BRAKING SYSTEM 5 5.1 INTRODUCTION Steering system as well as braking system contribute to safe operation of an automobile. We know that safety of passengers in a moving vehicle depends upon a good brake system. Now-a-days vehicles have much higher maximum speeds as compared to olden days. So, brake system of fast running vehicles must: be very effective to avoid accidents and for good controlling of vehicles. Brakes are expected to stop a moving vehicle in shortest time and distance. For this reason, the brakes must be well designed and regular inspection, adjustment and repair is required. 5.2 REQUIREMENTS OF A GOOD BRAKING SYSTEM A good braking system must fulfil the following requirements. ‘The fast running vehicle should be stopped in shortest distance and time. The brakes should be equally effective on good and bad roads. Brakes should work equally good in all weathers. Pedal effort applied by the driver for braking should be less. It should have less wearing parts and little maintenance. Steering geometry should not be disturbed, when brakes are applied. NaneRwONE There should be minimum sound when brakes are applied and should not pull the vehicle to either side. 8. Incase of emergency there should be an independent parking brake system. 5.3. PURPOSE OF BRAKES It is very much known that braking system is very important component of a vehicle. The running vehicle is not only safely-stopped but also controlled by using brakes Brakes play an important role to control the vehicle. Also safety of passengers depends upon the good brake system. So, brake system must be very effective and ffisient to stop the vehicle in shortest time and distance without giving any jerk and strain to driver.5.4 BRAKING ACTION Braking action is th . e use of a con prakes are applied, a friction ist i ule pores iaetopit iad p the running vehicle. When kinetic enexey is converted i eloped whi into heat energy rears the vehicle. In this way : es must stop the vehi ehicle in shortest distance and time. T! . Th SS. cee ne brakes must retard the vehi inaster power than that ge ibe-Foul thio brelied Sut | vehicle at a faster rate between horse power develo, loped by engine. Fig. 5.1 ist be designed to control Se ped by engine and controll Bare ea : urpose, th led by brakes. Ee hot bea elaine may be classified as th service brakes are the main b and. brakes’ or parking’ 0 oe aed Parking brak fats Wicd ls clep oe baie brakes are meant to hold theventiog : le while in motion. n a slope. Fig. 5.1: Rough Comparison of Horse Power of engine and brake the running vehicle and f friction by brakes. In a ergy 1S converted into kinetic energy put while braking, this d into heat energy by means of friction produced between m. The retarding force or force of friction between linings f friction for the two m: d the force 5.5 PRINCIPLE OF BRAKES stance which retard Principle of brake js to apply res ultimately stop it. This resistance is provided in the form o running vehicle, fuel en' kinetic energy is converte brake-lining and brake-dru and drum depends upon the co-efficient 0} exerted on the shoes by the prake mechanism. aterial an110 Direction of motion <——— Friction Force > Fig. 5. 5.6 TYPES OF BRAKES Brakes can be classified according ti 1. Purpose : 2: Simple representation of Li F=uR R F = Force of friction 1 = Co-efficient of friction R= Normal reaction Ww aw of Friction ‘0 the following considerations : (i) Foot brakes or service brakes. (ii) Hand brakes or parking brakes. 2. Location : (i) Wheel brakes i.e. located at wheels. (ii) Transmission brakes i.e. located at transmission. 3. Construction : @) Drum brakes Internal Expanding brakes External Contracting brakes (a) Disc brakes 4. Mode of operation : (i) Mechanical brakes (ii) Hydraulic brakes (ii) Vacuum brakes (wv) Air brakes () Electric brakes, 5.7 MECHANICAL BRAKE The brakes which are op cams and bell cranks ete, g employed in olden days by re t crt 3 ii mechanically by means of levers, linkages, pedals known as now taken its place. Also some lange 4.2 atti Tucks mechanical brakes. Mechanical brakes We and other type of braking system hat and articulated trailers employ such t/P°te ‘ployed j 3 stot mechanical Brake gan 1 parking brakes, Fig. jayout m0) frost wheel Brake pedal Fr Rear wheel brakes Over running slots Fig. 5.3 : Linkage of Mechanical Brake truction : Foot pedal is attached to the central rod and four levers are oa central rod. These levers are connected to the brake mechanism of all fet Og with the help of adjustaklemeaa one oo expanding mechanically operated brake usually consists of following Sratomporert as shown in fig. 5.4. % Xe Brake lining Spring Stopper Fig. 5.4 = Mechanical brake 1 ig. 2-4 * kes. jons. chanical connection! bra (i) Brake pedal to operate - a (ii) Links and levers to provice: (iii) Brake drum which moves with road wheel. The expanding brake shoes o contact to retard its speed. xpands the brake shoes. f friction oth are released- come int (iv) Cam which e? (v) Brake shoe with linings © i i i hich (vi) Retracting spring and helps them in contracting after the brakes Working : It is quite understanding from: s the central rod. ‘All four levers are cir respective prake rods When bra’ and expands the brake shoes. Brake shoes are forced duce retarding force. In this way, mechanical brakes are pedal, retractor spring pulls the brake shoes terial. connects b' the brake shoes at their loose ends fig, 6.3. and 6.4. When the brake pedal attached to central rod. So, is pressed, it turn: ke vod is pulled it activates these levers pull th the cam in brake assembly against brake drum and prot operated. After releasing the brake back. Use : Mechanical bra Parking brakes of the vehicles are brakes are operated by hands. For ex internal expanding type mechanical brakes. kes are used in some large trucks and articulated trailers. lso mechanical type brakes. These parking ample, hand brakes in Maruti vehicles are 5.8 HYDRAULIC BRAKES Brakes which are operated by means of hydraulic pressure or fluid pressure are known as hydraulic brakes. Most of the cars today use hydraulic brakes operated by ‘oot on all the four wheels with iti i pol eae ith an additional hand brake mechanically operated on Layout and Components : Th ¥ : The layout i i Its main components are as under. yout of hye ae a 1. Brake pedal, 2. Master cylinder, 3. Fluid reservoir, 4. Wheel cylinder. Master cylinder contai i ti re ntains reservoir for the brake fluid. M. Jinder uid. Master cylinder ! operated by brake pedal and i is fi through steel pipes. urther connected to wheel cylinders in each whetFront flexible hose connection 13 Brake fluid reservoir Rear flexible hose connection Brake: oe Wheel cylinders Master cyli r Front flexible ©” tinder hose connection Fig. 5.5 : Layout diagram of Hydraulic brake system Principle : Master cylinder is the main com; which contains reservoir for the brake fluid. Flaid ponent of hydraulic brake system brakes. So, hydraulic brake acts according to th Pressure is involved in this type of @ principle of ‘Pascal’s Law’ which tates that pressure applied to a liquid in a closed vessel is equally ransmitted in all sts directions. It is important to understand the pressure. Pressure is the ratio of external applied force (F) to the area of cross-section (A). According to Pascal’s law, pressure is transmitted equally in all direction. Its application can be easily understood from i fig. 5.6. ra A a fase! sell = a | Fig. 5.6 : Hydraulic Principlecylinder and ‘f’ is force As shown in fig. 5.7 ‘a’ represents the area of onalees ine welghecnGa applied on it. ‘A’ represents the area of large ee : : oe Weight is also a force. Then according to Pascal ,_F ie rs can lift hea It is very much clear from this equation that we Constant ivy weight with Smal) Paes dors take the place of brake sh, 1 cylinde x Fee ear Re nae re rictoos The ote ane He operating cam. The wheel cylinder ene ret cyindee nate oo is tons insi ends of these pistons. The pis! inside the cylinder. Master cylinder supplies the high hydraulic pressure acts inside the cy] ‘atoms then move outwardinitne cylindgs pressure fluid to wheel cylinders. The p: brake shoe. As a result, the brake shoeg exerting pressure on ee et nee Hee withthe’ brake®dram annem a are expanded outward and co: “aeagn Soe pedal is released, the retracting spring closes the brake Shoes which push the wheel cylinder’s pistons inwards. Inward going wheel cylinder's pistons develop back pressure and force back the fluid into the master cylinder, In this way brakes are released. Main components of hydraulic brake system are wheel cylinder and master cylinder. To understand the complete working of hydraulic brake we have to understand the working of wheel cylinder and master cylinder along- with their construction. So wheel cylinder and master cylinder are discussed separately, 5.9 ADVANTAGES AND DISADVANTAGES OF HYDRAULIC BRAKE SYSTEM Advantages : 1. There are no linkages, ro; ds and joints connecting brake shoes as such system is neat and simple, 2. System provides equal braking effect on all wheels. 3. Wearing Parts are lesser. Z 4. Less foot Pressure is re, quired for stopping t] 5. System ig self compensating. Meck 6. Different braking force can easily erent wheels according cal i i u ! ly be applied to diffi 7. The system is self lubricatingDisadvantages : 5 1, Bven slight leakage of air into the braking Eye minaret 2. This system is suitable for applying brakes pee a 3 useless. 5.10 VACUUM BRAKE The main components of vacuum brake are : 1. Exhauster 2, Vacuum Reservoir 3. Vacuum booster. In vacuum brakes, suction from the engine inlet manifold is utilised for brake application. A piston or diaphragm is operated in a cylinder and provided with suitable linkage for brake application. There are two types of vacuum brakes : 1, Suspended air type : In this type both sides of the piston are exposed to atmosphere when brakes are in released position. For applying brakes engine vacuum is applied on one side of the piston. Thus operating the linkage. 2. Suspended vacuum type : In this type both sides of the piston are subjected to engine vacuum in the brakes released position. To apply brakes, one ——__,_. a ee , 2 side is exposed to_atmosphere which provide the pressure difference and desired e pressure difference : force on the piston to operate the linkage. This is preffered over first type because this is comparatively more rapid in action. Construction : As shown in the fig. 5.7, vacuum reservoir is connected through @ non-return valve to the inlet manifold between carburettor and ce engine. Vacuum reservoir is also connected to servo cylinder on both sides of the piston, ” side of Fiston is connected through the control unit and right side bale connected. Control unit also contains a piston to which two valves are ae a * ce upper valve controls the connections between the atmosphere oe ee Piston in the servo cylinder. The lower valve controls the ae Saeco vacuum reservoir and left side of the servo cylinder piston: 7 ue unit itself is actuated by the brake pedal through the master cylinder.‘To atmosphere ae Servo cylinder AMAA Control unit —+ - } ra | -Se | WV To brakes Brake pedal ‘Non-return valve Brake fluid. Lae reservoir To inlet ZMaster cylinder 1 hod Fig. 5.7 : Vacuum brake Working : When the brake pedal is pressed to apply the brakes, the pressure of the brake fluid pushes the piston in the control unit up, thereby closing the lower valve and opening the upper valve. Thus left side of servo piston is exposed to atmospheric pressure, whereas vacuum acts on the right side. This causes the servo piston to move towards right side. This movement is utilized to apply the brakes in the wheels through some linkage. aaa Advantages : Force to be exerted by the driver is reduced because the braking effort is supplied by the engine vacuum. 9.11 AIR BRAKING SYSTEM Main parts of an Air Braking System are : 1. Air filter/suction strainer Compressor Unloader valve Air Reservoir A brake valve/control valve 6. Pressure gauge . Safety valvel/relief valve 8. Brake chambers 9. Low pressure indicator Zz 3. 4. 5.10. Stop light switch " yw. Air bottle for supplying air for the inflation of tyre 12. Aquick release valve 43, Limiting pressure valve Layout : ig ae sone the layout of air braki the air filter by the compressor i a inside the reservoir mes a ppedeorulned wate a, When the revents any further rise of pressure. When the pressure drops to a pre determined F G e value the unloader valve opens and pressure is again built up. Compressor ng system. The air is sucked Air ind Reservoir }—10_, Accessories Unloader Valve Air Filter Brakle Chamber REAR Fig. 5.8(a) : Layout of air brake system When the foot pedal is pressed for applying brakes, the compressed air from the reservoir pass through the brake valve and acts against the diaphragm in brake chambers [See Fig. 5.8(c)]. There are separate air brake chambers for each wheel. The diaphragms are connected to brake rods. The brake rods operate the brake shoe cams which in turn expands the shoes to apply the brakes. a When the pedal is released the brake valve returns to the off position, cuinall supply of air to the reservoir and at the same time, opening a valve which plone he air operating in the brake chambers to escape and the brakes are seleoeea oa valvelrelief valve and pressure gauge are fitted to the reservotr. The valve is safety purpose and pressure gauge indicates the pressure inside the reservoir Description of Main Parts of Air Brake System 1. Air filter : Air filters are used to prevent dust, Particle to enter inside the system. It is mounted on chas® dirt and any type of foreign is. It has a drain plug forremoving dust which is filled inside the filter. See Fig. 5.8(b) Air enters through the inlet passage, passes through filter lement and flows out through outlet passage. Any foreign particle or dust particles deposit in the bottom from where it is removed by opening the drain plug. Screw O oO Filter: Body C.l. ee Plug Fig. 5.8(b) : Air Filter 2. Compressor : An air compressor receives air from atmosphere, increases its pressure and delivers it to the reservoir. This high pressure air is supplied through pipe lines to the reservoir. 3. Unloader Valve : This valve is mounted between compressor and Air reservoir. The function of this valve is to control the pressure of air inside the reservoir. This valve releases the air to the atmosphere which is suppled by compressor so that the reservoir may not have excess of air than predetermined limit. 4. Air Reservoir : It stores the compressed air in s always an ample supply of air available when required in braking operation. It also stores the air which is also used for various other accessorries like horn, to run wiper motor etc. Total volume of air reservoir may be 20-25 litre. 5. Brake Valve : This valve controls th system. It consists of uch a way that there is e intensity of braking in an air pressurewe () Spring loaded hollow piston (ii) Inlet valve (ii) Exhaust valve (iv) Exhaust port (v) Piston return spring (vi) Bleed hole (vi) Graduating spring (viii) Stop light switch. When the driver presses the brake pedal for applying the brakes, the piston is pushed down against the force of graduating spring and thus the graduating spring js being pressed. The driver feels the intensity of braking due to this spring force. As the piston moves in downward direction the exhaust valve gets closed and the inlet yalve opens, thereby, allowing the air to enter the brake chambers at each wheels to apply the brake. Also some air goes to stop light switch to glow the stop lights. When the brakes are applied the air also enters the chambers under the piston through the bleed hole and the air pressure also acts on the bottom side of the piston and balances the mechanical force applied on the piston by the driver. If the air pressure is greater than the mechanical force applied by the driver, the piston is again lifted up, the exhaust valve opens and the air escapes through exhaust valve and exhaust port till the pressure is balanced on both sides of the piston. If the driver wants to increase the braking intensity, the brake pedal is pressed further and the piston will move down due to which the inlet valve will open further Applied Force Through Linkage : Graduating Spring: Piston Piston Return Spring Bleed Hole Exhaust Valve. To Stop Light Switch Air to Brake Chambers Air from Reservoir Fig, 5.8(c) :Brake Valve and more air will enter the chamber. On the other hand if the driver wants to decrease the braking intensity he will release slight amount of the pedal hard andthe piston will move up due to which the exhaust valve opens and the air ore through exhaust port till a balancing force is there on the piston. When the brake pedal is released completely, there is not any mechanical pressure on the piston. Hence, the air lifts up the piston and opens the exhaust valve and shuts off the inlet valve. Now there is no connection between reservoir and brake valve. So brake shoes are released. ‘Scale Pointer Diaphragm Wi Fig. 5.8(¢) : Diagram Pressure Gauge 6. Pressure gauge : It consists of a diaphragm. It is connected to the reservoir. The air inside the reservoir causes some elastic deformation of the diaphragm. With the help of same pinion arrangement the elastic deformation of the diaphragm rotates the pointer and this rotation of the pointer on the dial gives us the reading of pressure inside the air reservoir. This gauge is mounted in front of the drivers dash board so that the driver can read the pressure. 7. Safety Valve : The function of safety valve is to open if excessive air pressure is built inside the air reservoir so that excessive air pressure should not damage or explode the reservoir. 8. Brake chamber : It is mounted on each wheel. Its function is to convert the energy of compressed air into mechanical force. The brake chamber generally used is diaphragm type. Brake chamber consists of following parts : (@) Diaphragm @i) Inlet port (iii) Pressure Chamber (w) Spring (v) Push rod.Breatherhole To Brakes Air Inlet —> Push Rod pressure Chamber Fig. 5.8(e) : Brake Chamber (Single Diapragm) The return spring holds the push rod against the diaphragm where as seal prevents the passage of dust and dirt. The spring is located over the push rod. When the compressed air from brake valve enters the pressure chamber, it pushes the diaphragm thereby pushing the rod which actuates the cam of the brake shoes. Thus the brakes are applied. When brake pedals are released, there is no compressed air and thus the diaphragm comes to its original position due to spring pressure. 5.12 BRAKE SHOE EQUALISING On application of brakes the piston moves out of cylinder and pushes apart the brake shoes. Brake lining first comes in contact with brake drum. It is observed that ‘op portion of brake lining first comes in contact with brake drum and then the rest. So the top portion first comes in contact with brake drum. It, wears out quickly. For efficient braking complete brake lining area with equal thickness must come in contact with brake drum. After some time, brakes are not so efficient. __Toensure that complete braking area of shoe comes in contact with brake drum immediately on application of brakes, equilising rods are used. 5-13 BRAKE SHOE ADJUSTING (SHOE CLEARANCE) ane Considerable use of the brake, lining and drum get worn off, as the wheel ies “" Piston has a fixed stroke. When the brake shoe and drum get worn off, the ee shoe cannot exert sufficient pressure and the brakes start arn This gap i en brake shoe lining and drum is called shoe clearance. To adjust the clearance °en brake drum and shoe, brake adjusters are used.5.14 TYPES OF BRAKE ADJUSTERS There are four types of brake adjusters as follows : 1. Serrated Wheel Adjuster : An adjusted screw head fixed with serrated wheel (toothed disc). This adjustable screw can be screwed in or out by moving the serrated wheel with screw driver. 2. Crank Type Adjuster : These are used in Tata vehicles. In this case, crank portion of an adjusting bolt remains in contact with the back of shoe. On turning the bolt, the crank end will push the shoe close to drum. 3. Wedge Type Adjuster : These are used in Leyland vehicles. A bolt called wedge has a tapered head and can screw in or out from the back of prake-back-plate. While screwing in, the wedge pushes apart two links which in turn push the brake shoes out. 4, Snail And Cam Type Adjuster : These are widely used in small vehicles. In this type a cam rests against the back of shoe. The outer end of cam is square or hexagonal shaped. This cam can be turned by a spanner from the back of brake plate. The more the cam is pressed against shoe, the more the shoe will expand. 5.15 ANTILOCK BRAKE SYSTEM ‘Antilock braking system (ABS) is an automobile safety system which allows the wheels of a motor vehicle to maintain tractive contact with the road surface according to driver inputs while braking. It prevents the wheels from locking up and avoids uncontrolled skidding. It generally offers improved vehicle control and decreases stopping distances on dry and slippery surfaces. An antilock braking system consists of following components : 1. Electronic control unit (controller) (ECU), Speed sensors (one at each wheel), -- Solenoid valves (hydraulic) on each brake circuit, — Master cylinder, « Wheel brake cylinder. ‘The speed sensor constantly monitors the r.p.m. of each wheel and sends the information to the ECU. When the ECU senses that any wheel is about to lock up, it sends command to the solenoid valve unit to stop and reduce the build up of brake pressure until the danger of lock up has been reduced. The brake pressure again builds up so that the wheel is not ‘under-braked'. During such automatic brake control, it is necessary to detect the stability or unstability of the wheel motion constantly and the wheel must be kept in the slip range. ABS calculates the slip rates of the wheel depending upon the vehicle speed and wheel speed and then a A wwcontrols the brake fluid pressure to attain the desired slip rate, with maximum braking force by alternating the successive phases of pressure built up, pressure reduction and pressure holding. 2 1 — Manipulated U Reference variable variable Controlle variable - 1. Master cylinder 2. Solenoid-valve unit 3, Wheel-brake cylinder 4, Electronic control unit (ECU) Controlled 5, Wheel speed sensor system 4 | Controller Disturbance Fig. 5.9 : Antilock Braking System