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Study Material- 3 [Braking system]

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(A UNIT OF ENGINEERS HERITAGE TRUST)

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STUDY MATERIAL
BRAKING SYSTEM
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Study Material- 3 [Braking system]

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Study Material- 3 [Braking system]

Brake:The brakes are used to slow down, or Stop and to ensure that the vehicle does not roll
away.

CLASSIFICATION OF BRAKE:

Mechanical Brakes
Hydraulic Brakes
Air Brakes
Power Assisted Brakes

1) MECHANICAL BRAKE
In mechanical type, braking force is applied by pressing
brake pedal or brake lever. Brake operating force works on
brake shoes to hold the brake drums by using the cable or
rod.

2) HYDRAULIC TYPE
In hydraulic brake, operating force
applied to the brake pedal is
delivered to the hydraulic unit.
Then,
hydraulic
pressure
generates by using the Pascals
principle for braking. Since
braking force is delivered to every
wheel equally, it forms the equal
braking force among wheels and
the system works fine even with a
little brake effort. Though, the
brake function disappears totally
when hydraulic system fails.

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Study Material- 3 [Braking system]

3.) AIR BRAKE

In air brake, every brake shoe is pressurized to the drum by using the pressure of the
Compressed air. Brake valve opens and closes with brake pedal to control the air
supply to the brake chamber.

4.) POWER ASSISTED BRAKES

In power assisted Brakes assistance are provided for your brake input force to minimize
the Driver effort.
They are of two types:
Vacuum Assisted
Air assisted
Vacuum Assisted
In Vacuum assisted system
auxiliary (booster) equipment is
installed in hydraulic brake system
to magnify the braking force by
using the pressure difference
between
vacuum
(negative
pressure)
and
atmospheric
pressure during the intake stroke
of the engine.

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Study Material- 3 [Braking system]

Air assisted

In air assisted brake, specified braking force could be obtained with a little brake pedal
effort using the pressure difference atmospheric pressure and compressed air from air
compressor driven by vehicle engine.

HYDRAULIC BRAKE (construction & working)

It consists of following main parts: (i) Master Cylinder (ii) Wheel cylinder (iii) Brake
It consists of a master cylinder which is connected to four cylinders through a pipeline.
The wheel cylinder consists of brakes and shoe arrangement.
Principle: It works on the principle of Pascal's law, which states that "The confined liquid
transmits pressure intensity equally in all directions."

Working: When the driver depresses pedal, the effort is transmitted through rod to
piston of master cylinder. The piston moves in the cylinder and compress return spring
forcing out the fluid from the cylinder into brake line through a by-pass. Piston of a
brake cylinders are acted upon by the fluid and press against shoes, bringing their linings
tightly against the working surfaces of the drums as soon as the pedal is released, the
return spring pushes piston back. At the same time, the compression springs of the brake
shoe move pistons to their initial position and the fluid begins to the flow in the reverse
direction.

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Study Material- 3 [Braking system]

VAPOUR LOCK
It is the condition which arrives when the oil in the brake circuit boils and evaporates, it
prevents oil pressure transfer because of the following reasons
Use of foot brake has been used excessively.
Overheated by the drag of brake drum and lining.
Reduction in remaining pressure
The brake oil deterioration or poor quality oil is used.

DRUM BRAKES & DISC BRAKES

Drum Brakes
Drum brakes are generally internal expanding shoe type, here a set of brake liners
expand against a brake drum which is connected to wheel leading to braking of the
vehicle. The brake liners are operated by a wheel cylinder which receives hydraulic
pressure from the tandem master cylinder. Drum brakes are normally fitted on Front &
Rear brakes
Classification:
Leading-Trailing Shoe Type:-

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Study Material- 3 [Braking system]

These types of brakes are generally fitted at Rear wheels in which one shoe will be
leading shoe and the other will be trailing shoe. The trailing shoe is used to create the
self servo action.
The advantage of this type is the same braking force will be obtained in both directions.

Two-Leading Shoe Type:These types of brakes are generally fitted at Front

wheels in which both the shoes will be leading shoes
and also two wheel cylinders are fitted. In
comparison to the leading and trailing type, a large
amount of braking force can be obtained while
moving in forward direction.

Duo Servo type:With duo-servo brakes the wheel cylinder is mounted

below a top anchor pin. The top of the brake shoes
pivot on this pin and the bottom of the shoes are free
to move. When the wheel cylinder expands, the
primary shoe is pushed forward. Rotation of the brake
drum causes the shoes to rotate at the bottom. This
slight rotation forces the secondary shoe into contact
with the drum. This rotational assist greatly increases
the stopping force of duo-servo brakes. This system
relies on the shoes being able to move on the backing
plate. This also requires proper lubrication between
the shoes and backing plate.
Disc Brakes
Here a set of brake pads expand against a brake disc
which is connected to the wheels leading to braking
of the vehicle. The brake liners are operated by a
wheel cylinder which receives hydraulic pressure
from the tandem master cylinder. Disc brakes are
normally fitted on Front brakes.

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Study Material- 3 [Braking system]

What are the Advantages of Disc brake ?

Excellent heat radiation due to exposure to air.

Stable braking performance
Low deterioration in braking performance with the repeated use.
Water or mud can be detached easily from disc.
Brake pedal stroke seldom changes because disc hardly deforms with a heat.
Easy check and maintenance.

What are the Disdvantages of Disc brake ?

High strength Pad material
It requires strong brake pedal efforts.
Expensive in structure.
PARTS & WORKING OF DISC BRAKES:
The main components of a disc brake are:

The brake pads

The caliper, which contains a piston
The rotor, which is mounted to the hub

The Caliper assembly: Provides stopping force at the wheel by clamping the disc
pads against the disc / rotor.
Brake pad: A frictional material for braking by sandwiching the disc rotor.
Disc: A round plate of cast iron, installed at the hub of the wheel, rotates together with
wheels.

Working of a disc brake:

The disc brake is a lot like the brakes on a bicycle. Bicycle brakes have a caliper, which
squeezes the brake pads against the wheel. In a disc brake, the brake pads squeeze the
rotor instead of the wheel, and the force is transmitted hydraulically instead of through a
cable. Friction between the pads and the disc slows the disc down.

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Study Material- 3 [Braking system]

VENTILATED DISC
Disc, installed at the hub of the wheel and rotating
together with wheels, is round cast iron. They are
ventilated disc in which ventilation holes for cooling are
processed inside the disc to allow frictional heat
radiation in braking as shown in the figure.

HYDRAULIC BRAKE (LINE LAYOUT )

BRAKE SPLIT

FRONT/BACK SPLIT

X- SPLIT

(H-SPLIT)

ABS SYSTEM (Antilock Braking System):

Anti-lock Brake Systems are designed
to prevent wheel lockup under heavy
braking conditions on any type of road
condition.
The result is that, during heavy braking,
the driver retains directional stability
(Vehicle Stability)

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Study Material- 3 [Braking system]

If the front wheels lock:

o It is no longer possible to steer the
car.
If the rear wheels lock:
o The car can become unstable and
can start to skid sideways.
If a car on the different conditions of
surface brakes:
o The wheels on the slippery surface
easily lock up and the vehicle
begins to spin.
But ABS provides vehicle stability until it stops. ABS comes handy to reduce the slip and
achieve stability and maximum braking force.
ABS CONSTRUCTION
ABS consists of wheel speed sensors which detects a wheel lock-up tendency, on the
basis of wheel speed sensor signal an ABS CM(Control Module) which outputs control
signal and HCU(Hydraulic Control Unit) which supplies brake pressure to each wheel.
Control module and hydraulic control unit assembly is called as ABS EHCU
Various types of ABS:
4-Sensor 4-Channel type (Independent control type )

It has four wheel sensors and 4 hydraulic control

Channels which control each wheel independently.
3-Sensor 3-Channel type

It has three wheel sensors and 3 hydraulic control

channels which controls each front wheel independently and
both rear wheels together.

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Study Material- 3 [Braking system]

EBD Electronic Brake Distribution

When braking heavily in a car you get a dramatic
forwards weight transfer. The body pivots
forward, the front suspension is compressed, and
more weight is transferred to the front tyres.
More weight acting on the front tyres means
more grip is available, and conversely the more
lightly laden rear wheels have less grip at their
disposal.
If an equal amount of braking force was applied
to the front and rear wheels in a heavy braking
scenario, the lighter rear wheels would run out of
grip first and be much more prone to wheel lock.
Most cars however, sends the majority of the
braking effort to the front wheels to counter this
effect, however in this case the ratio of front
versus back is fixed.
Electronic Brake Force Distribution (EBD) provides an automatically adjusting system
which changes depending on conditions to ensure the front and rear axles exert the
most effective braking possible without wheel lock. EBD systems work in
conjunction with ABS and use an electronically controlled valve which diverts
hydraulic pressure to the front and rear axles in real time according to the
conditions and scenario.

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