Auto Brake

BRAKING SYSTEM IN AUTOMOTIVES
BY ASGHAR
BRAKING SYSTEM IN AUTOMOTIVES
SCHEMATIC VIEW OF BRAKING SYSTEM
MASTER CYLINDER
DISC BRAKE
DRUM BRAKE
PEDAL
COMBINATION VALVE
BRAKE BASICS
When the brake pedal is depressed, the car transmits the
force from your foot to its brakes through a fluid. Since the
actual brakes require a much greater force more than that
could apply with leg, the car must multiply the force of the
foot. It does this in two ways:
?Mechanical advantage (leverage)
?Hydraulic force multiplication
The brakes transmit the force to the tires using friction,
and the tires transmit that force to the road using friction
also. The three principles involved:
?Leverage
?Hydraulics
?Friction
LEVERAGE
The pedal is designed in such a way that it can multiply
the force from your leg several times before any force is
even transmitted to the brake fluid.
Force multiplication
Force F is being applied to the left end of the lever. The left
end of the lever is twice as long (2X) as the right end (X).
Therefore, on the right end of the lever a force of 2F is
available, but it acts through half of the distance (Y) that the
left end moves (2Y). Changing the relative lengths of the left
and right ends of the lever changes the multipliers.
HYDRAULIC SYSTEM
The basic idea behind any hydraulic system is:
Force applied at one point is transmitted to another

point using an incompressible fluid, almost always an
oil.
Most brake systems also multiply the force in the

process.
SIMPLE HYDRAULIC SYSTEM
In the figure above, two pistons (shown in red) are fit into two
glass cylinders filled with oil (shown in light blue) and
connected to one another with an oil-filled pipe. If you apply a
downward force to one piston (the left one, in this drawing),
then the force is transmitted to the second piston through the
oil in the pipe.Almost all of the applied force appears at the
second piston.
The other neat thing about a hydraulic system is that it makes
force multiplication. In a hydraulic system, all you have to do is
change the size of one piston and cylinder relative to the other,
as shown here:
EXAMPLE OF FORCE MULTIPLICATION
Distance from the pedal to the pivot is four times the distance from
the cylinder to the pivot, so the force at the pedal will be increased
by a factor of four before it is transmitted to the cylinder.
Diameter of the brake cylinder is three times the diameter of the
pedal cylinder. Thus the force is multiplied
MASTER CYLINDERS
Most modern car brake systems are broken into two circuits,
with two wheels on each circuit. If a fluid leak occurs in one
circuit, only two of the wheels will lose their brakes and your
car will still be able to stop when you press the brake pedal.
The master cylinder supplies pressure to both circuits of the
car. It uses two pistons in the same cylinder .
MASTER CYLINDER ASSEMBLY
Brake-fluid reservoir - The master cylinder's brake-fluid source.

Sensor - The electrical connection that triggers a warning light when
the brake fluid gets low.
There are two pistons and two springs inside the cylinder.
WORKING PRINCIPLE OF MASTER CYLINDER
When the brake pedal is pressed, it pushes on the primary

piston through a linkage. Pressure builds in the cylinder and
lines as the brake pedal is depressed further. The pressure
between the primary and secondary piston forces the secondary
piston to compress the fluid in its circuit. If the brakes are
operating properly, the pressure will be the same in both circuits.
If there is a leak in one of the circuits, that circuit will not be able
to maintain pressure. Here you can see what happens when one of
the circuits develops a leak.
When the first circuit leaks, the pressure between the primary and
secondary cylinders is lost. This causes the primary cylinder to
contact the secondary cylinder. Now the master cylinder behaves
as if it has only one piston. The second circuit will function
normally.
THE COMBINATION VALVE
The combination valve warns the driver if there is a problem with

the brake system, and also does a few more things to make the car
safer to drive.
There will be a combination valve on most cars with front disc
brakes and rear drum brakes.
THE COMBINATION VALVE ASSEMBLY
The valve does the job of three separate devices:

?The metering valve
?The pressure differential switch
?The proportioning valve
Metering Valve
The metering valve section of the combination valve is
required on cars that have disc brakes on the front wheels and
drum brakes on the rear wheels.The disc brakes are in a
position to engage before the drum brakes when you push the
brake pedal down.
The metering valve compensates for this, making the drum
brakes engage just before the disc brakes. The metering valve
does not allow any pressure to the disc brakes until a threshold
pressure has been reached. The threshold pressure is low
compared to the maximum pressure in the braking system, so
the drum brakes just barely engage before the disc brakes
engages.
Having the rear brakes engage before the front brakes provides
a lot more stability during braking.
Pressure Differential Switch
The pressure differential valve is the device that alerts you if you
have a leak in one of your brake circuits. The valve contains a
specially shaped piston in the middle of a cylinder. Each side of
the piston is exposed to the pressure in one of the two brake
circuits. As long as the pressure in both circuits is the same, the
piston will stay centered in its cylinder. But if one side develops a
leak, the pressure will drop in that circuit, forcing the piston off-
center. This closes a switch, which turns on a light in the
instrument panel of the car. The wires for this switch are visible in
the picture above.
Proportioning Valve
The proportioning valve reduces the pressure to the rear brakes.
Regardless of what type of brakes a car has, the rear brakes require
less force than the front brakes.
The amount of brake force that can be applied to a wheel depends on
the amount of weight on the wheel. More weight means more brake
force can be applied. Also, most cars have more weight over the front
wheels because that is where the engine is located.
If equal braking force were applied at all four wheels during a stop,
the rear wheels would lock up before the front wheels. The
proportioning valve only lets a certain portion of the pressure through
to the rear wheels so that the front wheels apply more braking force.
DISC BRAKES
Most modern cars have disc brakes on the front wheels, and
some have disc brakes on all four wheels. The figure above
shows the part of the brake system that does the actual work
of stopping the car.
WORKING PRINCIPLE OF DISC BRAKES
DISC BRAKE BASICS
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
DISC BRAKE ASSEMBLY & WORKING PRINCIPLE
The working principle of disc brake is similar to the brakes on a

Bicycle.The Bicycle brakes have a caliper, which squeezes the brake
pads against the wheel. In a disc brake, the brake pads squeeze the
rotor (wheel).Friction between the pads and the rotor disc slows the
vehicle down.
DISC BRAKE VENTS
To reduce the heat generated due to the friction between the pad
and the disc, vent holes are provided in the vanes. Most car disc
brakes are vented.
Vented disc brakes have a set of vanes, between the two sides of the
disc, that pumps air through the disc to provide cooling.
DRUM BRAKES
Drum brakes work on the same principle as disc brakes:
Shoes press against a spinning surface. In this system, that
surface is called a drum.
Many cars have drum brakes on the rear wheels and disc brakes on
the front. Drum brakes have more parts than disc brakes and are
harder to service, but they are less expensive to manufacture.
DRUM BRAKE ASSEMBLY & WORKING PRINCIPLE
The drum brake has two brake shoes and a piston.The

drum brake has an adjuster mechanism, an emergency
brake mechanism and lots of springs.
When brake pedal is pressed, the cam actuates the piston.The
piston pushes the brake shoes against the drum. As the brake shoes
contact the drum, there is a kind of wedging action, which has the
effect of pressing the shoes into the drum with more force.The
springs are provided to pull the shoe away from the drum when the
brakes are released.
WORKING PRINCIPLE OF DRUM & DISC BRAKE ASSEMBLY
POWER BRAKES
In olden days most of the cars have drum brakes so power brakes
were not really necessary.Drum brakes naturally provide some of
their own power assist. Nowadays most of the cars have disc brakes,
at least on the front wheels, so they need power brakes. Power brake
booster is located at the back of the engine compartment on the
driver's side of the car. The brake booster uses vacuum from the
engine to multiply the force that your foot applies to the master
cylinder.
VACUUM BOOSTER
The vacuum booster is a metal canister that contains a valve and

a diaphragm. A rod going through the center of the canister
connects to the master cylinder’s piston on one side and to the
pedal linkage on the other.
WORKING PRINCIPLE OF VACUUM BOOSTER
On cars with a vacuum booster, the brake pedal pushes a

rod that passes through the booster into the master cylinder,
actuating the master-cylinder piston. The engine creates a
partial vacuum inside the vacuum booster on left side of
the diaphragm. When you hit the brake pedal, the valve will
be opened, allowing air to enter the booster on one side of
the diaphragm while sealing off the vacuum. This increases
pressure on that side of the diaphragm so that it helps to
push the rod, which in turn pushes the piston in the master
cylinder.
ANTI-LOCK BRAKE SYSTEM
Stopping a car in a hurry on a slippery road can be very

challenging. Anti-lock braking systems (ABS) take a lot of the
challenge out of this.
ANTI-LOCK BRAKE SYSTEM COMPONENTS
Inside ABS there are four main

components :
?Speed sensors
?Pump
?Valves
?Controller
Speed Sensors
The anti-lock braking system needs some way of knowing
when a wheel is about to lock up. The speed sensors, which are
located at each wheel, or in some cases in the differential,
provide this information.
Valves
There is a valve in the brake line of each brake controlled by the
ABS. On some systems, the valve has three positions:
In position one, the valve is open; pressure from the
master cylinder is passed right through to the brake.
In position two, the valve blocks the line, isolating
that brake from the master cylinder. This prevents the
pressure from rising further should the driver push the
brake pedal harder.
In position three, the valve releases some of the
pressure from the brake.
Pump
Since the valve is able to release pressure from the
brakes, there has to be some way to put that pressure
back. That is what the pump does; when a valve
reduces the pressure in a line, the pump is there to get
the pressure back up.
Controller
The controller is a computer in the car. It watches the
speed sensors and controls the valves.
ANTI-LOCK BRAKE SYSTEM WORKING PRINCIPLE
There are many different variations and control algorithms for ABS
systems. We will discuss how one of the simpler systems works.
The controller monitors the speed sensors at all times. It is looking for
decelerations in the wheel that are out of the ordinary. Right before a
wheel locks up, it will experience a rapid deceleration. If left
unchecked, the wheel would stop much more quickly than any car
could. It might take a car five seconds to stop from 96.6 kph under
ideal conditions, but a wheel that locks up could stop spinning in less
than a second.
The ABS controller knows that such a rapid deceleration is
impossible, so it reduces the pressure to that brake until it sees
an acceleration, then it increases the pressure until it sees the
deceleration again. It can do this very quickly, before the tire can
actually significantly change speed. The result is that the tire
slows down at the same rate as the car, with the brakes keeping
the tires very near the point at which they will start to lock up.
This gives the system maximum braking power.
When the ABS system is in operation you will feel a pulsing in
the brake pedal; this comes from the rapid opening and closing of
the valves. Some ABS systems can cycle up to 15 times per
second.

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BRAKING SYSTEM IN AUTOMOTIVES

The basic idea behind any hydraulic system is:

Force applied at one point is transmitted to another

Most brake systems also multiply the force in the

Brake-fluid reservoir - The master cylinder's brake-fluid source.

When the brake pedal is pressed, it pushes on the primary

The combination valve warns the driver if there is a problem with

The valve does the job of three separate devices:

The main components of a disc brake are:

The working principle of disc brake is similar to the brakes on a

The drum brake has two brake shoes and a piston.The

The vacuum booster is a metal canister that contains a valve and

On cars with a vacuum booster, the brake pedal pushes a

Stopping a car in a hurry on a slippery road can be very

Inside ABS there are four main

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