Industrial Consultancy & Sponsored Research (IC&SR) , IIT Madras
A Braking System And Method For Emergency Braking
Technology Category/Market
Category- Automobile & Transportation
Industry Classification:
Automotive and Transportation; Electric Vehicle (EV) and Hybrid Systems; Railroad Equipment Manufacturing; Industrial Machinery
Applications:
Suitable for heavy-duty vehicles such as trucks and buses; braking applications in rail systems; challenging environments where pneumatic or hydraulic systems may be unreliable due to extreme conditions; vehicles with space constraints as system integrates directly into the axle, optimizing space utilization.
Market report:
The global automatic emergency braking market was valued at USD 74.68 billion in 2025 and is projected to grow to USD 134.41 billion by 2034 with a CAGR of 6.72%
Problem Statement
- Reliable emergency braking systems reduce accidents and are essential for vehicle safety, in heavy-duty and industrial vehicles.
- Conventional systems such as pneumatic, hydraulic, electronic, and regenerative brakes provide effective braking. However, these systems require regular maintenance and are prone to failures like leaks or software glitches.
- Further, Pneumatic and hydraulic brakes suffer from complexity, slow response times, and maintenance challenges. Whereas, advanced systems like regenerative and electronic brakes increase costs and introduce new failure risks.
- There is a need for a mechanical emergency braking system that improves reliability, reduces maintenance costs, and offers a quicker, cost-effective, and efficient alternative to traditional systems.
Technology
- Utilizes purely mechanical components (e.g., brake shafts, gears, springs) for reliable emergency braking, eliminating dependence on pneumatic or hydraulic systems prone to leaks or maintenance issues.
- Converts rotational motion into linear force via a spring compressor and screw gear. Stops vehicles in 3.6–4.6 seconds, faster than traditional brakes.
- Includes a resetting gear and actuators that restore components to their original state without external force, ensuring seamless reuse.
- Directly integrated with the axle, optimizing space utilization and reducing the complexity of installation in vehicles or machinery.
- Spring length: 165.3 cm, gear diameters: 7–23 cm, system components aligned for safety and efficiency, designed for heavy-duty vehicles, industrial equipment, and extreme conditions.
Key Features/Value Proposition
- Unlike pneumatic and hydraulic systems prone to leaks or air bubbles, the purely mechanical design eliminates these risks, ensuring consistent and dependable braking performance.
- The system avoids complex components like compressors and reservoirs, reducing maintenance frequency and costs compared to traditional pneumatic or hydraulic brakes.
- Immediate mechanical engagement upon activation ensures quicker braking compared to the pressure build-up required in pneumatic and hydraulic systems.
- Compact, axle-mounted integration minimizes complexity and costs, making it more economical than electronic braking systems, which involve sophisticated software and hardware.
- Operates entirely on mechanical principles, avoiding software glitches or electrical failures that can affect electronic braking systems. The system is ready for repeated use without manual reset intervention.
Questions about this Technology?
Contact for Licensing
Research Lab
Prof. Jayaganthan R
Department of Engineering Design
Intellectual Property
- IITM IDF Ref 2909
- IN 202441046447 Patent Application
Technology Readiness Level
TRL 7
System prototype demonstration in operational environment