BRAKING SYSTEM

HYDRAULIC ELECTROHYDRAULIC

brake fluid reservoir 4 4

tandem master 3 2 3 2
cylinder (TMC)
1 1
brake pedal
brake booster

disk brake
7 7

5 5
pressure reducer valve

RF RR
6
6
FRONT BRAKES REAR BRAKES
ABS
LF LR
5 7 5 7

File name
sysbrake_eng
Date
03 Feb 2013
 Vacuum hose from engine downstream
VACUUM BRAKE BOOSTER of butterfly valve; vacuum pump

AT REST (no action on brake pedal)

the two chambers of the linear
actuator are connected and held
check valve
at identical vacuum pressure

TMC push rod

brake pedal
push rod

REAR
CHAMBER empty shell divided into
two chambers by a
FRONT rubber diaphragm
CHAMBER

File name
sfreno0_eng
Date
03 Feb 2013
VACUUM BRAKE BOOSTER
BRAKE PEDAL ACTIVATED
the front chamber becomes
isolated from the rear chamber
and progressively connected to
ambient pressure. A resultant
force on the actuator is
originated that pushes the
integral sleeve ahead (negative
feedback)

REAR CHAMBER
(always at minimum pressure)

FRONT CHAMBER
File name
sfrenol_eng
Date
03 Feb 2013
 AT REST (brake pedal released)

RETAINER
PLATE PISTON PNEUMATIC SERVOSYSTEM
AIR FILTER 1 to vacuum pump
SPOOL

SLEEVE p atm p min

2 4

brake booster

TMC
PUSH 1. Source of constant pressure
ROD 2. Continuous position directional control valve
(brake pedal connected with the spool)
RUBBER
REACTION 3. Linear actuator
PAD 4. Negative position feedback (on the sleeve)

PEDAL PUSH ROD

File name
sfrnott0_eng
Date
04 Feb 2013
 BRAKE PEDAL DEPRESSED (crack point)

SLEEVE SPOOL
1 to vacuum pump

pmin
Fin
2 4

3
pmin

brake booster

 FRONT CHAMBER ISOLATED

 ACTUATOR STILL AT REST
 EFFORT ON PEDAL ONLY DUE TO
SPRINGS FORCES
 NO FORCE ON TMC

File name
sfrnottc_eng
Date
04 Feb 2013
BRAKE PEDAL DEPRESSED (generation of output force)

1 to vacuum pump

p
atm p
min
Fin
2 4

3
Fout
p
x

brake booster

 CONNECTION BETWEEN FRONT CHAMBER

AND ATMOSPHERE FULLY OPEN

 PRESSURE px IN THE FRONT CHAMBER

INCREASES
 THE PRESSURE DIFFERENCE GENERATES A
FORCE ON THE ACTUATOR

File name
sfrnottb_eng
Date
04 Feb 2013
BRAKE PEDAL DEPRESSED (negative position feedback)

1 to vacuum pump

p p
atm min

Fin
2 4

3
Fout
p
x

brake booster

 PISTON AND SLEEVE MOVE TO THE RIGHT

 VALVE RETURNS IN CENTRAL POSITION
 PRESSURE IN FRONT CHAMBER AT INTERMEDIATE

VALUE BETWEEN pmin AND patm

 REACTION PAD EXTRUDED TOWARDS THE
CENTRE OF THE PISTON AND AGAINST THE SPOOL

File name
sfrnotth_eng
Date
04 Feb 2013
BRAKE PEDAL DEPRESSED (servosystem saturation)

1 to vacuum pump

p
atm p
min
Fin
2 4

3
Fout
patm

brake booster

 MAXIMUM PRESSURE (ATMOSPHERIC) IN

THE FRONT CHAMBER
 FURTHER INCREMENT OF THE FORCE ON
TMC IS SUPPLIED ENTIRELY BY THE DRIVER

File name
sfrnotts_eng
Date
04 Feb 2013
 STEADY-STATE CHARACTERISTIC
Fout
m
p at
=
knee p x
saturation
point
45°
Fin Fout
atm d D
p

steady-state point
p <
x
min <

Fservo
p

transient

jump-in

Fin
crack
p x = p min point

p atm p min amplification ratio (3:1)

File name
amplratio
px A Date
03 Feb 2013
 TANDEM MASTER CYLINDER
first variable volume second variable
T chamber T volume chamber

Rest
position

second
first piston
piston F0 = 135 N
F0 = 120 N
k = 6.6 N/mm
P1 k = 7.2 N/mm P2

T T
Working
position

P1 P2
File name
pdoppia2_eng
Date
03 Feb 2013
TMC AT REST: CONNECTION OF CHAMBERS TO OIL RESERVOIR

AT REST IN OPERATION

File name
pdppingr_eng
Date
03 Feb 2013
BRAKE BOOSTER - TANDEM MASTER CYLINDER ASSEMBLY

Rest position

T T

A B

File name
sfrnpp0_eng
Date
03 Feb 2013
BRAKE BOOSTER - TANDEM MASTER CYLINDER ASSEMBLY

Working
position

File name
sfrnpp1_eng
Date
03 Feb 2013
TMC BOSCH WITH CENTRAL CLAPET

File name
tmc1_eng
Date
11 Feb 2014
 TANDEM MASTER CYLINDER
REST POSITION

WORKING POSITION

File name
tmc3_eng
Date
06 Feb 2013
 air suction from brake-booster SINGLE VANE VACUUM PUMP
air suction from
oil inlet
secondary user

air suction port

(connected with
secondary user)

oil inlet oil + air mixture port

(connected with oil + air outlet)
oil + air outlet
air suction port
(connected with brake booster)
3 variable
volume
chambers slipper

File name
depressore_eng
SIZES: 130 - 190 - 260 cm3/rev Date
03 Feb 2013
 DISPLACEMENT OF SINGLE-VANE VACUUM PUMPS

0° 90° 180°

outlet port

Vmax

inlet port

270° 360° 540°

Vmin

N=3 No. of chambers

nc = 2 / 3 No. of cycles per

shaft revolution

unit displacement 1 cycle in 1,5 revolutions

File name
vpcycles
Date
03 Feb 2013
 PERFORMANCE CURVE OF A VACUUM PUMP

File name
testvacuump
Date
03 Feb 2013
LOCATION OF THE VACUUM PUMP ON THE ENGINE

File name
multijet_1600_depr_eng
Date
03 Feb 2013
 OTHER VACUUM PUMPS
SUCTION PORT FROM BRAKE BOOSTER

OIL INLET

DISCHARGE OF
MIXED AIR + OIL

NON RETURN VALVE

IN THE SUCTION LINE
File name
nissan_depr_eng
Date
03 Feb 2013
OTHER VACUUM PUMPS

OIL + AIR MIXTURE

DISCHARGE

OIL INLET

AIR SUCTION FROM

BRAKE BOOSTER

File name
lanciadelta_depr_eng
Date
03 Feb 2013
free rolling wheel vp WHEEL SLIP
friction force
typical ABS operating range

C vv
braking force coefficient
FN 1.0 lateral force coefficient
(steerability)
0.8

vp 0.6
braked wheel

0.4

0.2
C vv
0
FN 0 0.2 0.4 0.6 0.8 1
slip factor
free rolling wheel locked wheel

v v = vehicle speed
v p = peripheral wheel speed File name
slip factor
FN = normal force slip_coef_eng
Date
05 May 2014
 PARTIAL CIRCUIT SCHEMATIC OF MODULE ABS 2S

Tandem master cylinder

fixed capacity
damping orifice

P
delivery check
valve hold

increase
M
decrease

suction check
valve
B
spring accumulator

Caliper pistons

File name
abs2s_eng
Date
08 Feb 2010
 MODULE ABS-2S
A'1 (A"1 ) A'2 (A" )2 (simplified) A' 1 (A'2) A"1 (A"2 )
B 1 (B 2)

B1 B2
1

electrovalve
2

P1 P2 P 1 (P2 )
7

electric
motor

p0 = 3 bar eccentric driving the File name

recirculation pump abspipe_eng
Oct 1978 ABS 2S on Mercedes S
Date
and BMW 7 (mass of 6.3 kg)
04 Feb 2013
 RECIRCULATION PUMP IN ABS 8

ECCENTRIC
PUSHES ON THIS
STEM

DELIVERY
INLET

File name
sez_pompa_ricircolo_abs8

VARIABLE VOLUME CHAMBER Date

08 May 2009
to recirculation duct B ELECTROVALVE - REST POSITION

to caliper piston
A A

brake pressure increase

P
File name
abs2sv30_eng
scale 2:1 Date
04 Feb 2013
 ELECTROVALVE - INTERMEDIATE POSITION
B

A A

brake pressure hold

A

P File name
scale 2:1 abs2sv31_eng
Date
04 Feb 2013
 ELECTROVALVE AT MAX STROKE
B
 max current
 electric motor running
A A

brake pressure decrease

A

P File name
abs2sv32_eng
scale 2:1 Date
04 Feb 2013
 SOME COMPONENTS OF THE 3/3 ELECTROVALVE
roller bearing
poppets
upper end stop of
the sleeve

poppet seats

sleeve

upper filter
lower filter check valve
File name
elettrovalvola2S
Date
05 May 2015
 END STOPS IN THE ELECTROHYDRAULIC VALVES

movable end stops fixed end stops

upper end stop
of the sleeve

end stop of the

movable end
recirculation poppet
stop of the
recirculation
poppet

movable end
stop of the
inlet poppet end stop of the inlet
poppet

lower end stop

of the sleeve

File name
abs2sest_eng
Date
08 Feb 2010
 COMPLETE CIRCUIT SCHEMATICS OF MODULE ABS 2S

vacuum
pump
tandem
master
cylinder

brake booster
ABS 2S

caliper pistons caliper pistons

RF X link LR LF X link RR
File name
sysbraeq_eng
Date
04 Feb 2013
14 PISTON FIXED CALIPER ON VENTILATED BRAKE DISK

File name
brake_disk_14_eng
Date
04 Feb 2013
 MODULE ABS 5.3

1993 ABS 5.3: transition from 3/3 to 2/2 electrovalves

File name
abs53img_eng
Date
20 Nov 2015
CIRCUIT LAYOUT OF MODULE ABS 5.3
No. 8 2/2 electrovalves
ABS 5.3

MC2 MC1
st2 st1
D2 D1

RP2 M RP1

LREV RFEV LFEV RREV

A2 A1

LRAV RFAV LFAV RRAV

LR RF LF RR

File name
abs5_3_eng
Date
14 Dec 2015
 CONDITION OF PRESSURE INCREASE
(PARTIAL CIRCUIT LAYOUT) ABS 5.3

st1
D1
RP1

TMC1

RREV LFEV
A1

RRAV LFAV

EV: EINGANG VENTIL

AV: AUSGANG VENTIL
File name
RR LF abs5_3_cut_accr_eng
Date
14 Dec 2015
 CONDITION OF PRESSURE HOLD
(PARTIAL CIRCUIT LAYOUT) ABS 5.3

st1
D1
RP1

TMC1

RREV LFEV
A1

RRAV LFAV

File name
RR LF abs5_3_cut_mant_eng
Date
14 Dec 2015
 CONDITION OF PRESSURE DECREASE
(PARTIAL CIRCUIT LAYOUT) ABS 5.3

st1
D1
RP1

TMC1

RREV LFEV
A1

RRAV LFAV

File name
RR LF abs5_3_cut_riduz_eng
Date
14 Dec 2015
 ESP FOR LATERAL STABILITY
Understeering Oversteering

without ESP

desired desired with ESP

trajectory trajectory

with ESP

without ESP

Additional transducers:
- steering wheel angle sensor: desired trajectory
File name
- yaw rate and lateral acceleration sensors: real trajectory underoversteering
Date
04 Feb 2013
 ELECTROHYDRAULIC MODULE ABS 5.7 ESP

1998 ABS 5.7 ESP: a total of 12 electrovalves

File name
ABS_5.7_ESP_nn
Date
20 Nov 2015
CIRCUIT LAYOUT OF THE ABS
5.7 ESP MODULE

TP ESP
P

HSV2 HSV1

USV2 USV1

sRP2 D2 D1 sRP1

RVR2 RVR1

LREV RFEV LFEV A1 RREV

A2

LRAV RFAV LFAV RRAV

LR RF LF RR
File name
esp_new_eng
Date
04 Feb 2013
ESP intervention: generation of a
counteracting jaw torque

TP ESP

HSV2 HSV1

USV2 USV1
D2 D1

sRP2 sRP1

RVR2 RVR1

LREV RFEV LFEV A1 RREV

A2

LRAV RFAV LFAV RRAV

LR RF LF RR
File name
esp_yaw_eng
Date
13 Feb 2014
 INLET VALVE: EINGANG VENTIL (EV)

OUT

EV

OUT OUT IN

File name
Assem_EV_eng
scale 4:1 IN Date
11 Feb 2014
 OUTLET VALVE: AUSGANG VENTIL (AV)

OUT

AV

IN

IN

File name
Assem_AV_eng
OUT Date
scale 4:1
11 Feb 2014
 USV NORMALLY OPEN VALVE
IF ESP ACTIVE IT SHUTS AND TAKES
ON THE ROLE OF A RELIEF VALVE

IN

USV

OUT
IN

File name

scale 4:1
OUT Assem_USV_eng
Date
11 Feb 2014
 HSV NORMALLY CLOSED VALVE
IF ESP ACTIVE IT SHIFTS CONFIGURATION TO ALLOW
FLOW RECLAMATION FROM FLUID RESERVOIR

IN

HSV

s S S
k2

k1

IN OUT

File name
OUT Assem_HSV_eng
Date
scale 4:1
11 Feb 2014
MODULE ABS8 ESP

HSV valves section

File name
abs8_overview_eng
Date
22 Dec 2015