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Air Brake System Using Exhaust Gas

Published on Sep 03, 2023


An exhaust brake is a means of slowing a diesel engine by closing off the exhaust path from the engine, causing the exhaust gases to be compressed in the exhaust manifold, and in the cylinder. Since the exhaust is being compressed, and there is no fuel being applied, the engine works backwards, slowing down the vehicle. The amount of negative torque generated is usually directly proportional to the back pressure of the engine.

Exhaust brakes are manufactured by many companies, including competitors Pacbrake and Jacobs. The brakes vary in design, but essentially operate as described above. More advanced exhaust brakes have exhaust pressure modulation (EPM) that controls the back pressure which in turn improves the braking performance across a range of engine speeds.

An exhaust brake is a device that essentially creates a major restriction in the exhaust system, and creates substantial exhaust back pressure to retard engine speed and offer some supplemental braking. In most cases, an exhaust brake is so effective that it can slow a heavily loaded vehicle on a downgrade without ever applying the vehicle’s service brakes.

This system will be working on pneumatic cylinder power, that pneumatic cylinder working exhaust gas collecting air.


With the development of highways, logistics and the pace of life, weight and velocity of vehicles has become more and larger, which has reduced the safety of driving an auto-mobile. The braking load of vehicles increases quickly so that the primary brake system is easily overloaded and can be damaged by overheating, possibly resulting in brake failure.

In addition, for vehicles in the mountains, hills and city, the driver will need to use the main braking system frequently for security reasons, which leads to a reduction of average speed, which affects the operating cost. The road hazards related to heavy goods vehicles are partly due to inefficient brake systems, or the failure of brakes. The commonly used braking system in these heavy duty trucks is the "Jake" brake used on diesel big rigs and dump trucks. A Jake brake works by using hydraulic pressure to momentarily open the exhaust valve at the end of the compression stroke, venting off the compressed air into the exhaust system.

That’s where all the noise comes from. The braking system attached to the wheel arrangement in attached the pneumatic cylinder getting air in exhaust gas of a Jake brake occurs because of the pumping loss compressing the air, and then eliminating the compressed air “rebound” on the power stroke. Additionally, there’s a pumping loss as the pneumatic piston descends on the power stroke with both valves closed and no combustion.


This project working on pneumatic powered, this is cylinder working on exhaust gas power utilize, If the piston moves forward, then the breaking arrangement activated. The breaking arrangement is used to break the wheel gradually or suddenly due to the piston movement. The breaking speed is varied by adjusting the valve is called “FLOW CONTROL VALVE”.

In our project, we have to apply this breaking arrangement in one wheel as a model. The compressed air drawn from the engine exhaust gas in our project. The exhaust air flow through the Polyurethane tube to the flow control valve. The flow control valve is connected to the solenoid valve as mentioned in the block diagram.
Normally working on two stroke or four stroke engine model that is engine model running condition while getting the exhaust gas in silencer in air tank arrangement.


Air Brake System


Air Brake System


• If don’t be used in external power on braking system.

• Cost wise low project.

• Simple construction.

• Maintenance is easy.


• It is used on four wheeler and two wheeler.

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