International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 12 | Dec 2025
p-ISSN: 2395-0072
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Design and fabrication of an Autonomous Anti-Rollback System Brihadish JB1, Sajith N1, Lokesh P.N1, S. Thulasi2, and V.R. Sarma Dulipala3 1Final Year Student, Dept. of Automobile Engineering, University College of Engineering BIT Campus, Anna
University, Tiruchirappalli, India
2Assistant Professor, Dept. of Automobile Engineering, University College of Engineering BIT Campus, Anna
University, Tiruchirappalli, India
3Assistant Professor (Sr. Gr), Dept. of Physics, University College of Engineering BIT Campus, Anna University,
Tiruchirappalli, India -------------------------------------------------------------------------***------------------------------------------------------------------------
Abstract - Unintended vehicle rollback on inclines
particularly pronounced in vehicles with manual transmissions, where the driver must coordinate the clutch, throttle, and brake.
remains a significant safety risk. Contemporary solutions, notably Hill Hold Assist, rely on co-opting the vehicle service brakes via the ABS controller, introducing hydraulic complexity and potential brake wear. Manual systems require driver intervention and are prone to error. This paper details the design, fabrication, and validation of a novel autonomous anti-rollback system that overcomes these limitations by introducing an independent, electropneumatically actuated mechanical lock. The proposed system integrates a robust ratchet and pawl mechanism with an Arduino-based control unit. An MPU6050 accelerometer provides real-time inclination data, which the microcontroller processes to autonomously trigger a 5 by 2 solenoid valve. This valve governs a pneumatic actuator to engage the pawl, mechanically preventing rollback. Finite Element Analysis was employed to validate the system mechanical integrity and guide material selection. This analysis confirmed structural steel as insufficient, leading to the selection of AISI 4140 low-alloy steel. The final design was validated to withstand forces exceeding 20,000 Newtons, far exceeding the 7500 Newton operational load, with a maximum equivalent stress of 360.15 MPa and strain of 0.0017 remaining well within the allowable limits of 393 MPa and 0.002. Experimental validation of the fabricated prototype confirmed its efficacy, demonstrating a rapid response time of 1.00 to 1.25 seconds and a greater than 99 percent engagement success rate. This research validates a low-cost, reliable, and fully autonomous mechatronic solution that serves as a viable alternative to brakedependent systems, demonstrably enhancing vehicle safety.
To mitigate this, automotive manufacturers have implemented two primary solutions: the manual handbrake and electronic Hill Hold Assist (HHA). The manual handbrake, while mechanically simple, is entirely dependent on driver intervention. Its effectiveness is contingent on human factors, such as being correctly engaged with sufficient force, and it is prone to human error [2, 4]. Modern vehicles increasingly adopt electronic HHA (also known as Hill Start Assist or HSA). These systems, however, are typically software-based functions that coopt the vehicle's existing Anti-lock Braking System (ABS) and Electronic Stability Control (ESC) modules. HHA holds the vehicle by applying hydraulic pressure to the service brakes, temporarily preventing rollback after the driver releases the brake pedal. While effective, this approach relies on a complex network of sensors and hydraulic controls, adds potential electronic failure points, and contributes to the wear of the service brakes. The literature reflects a clear need for a more robust and reliable alternative. Research has explored various mechanical anti-rollback mechanisms, including ratchet and pawl designs, to improve safety [6, 9]. Some proposals have focused on integrating these mechanisms within the disc brake assembly [9], while others have suggested automating existing manual levers [5]. While these efforts validate the interest in mechanical solutions, a gap remains for a cost-effective, mechatronic system that is both fully autonomous (like HHA) and mechanically independent from the primary braking system.
Key Words: Autonomous Anti-Rollback System (AARS), Vehicle Safety, Ratchet and Pawl Mechanism, Finite Element Analysis (FEA), Hill hold Assist, Gear Design and Fabrication.
This paper details the design, fabrication, and multi-stage validation of a novel Autonomous Anti-Rollback System (AARS) that directly addresses this gap. The proposed system introduces a robust, independent mechanical lock based on a ratchet and pawl mechanism. This lock is not reliant on the vehicle's hydraulic brakes; instead, it is autonomously controlled by a dedicated mechatronic system. An Arduino microcontroller, processing real-time
1. INTRODUCTION Unintended vehicle rollback on inclined surfaces is a persistent and significant safety concern in automotive engineering. Such incidents, often occurring during uphill starts or parking manoeuvres, can lead to collisions, property damage, and personal injury [1]. This risk is
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