Road accidents in Ghana are a re-occurring phenomenon. According to the National Road Safety Authority, most accidents can be attributed to brake pad failure or worn-out brake pads. By using proximity sensors to warn drivers before any failure due to worn-out brake pads occurs, vehicle safety can be improved. The brake pad is the key component in the braking system, which plays a vital role by converting the kinetic energy of the vehicle to thermal energy through friction to bring the vehicle to a stop. Therefore, a brake pad wear detection sensor is a useful tool for improving vehicle safety and lowering the risk of rear-end collisions. In this paper, an ultrasonic brake pad wear detection sensor with alert signals was designed to give precautionary measures as a means to reduce road accidents. This study involved the development of the software component of the sensor in C language and incorporated it into Arduino pro mini (ATmega328p) and microcontroller for sensing and comparing wear status to preloaded value of 1.6mm for hydraulic brake for prediction. Proteus Virtual System Modelling (VSM) was used to create the system's control component (sensor). The designed circuitry was created and tested in a virtual environment. The test findings showed that the brake pad was in good condition when the LED emitted a green light under normal operating conditions. The result also shows that a yellow LED was emitted, signifying an approaching danger zone that needed replacement. Furthermore, the result predicts that the red LED indicates an interruption of the fuel supply line, leading to jerking and shutting down of the engine for the worn-out brake pad to be replaced. The results again indicate that at 10 mm thickness, the ultrasonic signal is strongest (80 dB), progressively decreasing as the pad wears down. At the minimum safe limit of 1.6 mm, the signal amplitude drops to 45 dB, signifying the need for brake pad replacement. Therefore, it is recommended that every vehicle must be installed with an ultrasonic brake pad wear detection system with an alert to reduce road accidents caused by worn-out brake pads. This technology helps reduce the number of accidents on the roads due to braking system faults.
Keywords: Vehicle brake pad, microcontroller, ultrasonic sensors, wear rate detection