Mechanical Engineering

GPTC Muttom

INTRODUCTION

The Electric brakes are similar to the drum brakes on your automobile.
The basic difference is that automotive brakes are activated by hydraulic
pressure while electric brakes are activated by an electro magnet. With all of the
brake components connected in t the system. In this braking system is actuated
by a special type of electro magnet. This brakes are designed to work in
synchronization with tow wheel vehicle brakes. Never use tow vehicle or trailer
brakes alone to stop the combined load. It is mainly used in the longest trailers.
They can be manually adjusted.

It is being working by using a controller. The brake controller must be set

up according to the manufacturers recommendations to ensure proper
synchronization between the tow vehicles and the trailers. Additionally , may
have to small adjustments occasionally to accommodate changing loads and
driving conditions. Proper synchronization of tow vehicles to trailer braking can
only be accomplished by road testing. Brake lockup ,grabbiness is quite often
due to the lack of synchronization between the tow vehicles being towed, too
high of a threshold voltage (over 2 volts), under adjusted brakes.

Before any synchronization adjustments are made, trailer brakes should be

burnished in by applying the brakes 20-30 times with approximattely a 20 m.p.h
decrease in speed. This allows the brake shoes and magnets to slightly wear in
to the drum surfaces.

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ELECTRIC BRAKE

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COMPONENTS
Controller

Magnet

Actuating lever

Primary shoe and secondary shoe

Adjuster

Adjuster spring

Retractor spring

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WORKING

When the electric current is fed into the system by the controller, It flows
through the electromagnets in the brakes. The high capacity electromagnets are
energized and are attracted to the rotating armature surface of the drums which
moves the actuating levers in the direction that the drums are turning.

The resulting force causes the actuating camblock at the shoeend of the
lever to push the primary shoe out against the inside surface of thebrake
drum.the force generated by the primary shoe acting through the adjuster moves
the secondary shoe out into the contact with the brake drum.

Increasing the current to the electromagnet causes the magnet to grip the
armature surface of the drum more firmly. This results in increasing the pressure
against the shoes and brake drums until the desired stop is accomplished.

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ELECTRIC BRAKE CIRCUITS

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ADVANTAGES

They can be manually adjusted at the controller to provide the correct

braking capability for varying road and load conditions.
They can be modulated to provided more or less braking force, thus easing
the brake load on the towing vehicle
They have very little lag time from the moment the tow vehicles brakes
are actuated until the trailer brakes are actuated.
In an emergency situation, they can provide some braking indepent of the
tow vehicles
Simple in design and installation
Much better control over breaking effort
Reduced time lag between application of break and response at the drum
Absence of grab
No adjustments required during its lining life

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DISADVANTAGES

It consumes power as long as the power is ON

Parking brake option is not available on all sizes

Self adjusting features is not available on all sizes

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GENERAL MAINTENANCE

Brake adjustment

1. Jack up the trailer and secure on adequate capacity jack stands. Follow
trailer manufacturers recommendations for lifting and supporting the unit.
Make sure the wheel and drum rotates freely.
2. If equipped, remove the adjusting hole cover, if present, from the adjusting
slot on the bottom of the brake backing plate.
3. With a screw driver, rotate the star wheel of the adjuster assembly to
expand the brake shoes. Adjust the brake shoes outuntil the pressure of the
linings against the drum makes the wheel difficult to turn.
4. Then rotate the star wheel in the opposite direction until the wheels turns
freely with a slight lining drag.
5. Replace the adjusting hole cover, if available, and lower the wheel to the
ground.
6. Repeat the above procedure on all brakes. For best results, the brakes
should all be the same clearance.

Brake cleaning and inspection

Trailer brakes must be inspected and serviced immediately if a loss of

performance is indicated. With normal use, servicing at one year intervals is
usually adequate. With increasing usage, this work should be done more
frequently as required. Magnets and shoes must be changed when they become
excessively scored, a condition which can reduce vehicle braking.

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Clean the braking plate, magnet arm, magnet and brake shoes. Make
certain that all the parts removed are replaced in the same brake and drum
assembly. Inspect for any loose or worn parts, stretched springs and replace as
necessary.

Brake lubrication

Before reassembling, apply a light film of grease or anti-seize compound

on the brake anchor pin, the actuating arm bushing and pin, and the areas on the
backing plate that are in contact with the brake shoes and magnet lever arm.
Apply a light film of grease on the actuating block mounted on the actuating
arm.

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TROUBLE SHOOTING

Most electric brake malfunctions that cannot be corrected by either brake

adjustments or synchronization adjustments, can generally by traced to electrical
system failure. Volt meters and ammeters are essential tools for proper
troubleshooting of electrical brakes.

Mechanical cases are ordinary obvious, I.e. bent or broken parts, worn out
lining or magnets. Seized lever arms or shoes, scored drums, loose parts, etc.
replace defective parts with genuine dexter replacements.

NO BRAKE
WEAK BRAKE
LOCKING BRAKES
INTERMITTENT BRAKES
BRAKE PULL TO ONE SIDE
NOISY BRAKES
DRAGGING BRAKES

CONCLUSION
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Electric brakes is a good invention for the speed control of high speed
vehicles and trailers.We can control the speed of this vehicles without wear and
tear in parts of it.Drawback of ordinary mechanical braking system can be
overcome by application of electric brakes.It makes uses of opposing tendency
of eddy current.And if the speed of the vehicle is very high the brake could not
provide that much high braking force and it will cause problems.It is an abrasion
free method for braking of vehicles including trailers.

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REFERENCES

Tech India publication automobile text

www.seminarsonly.com
www.tezu.ernet.in
www.scribed.com
Training.sae.org

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