DESIGN AND PROTOTYPING OF

TRANSMISSION LOCK SECURITY SYSTEM

FOR AUTOMOTIVES
S.Prakash
ME-INDUSTRIAL ENG
Regional Centre of Anna University
Coimbatore, India
prak_1221@yahoo.co.in
Dr. K.Soorya Prakash M.E, Ph.D
Associate Professor, Mechanical Engineering
Regional Centre of Anna University
Coimbatore, India

Abstract- Design of an innovative transmission lock security

system for automotive. Electro Mechanical based
transmission lock, designed to suit at gear box point. Effective
method to overcome security threads.

A. Problem Identification
Vehicle safety is became a part of vehicle
manufacturing nowadays, there are many safety system
coming in the market at regular time but the reliability of
the system eases out over a period of time, the literature
reviews showed the application of electronic controlled
system into automotive security very much, it details
various aspects of the security system and the continuous
improvement to overcome the performance are discussed,
most of the security systems depends on electronic system
mainly where the possibility of attacking and hacking is
became easier over a period of time, so it is evident to have
a stronger and better security system where the chance of
insecurity is minimized.

Keywords- Gear Box, Cali[per, Disc, Vehicle Safety, threat.

I. INTRODUCTION
Security is the degree of resistance to, or
protection from, harm. It applies to any vulnerable and
valuable asset, such as a person, dwelling, community,
nation, or organization. As noted by the Institute for
Security and Open Methodologies (ISECOM) in the
OSSTMM 3, security provides "a form of protection where
a separation is created between the assets and the threat."
These separations are generically called "controls," and
sometimes include changes to the asset or the threat.
Perception of security may be poorly mapped to
measureable objective security. For example, the fear of
earthquakes has been reported to be more common than the
fear of slipping on the bathroom floor although the latter
kills many more people than the former. Similarly, the
perceived effectiveness of security measures is sometimes
different from the actual security provided by those
measures.

B. Proposed Solution
In this present project work, design and
prototyping of hydraulic operated drive lock system is
proposed, this is an innovative drive lock system which
bases on braking technique, in this project work a
conceptual model of drive lock is presented with design
validation which is further taken to prototyping for
demonstration purpose in the final phase. This design locks
the transmission shaft through braking system which is
designed to operated at much higher braking torque than
the maximum torque limit of the specific vehicle, so
individual design comes into play here, which will be
unique and difficult to fit for all type of vehicle, which adds
additional security, this project work also provides unique

II. PROBLEM IDENTIFICATION AND

PROPOSED SOLUTION

key system for each customer which adds more complexity

for the security system and makes this more tightened
security system of existing category.

e (Te)
(Nm)
67.00

3750

170.61

205.00

34.39

307.50

75.50

6500

110.92

146.00

35.08

219.00

71.00

6250

108.48

102.00

-6.48

153.00

82.00

6300

124.29

140.00

15.71

210.00

115.00

3200

343.18

380.00

36.82

570.00

III. DESIGN AND VALIDATION

A. Engine Power Data
The design of drive completely depends on the
maximum torque and power of the engine, fundamental
calculations are derived from the engine power and rpm
and compared with maximum torque of the engine to
design this drive locks system. The following table
provides power and torque data of Ford vehicles.
TABLE I
ENGINE DATA

The above table provides a clear understanding of

the design torque, taking the maximum torque range of the

Max.

Model
Ford Fiesta
Classic
Figo
ECO sports
Endeavour

Torque

(NM)
205Nm@3500
146Nm@3500
102Nm@4000
140Nm@4400
380Nm@2500

vehicle category would yield safer side deign which can

Max. Power (KW)

also fit into all vehicle model, so a design torque should be

67KW@3750
75.5KW@6500
71KW@6250
82KW@6300
115KW@3200

equal or greater than 570 Nm, so that drive will be firmly

locked by the hydraulic friction pad to avoid drive.
C. Drive Lock Design
The drive lock parameters are based on the gearbox

B. Torque Calculation

output shaft, most of the gear box output shafts are in the

Based on the maximum power and the RPM, the

range of 23 to 36 mm (Table 1.3) and the larger diameter is

following calculations are performed and tabulated to

taken for reference design so that the design will fall in

find out the difference in the Actual torque and

safer region. Hardened plain carbon steel is the best

maximum torque based on this the design torque for

economical choice for drive lock system, where the lock

drive lock is derived and it is kept as 1.5 times of the

model is selected and redesigned to fit for this drive lock

maximum torque.

design.

P = 2 N T / 60
Where,
P
=
N
=
T
=

Power in watts
RPM
Torque in Nm
T = P 60 / 2 N
TABLE III
DIAMETER RANGE

TABLE II
DESIGN TORQUE

Power
(KW)

RPM

Torque
(T)
(Nm)

Max.
Engin
e
Torqu

Diff.
(Te
T)
(Nm)

Design
Torque
(Nm)

Dia.(mm)

Dia.(mm)

Power

Torque

27.90

29.66

24.17

26.49

23.99

23.50

25.10

26.125

35.21

36.42

=
4163.10 x (0.15 / 2)
=
312.25 Nm
The designed disc lock generates 312.25 Nm of
brake torque at 6 bar pressure, which is very much
sufficient to lock the drive at its maximum rated torque.
Since the first gear produces maximum amount of torque,
this ensures the safety of the lock system to hold the drive
from moving. The following are the simulation results of
the drive disc at maximum designed torque.

D. Design Inputs

Shaft Diameter - SD (mm)

Shaft diameter to Disc diameter Ratio

(mm)
Pad Covering Angle ()
Shaft Clearance (mm) (2 x 0.1SD)
Pad Area (m2)
Coefficient of Friction and Pressure (Bar)

E. Sample Calculation (Ford Fiesta)

The following section shows the sample design of
drive lock and simulation verification for stress and
deformation.
Shaft diameter (SD)
=
30 mm
SD Ratio
=
5
Pad Covering Angle
=
120
Frictional Coefficient
()
=
0.25
Pressure (P)
=
6 Bar
Calculations
Shaft Clearance
10 % of Shaft diameter

2x
=

6 mm
Disc Diameter (Dd)
SD * Ratio

=
Fig. 1 Sample Model

=
150 mm
Pad Area (A)
0.005551 m2
Pressure

=
=

6e6

IV. CONCLUSION

Pascal
Braking Force (F)
(P/2) A

The present work conclude with the following

status. Advanced electronic and internet facilitated security
systems that are available in the market, but eases out and
lacks in solidarity of eliminating vehicle theft. The problem
identification address this, where electronic system may
malfunction and easily decidable for the present
technology, the gearbox locks provides much better
resistance mechanically but can be breakable explicitly. So
the proposed system presents a novel idea of drive lock,

=
0.25 x (6e6/2) x 0.005551
=
4163.10 N
Braking Torque (Nm)

(Dd/2)

where the author of the vehicle locks the transmission

system with a hydraulic drive lock system in the form of
disc and caliber and also coins a unique key design
proposal further to avoid key duplicating.

5.

Elmqvist J. et. al (2007) Safety-Oriented Design

of Component Assemblies using Safety
Interfaces, Electronic Notes in Theoretical
Computer Science 182, pp: 5772.

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