BRAKING SYSTEM

2
Can you tell the situations when driver normally apply brakes of a vehicle:
• At speed breakers
• At turnings
• Any obstacles on the road
 INTRODUCTION
3
• In order to bring the moving motor vehicle to rest or show down in a shortest possible
time, the energy of motion possessed by the vehicle must be converted in to some other
form of energy.
• The rate of slowing down or retardation is governed by the speed of conversion of energy.
• Kinetic energy is the energy of motion which is converted in to heat given up to air, blowing
over the braking system.
• They are vitally important in the running and control of the motor vehicle.
 INTRODUCTION
4
• The brakes provided by the manufacturers should be effective, safe in operation,
progressive and consistent in response to pedal as well as reasonably easy to adjust.
• Lives and comfort of not only the driver and the passengers but also those of the other
road users are saved.
• Brake is friction device for converting the power of momentum or kinetic energy of the
moving vehicle in to heat by means friction.
• It is the main factor governing even if sufficient effort is available to lock the wheels.\
• This amount of friction developed between two surfaces in contact is independent of the
area of the surface in contact
 INTRODUCTION
5
• On the early motor vehicles, single shoe brakes were used.
• They were based on the fact that the heat generated due to friction between the wheel and the
shoe is proportional to the force pushing the shoe into contact.
• The greater the force applied to shoe, the quicker is the stoppage of the vehicle.
• But there is a limit to the force applied due to skidding of the wheel over the road.

• Brakes are one of the most important control components of vehicle

• They are required to stop the vehicle within the shortest possible distance immediately.

• This is done by converting the kinetic energy of the wheels into heat energy, which is dissipated
into the atmosphere
 FUNCTIONS OF THE BRAKES

The main function of the Brakes are

• To stop or slow down the Vehicle in the shortest possible distance in an emergency

• To retain the control over the vehicle when descending in a hill.

REQUIREMENTS OF BRAKES
• The Brakes must be strong enough to stop the vehicle with in a minimum distance in
an emergency, consistent with safety

• The driver must have proper control over the vehicle during emergency Braking and
the vehicle must not skid.

• The Brakes must have good antifade characteristics i.e. their effectiveness should not
decrease constant prolonged application

Ex: while descending hill

• The above requirement demands that the cooling of the brakes should be very efficient
Some terms related to Braking:

• Stopping distance

• Stopping time

• Brake efficiency
Stopping Distance: It is the distance travelled by the vehicle after the application of
brakes. The distance generally measured in meters. It is given by the formula.
S= U²/2a
Stopping Time : It is time taken to stop the vehicle after the application of brakes. The time
generally measured in seconds.
It is given by the formula
t = u/a
where S = Distance travelled in meters.
U = Initial velocity in m/sec
a = Deceleration in m/sec²
 Brake Efficiency
• The rate at which the braking system will bring the vehicle to a stationary position from a
given speed is known as braking efficiency.

• It is a ratio of its rate of deceleration to the acceleration due to gravity.

Braking efficiency = /g x 100 %
• The efficiency being 100% when  = g.

Theoretically 100% Brake efficiency present, But in actual practice, 100% efficiency is not

possible because of due to safety of passengers and goods

 STOPPING DISTANCES

Efficiency Approximate stopping distance (mts)

from speeds
% 30km/h 50km/h 80km/h 100km/h

100 3.5 9.8 25.2 39.3

80 4.4 12.2 31.5 49.1

60 6.0 16.3 42.0 65.5

30 12.0 32.6 84.0 131.0

 Brake Efficiency
• A highly efficient brake gives a large value of deceleration subjecting the passengers to heavy
jolts.

• The safe value of deceleration is 2m/sc

• The minimum braking efficiency is 50% and the highest braking efficiency is 80%

• For hand brakes, the braking efficiency is 30%

1. Find the stopping distance and stopping time of a vehicle when it is travelling at a speed of 72 km.ph, the rate
of deceleration is 4m/s²

Solution:
Given Speed (u) = 72 Km/h
= 72x1000m/3600 s
= 20 m/s
• Deceleration (a) = 4m/s²
• Stopping distance S = u² / 2a
= (20) ²/2x4 = 400/8 = 50 meters
Ans.
• Stopping time (t) = u/a
= 20/4 = 5 seconds Ans
2. Find the stopping distance, stopping time and brake efficiency of the vehicle when it is
travelling at 80kmph, the rate of deceleration is 5m/s².
Given:
Speed (U) = 80 Kmph
= 80x1000m/3600 sec
= 22.3 m/s
Deceleration (a) = 5m/s²
Stopping distance S = U² / 2a
= (22.3) ²/2x5 = 22.3x22.3/2x5
= 22.5mts .
Stopping time (t) = u/a
= 22.3/5 = 4.5 seconds
3. Find the stopping distance, stopping time and brake efficiency of the vehicle when it is travelling at 54 kmph, the
rate of deceleration is 5m/s².
Given:
Speed (U) = 54 Kmph
= 54x1000m/3600 sec
= 15 m/s
Deceleration (a) = 5m/s²
Stopping time (t) = u/a
= 15/5 = 3 seconds
Brake efficiency = /g x100
where  = 5m/s²
g = 9.8m/s²
= 5/9.8 = 51%
Brake efficiency = 51%
4. Find the stopping distance, stopping time and brake efficiency of the vehicle when it is travelling at 60 kmph, the rate of deceleration is
5m/s².
Given: Speed (U) = 60 Kmph

= 60x1000m/3600 sec
= 16.3 m/s
Deceleration (a) = 5m/s²
Stopping distance S = U² / 2a

= (16.3) ²/2x5 = 16.3x16.3/2x5 = 26.5mts .

Stopping time (t) = u/a

= 16.3/5 = 3.2 seconds
Brake efficiency = /g x100
where  = 5m/s²
g = 9.8m/s²
= 5/9.8 = 51%

Brake efficiency = 51%

 TYPES OF BRAKES
The brakes for automotive use may be classified according to the following considerations.

According to purpose: According to method of Actuation:

• Mechanical brakes
• Service or primary brakes • Hydraulic brakes
• Parking or secondary brakes • Electric brakes
• Vacuum brakes
• According to location: • Air brakes
• Transmission brakes
• Wheel brakes
According to Extra braking effort:
• According to Construction: • Power brakes
• Power assisted brakes
• Drum brakes
• Disc brakes
Parking Brakes
• Hand brakes are the secondary brakes. These are
also called parking brakes.

• These are mainly used to hold the vehicle on a slope

• The hand brake is used by the driver on two
occasions

• when the primary foot brake system fails,

• when the car is to be parked on a gradient

Hand Brake

Fig : 2
Hand Brake
1) Ratchet release handle
2) Hand brake lever
3) Catch rod
4) Guide
5) Pawl
6) Ratchet
7) Bracket
8) Brake cable
WORKING OF HAND BRAKE
• A ratchet release handle to which the catch rod is attached, is
hinged on the hand brake lever.
• To the other end of the catch rod, a pawl is attached, which slides
in the guide fixed on the brake lever
• The brake lever itself is hinged on a bracket, which is bolted to the
chassis frame on the in side.
• On this bracket is also mounted a ratchet as shown in the figure.
The operating cable is attached to the lower end of the brake
lever.
• To apply the brakes, the ratchet release handle is pressed, which
causes the pawl to move up, disengaging the ratchet.
• Then the brake lever is pulled up which further pulls the cable
which operates the rear brakes.
• The ratchet release handle, which had been pressed so far, is
released now, so that the pawl moves down with the spring action
and engages with the ratchet thus keeping the brakes applied.
Mechanical Brakes
 MECHANICAL BRAKES
• Brakes, which are operated mechanically by means of links, levers, pedals, cams etc., are called
mechanical brakes.

• In a motor vehicle, the wheel is attached to an auxiliary wheel called drum.

• The brake shoes are made to contact this drum.

• In most designs, two shoes are used with each drum to form a complete brake-mechanism at

each wheel

• These are widely used in two wheelers and farm tractors

 MECHANICAL BRAKES
Drum Brakes:

• The Brake drum is attached to the axle hub and

the back plate is mounted on the Axle casing.

• The back plate is made of steel and provide

support for the expander, anchor and brake shoes.

• The back plate absorbs the complete torque

reaction of shoes, so it is called as Torque plate

Drum Brakes:

• The back plate protects the drum and shoe assembly from mud and

dust.

• The brake shoes are anchored at one end, on the other end some

force is applied by brake actuating mechanism

• The brake shoes have brake linings on their outer surfaces.

• Each brake shoe is hinged at one end by an anchor pin, the other end
is operated by some means so that the brake shoe expands outwards
the brake linings come into contact with the drum.
• Retracting spring keeps the brake shoes into position when the brakes
are not applied.
 MECHANICAL BRAKES
• When the brake pedal is pressed, the cam turns by means of brake linkage.

• When the cam turns, the shoe expands outwards against the drum.

• A toggle lever is also used for the same purpose as shown in fig.2.

• The brake linings rub against the drum and thus stop its motion.

• The entire mechanical linkage between the brake pedal and the shoes operates to transmit

pedal force to the brake shoes

• To multiply that force through leverage to produce effective braking forces against the drum
Hydraulic brakes
HYDRAULIC BRAKES
• Most of the cars today use hydraulically operated foot brakes on all the four wheels

• An additional hand brake mechanically operated on the rear wheels

• Some two wheelers have hydraulic brakes for the front wheels
WORKING PRINCIPLE
The principle by which hydraulic brakes operate is based on PASCAL's law

Which states that a pressure applied to a liquid enclosed on all sides is propagated
uniformly in all directions

Hydraulic transmission of braking force is usually arranged to step up the transmitted

force at the same time
 Pascal’s Law

•This principle ensures that the same working pressure is built up at all the wheel
cylinders
• In hydraulic system the forces interact in the same ratio as the piston areas in the

cylinders i.e larger the surface area, greater the force and vice-versa.

• Piston travel distances are in inverse proportion to the forces

 Layout of Hydraulic Brakes
• Pedals

• Reservoir

• Master cylinder

• Hydraulic lines ( steel pipes and flexible hoses )

• Wheel cylinder

• Wheel brake unit

• Brake fluid
Hydraulic Brake System
Hydraulic Braking System
 WORKING
• When the brake pedal is pressed, the Fluid under pressure enters into Fluid lines from the Master cylinder.

• From the Fluid lines it enters into the wheel cylinder (incase of Drum Brakes) or Caliper (incase of Disc brakes)

• Due to Fluid pressure, the wheel cylinder or Caliper actuated and the Brakes are applied
• In some vehicles on front wheels each brake shoe is operated by separate wheel cylinder (thus making the brake
with two leading shoes)
• Whereas in case of rear wheels there is only one cylinder on each wheel, which operates both the shoes (thus giving
one leading and one trailing shoe brakes).
• As the rear wheel cylinders are also operated mechanically with the hand brake, they are made floating.

• The system is so designed that even when the brakes are in the released position, a small pressure of about 50 kPa is
maintained in the pipelines to ensure that the cups of the wheel cylinders are kept expanded.

• This prevents the air from entering the wheel cylinders when the brakes are released.
MAIN COMPONENTS OF HYDRAULIC BRAKES
• Break Pedal
• Reservoir
• Master cylinder
• Hydraulic lines ( steel pipes and flexible hoses )
• Wheel cylinder
• Wheel brake unit
• Brake fluid
BRAKE PEDAL
• The brake pedal is a lever with the pedal end very much longer

than the end operating the master cylinder piston

• Mechanical ratio is between 1:4 and 1:5

• In many cases the complete pedal assembly comprising clutch,

brake and accelerator pedals is suspended from a point above

the drivers feet

( Pendant pedals )
RESERVOIR
• It stores the brake fluid.

• The fluid reservoir is an integral part or some times

made as separate part and attached to compression

chamber.

• The fluid in the reservoir compensates for any change in

the fluid volume in the pipelines due to temperature

variations and to some extent due to leakage.

MASTER CYLINDER
• The master cylinder builds up pressure in the brake
circuits
• It is actuated by brake pedal using a linkage of adjustable
length
• It is usually made of steel or cast iron
• Present day master cylinders are made of Aluminum alloy
• Master cylinder is dealt further in lesson
• Used to link the hydraulic brake system elements at
various points on the vehicle together
• They must be of seamless drawn, rolled and welded double
walled steel tube
• The tube surface must be smooth clean and free from
inside and outside
• Pipes with external dia of 4.75 mm, 6mm,8mm and 10 mm
are used
 HYDRAULIC LINES STEEL PIPES
• An outer plastic coating improves corrosion protection
• Pipes must be secured with straps or clips at intervals of not
more than 500 mm to prevent vibration
• The flexible brake hose acts as a transition between rigid pipe
system and parts of the vehicle which have to move For
example: axles and suspension
• Brake hoses must never be too tight when installed nor
should sag at any point or be twisted
• Brake hoses must not be run close to the vehicle’s exhaust
system
• Brake hoses should be protected against oil, fuel and
penetrating sprays
WHEEL CYLINDERS

• The pressure built up in the master cylinder acts on

the pistons and generates the clamping or expanding
force needed to apply brake shoes to the drums or
the pads to the discs

• Wheel cylinder of drum brakes are attached to the

brake back plate.

• They are discussed further in lesson

 WHEEL BRAKE UNIT
• The friction most commonly used on road vehicles are the drum brakes and disc type
• Many passenger cars have disc brakes at the front and drum brakes at the rear wheels
• Because it is easier to arrange for a parking brake at all wheels
• Most commercial vehicles have drum brakes at all wheels
DRUM BRAKE
• The most frequently used form of drum brake on road
vehicles is the internal – expanding shoe brake

• Its principal components are the brake drum, the back

plate, the brake shoe and tensioning device.
 DISC BRAKE
• Disc brake consists of cast iron disc bolted to the wheel hub

• A stationary housing called caliper

• Caliper is connected to some stationary part of the vehicle like stub axle

• Caliper houses piston.

• The caliper can be of fixed or floating type

• The fixed caliper contains two (sometimes four) brake cylinders in

opposed pairs, each with a piston to which the brake pad is attached

• The floating caliper has a hydraulic cylinder on one side of the disc only.
 BRAKE FLUID
• The fluid used in Hydraulic brakes is a mixture of Glycerin and alcohol or caster oil, denatured alcohol and
some additives.
• The brake fluid should have high boiling point i.e. about 250 to 300c,

• No change in Viscosity

• Resistance to high temperature

• Low setting point ( below – 40 0 C )

• Resistance to ageing
• Hygroscopic ( water absorbent ) only to a minimum extent
• Low internal friction
• Good lubricating effect
• There should not be any effect on rubber and corrosive action. It should have good storage stability.
Master Cylinder
• It is rightly named as heart of the hydraulic braking
MASTER CYLINDER
system.

• There are two main chambers

• The fluid reservoir and

• Compression chamber in which the piston operates.

• The master cylinder builds up pressure in the brake

circuits

• It is actuated by brake pedal using a linkage of

adjustable length

• It is usually made of steel or cast iron

• Present day master cylinders are made of Aluminum

alloy
Master Cylinder
PURPOSE OF FLUID RESERVOIR
• The fluid in the reservoir compensates for any change in the fluid volume in the pipelines
due to temperature variations and to some extent due to leakage
• Usually it is made of plastic
COMPRESSION CHAMBER
• Compression chamber is made of cast iron
• Compression chamber consists of piston , seals, piston return spring and fluid check valve
• To prevent leakage, there are rubber seals on both ends of the piston in the compression chamber.
• A rubber boot covers the push rod end of the master cylinder to prevent the dirt from entering
inside Two holes connect the fluid reservoir to the compression chamber.
• The smaller one out of these is about 0.7mm diameter and is called by pass or compensating port.
• The second hole is called the intake port. Besides, there is a vent in the cap, to keep the brake fluid
always at atmospheric pressure.
 PISTON
• The reduced diameter region of the piston is always surrounded
by the fluid.

• There are a number of holes in the piston head on the primary

(high pressure) seal side

• Piston is made of Aluminum alloy

• Piston is operated by push rod

• The push rod is operated with the foot brake pedal through
linkage.
 FLUID CHECK VALVE
• Towards the brake lines side of the compression chamber, there is a fluid check
valve with a rubber cup inside.
• It serves to retain the residual pressure in the brake lines even when the
brakes are released.

• As the pedal is pressed, push rod moves to left side against the force of the
spring, till it covers the bypass port.

• Further movement of the push rod causes building up of pressure in the

compression chamber.

• Finally, when sufficient pressure has built up, the inner rubber cup of the fluid
check valve is deflected forcing the fluid under pressure in the lines.

• This fluid enters the wheel cylinder or the caliper and moves the pistons
thereby applying the brakes.
WHEN BRAKES RELEASED
• When the brake pedal is released, the spring pressure
in the master cylinder moves the piston to the right
extreme position.
• This same force of the spring keeps the fluid check
valve pressed on its seat for sometime and thereby
delays the return of fluid from the lines into the
compression chamber again.
• Some delay is also caused by the inertia of the fluid in
the lines.
• This produces a vacuum in the compression chamber
and unless this is destroyed immediately, there are all
chances of air leaking into the system.
• Even a very small amount of air will render the brakes
useless, the air being compressible
TO KILL VACUUM
• This problem is solved by intake port
• As soon as some vacuum is formed, the atmospheric pressure in the fluid reservoir forces the
fluid through intake port and through holes of the piston into the compression chamber
• As the Fluid is entered into the compression chamber, the vacuum is destroyed.
AFTER DESTROYING VACUUM
• But by the time this vacuum is destroyed, the fluid from the lines comes back into
reservoir by lifting the fluid check valve off its seat.
• This extra fluid now has to be accommodated somehow, because compression chamber is
already full.
• If this is not done the pressure in the lines will not be relieved fully and there are all
chances of brake shoes rubbing with the drum.
• This is avoided by means of bypass port. The extra fluid coming from the lines passes to
the fluid reservoir, where pressure is maintained atmospheric by providing an air vent.
 COMPENSATION FOR WEAR OF BRAKE SHOES

• In case brake linings or pads are worn so that there is excessive clearance between lining and
drum or between pad and disc.

• A quick release of brake will draw extra fluid from the reservoir into the compression
chamber and thereafter a quick pressing of the pedal will send this extra fluid into the brake
pipelines,

• Thus taking up the excessive clearance. In this way a quick pumping up of the brake pedal
helps compensate for the wear of the brake linings or pads.
 DRAWBACK IN MASTER CYLINDER

• Since there is only one outlet from master cylinder any damage in pipelines even at one
wheel end will render complete brakes useless

• To avoid such problem Master cylinder is replaced with Tandem Master Cylinder
Tandem Master Cylinder
Tandem Master Cylinder

Fig .3
 HOW FAILURE OF BRAKE LINE IS DETECTED ?

• Considerable longer pedal travel when brakes are applied

indicates failure in brake line
TANDEM MASTER CYLINDER
• It ensures reliability with not much extra cost
• In this separate lines go to different sections of the brake system, say the rear and the front brakes
• It is so arranged that if the front brake lines are damaged, the rear brakes will be still effective
• Similarly if rear brake lines are damaged, at least front brakes will be applied.
 TANDEM MASTER CYLINDER
• Under ordinary conditions the brake fluid will transmit
pressure both to front as well as to the rear brakes, when
the brake pedal is applied

• However when the rear brake lines are damaged, piston(2)

will move till it comes up against stop(3)

• After this, pressure will start building up in space between To Rear break lines
pistons (1) and (2) and front brakes will be applied
• Similarly, when the front brake lines are damaged, no pressure will build up in space
• between pistons (1) and (2)
• So piston(1) will move freely till it comes up against (2).
• Further push at the brake pedal will move both pistons (1) and (2) together thereby
• applying the rear brakes.
Wheel Cylinder

Wheel Cylinder

Return Spring

Back Plate

Brake Shoes
WHEEL CYLINDER
• Wheel Cylinder (Or Slave Cylinder): Wheel cylinder is the second important component of the

hydraulic brake system.

• The pressure built up in the master cylinder acts on the pistons in the wheel cylinder

• It Generates the clamping or expanding force needed to apply the shoes to the drums or the pads

of the discsThe wheel cylinders of drum brakes are attached to the brake back plates.

• Their pistons are sealed by rubber cup type or slotted ring sleeves

• Dust caps are provided to prevent contamination

WHEEL CYLINDER
WHEEL CYLINDER CONSTRUCTION
• It consists of two pistons, which can move in opposite directions by the fluid
pressure.
• It is rigidly mounted on the backing plate.
• The boots protect the cylinders from foreign substances.
• Bleeder valves are provided in the cylinder to permit air and liquid to be
pumped out of the system during the bleeding operation.
• Piston cup fits tightly in the cylinder against each piston and seal the
mechanism against leakage of the brake fluid.
• A spring serves to hold the cups against the piston when the pressure is
decreased.
WHEEL CYLINDER CONSTRUCTION
• The copper coated, tinplated annealed steel tubing and flexible

hoses are used to connect the master cylinder to the wheel

cylinders.

• The hoses are used to connect the lines to the front wheel

cylinders to permit the front wheel to be turned.

• Rear wheel cylinders are generally connected directly to a line

fastened to the rear axle housing.

• The brake lines are attached directly or by means of brackets

to the frame or axle housings.

WORKING OF WHEEL CYLINDER
• When the brakes are applied the brake fluid enters the

cylinder from a brake line connection inlet between the

two pistons.

• It causes to force out the two pistons in opposite

directions.

• This motion is transmitted to the brake shoes directly or

through links force them against the brake drum, thus EXPLODED VIEW OF THE WHEEL
CYLINDER
applying the brake.
TYPES OF WHEEL CYLINDER
Wheel Cylinder With Adjusting Cap
Do you know about Drum brakes ?

What is leading Shoe ?

What is Trailing Shoe ?

DRUM BRAKE 9A404.25

68
Drum brake consists of the
following components
1. Brake drum
2. Backing plate
3. Brake linings
4. Brake springs
5. Anchors
6. Adjusters
7. Wheel cylinders
 DISC BRAKES
• Disc brake consists of two main parts: the disc, also
called the rotor, and the caliper assembly.

• The disc rotates with the wheel hub. The caliper, which
straddles the disc, is held stationary.
• The caliper is connected to some stationary part of the
vehicle

• Disc brake consists of two main parts: the disc, also

called the rotor, and the caliper assembly.

• The disc rotates with the wheel hub. The caliper, which
straddles the disc, is held stationary
DISC BRAKES
• The caliper is connected to some stationary part of the vehicle

• In front wheel brakes the caliper is bolted to the steering knuckle, in rear-wheel brakes the caliper is
bolted to the axle flange.

• The caliper is cast into two parts , each part containing a piston.

• In between each piston and the disc , there is a friction pad held in position by retaining pins.
• Passages are drilled in the caliper for the fluid to enter or leave each housing
• These passages are also connected to another one for bleeding
• Each cylinder containing a rubber sealing ring between the cylinder and piston
PRINCIPLE OF DISC BRAKE OPERATION.
• With the brake in the released position, the pads are slightly clear of the disc, which rotates between them.

• When the brake is applied the oil under pressure from the master cylinder forces the pistons against the
pads, which are then forced against the disc.

• This produces a clamping action, which slows or stops the disc.

• When the brake is released, the pistons retract slightly to allow the pads to move away from the disc.

• The pads have no return springs, but the pistons are returned slightly in their bores by the resilience of the
piston seals.

• The small run out of the disc (around 0.05) moves the pads away from the disc surface to provide clearance and
prevent wear.
COMPONENTS OF DISC BRAKE
COMPONENTS OF DISC BRAKE
Disc:

• Disc is made of cast iron, with a machined surface on each side against which the pads

are applied.

• The disc is usually shaped to fit the wheel hub to which it is bolted.

• Some brakes use a ventilated disc. This is of hollow construction, consisting of two
flanges separated by fins.

• The rotating disc acts as a form of air pump to maintain a flow of air through the disc
and so remove heat generated during braking.
TYPES OF BRAKE DISCS
Disc Brake Calipers
• The typical disc brake caliper assembly has a caliper housing, one or more pistons seal on

each piston, adjust boot for each piston, and two brake pads.

• The disc brake caliper may be fixed, sliding, or floating.

Disc Pads
• A disc pad consists of a steel backing plate with friction material bonded to it surface.

• The pad is positioned by guide lugs that fit into slots in the caliper or in the anchor plates
 Caliper Pistons
• Caliper pistons have the piston seal mounted

stationary in the housing and the piston in the

seal.

• This design requires a good piston surfaces

finish for maximum seal life

TYPES OF DISC BRAKES

Disc brakes are mainly classified into three types

• Fixed caliper

• Sliding caliper

• Floating caliper
 FIXED – CALIPER
• The fixed caliper disc brake has piston on both sides of disc.

• Some fixed-caliper disc brakes have two pistons, one on each side.

• Other has four pistons two on each side. The caliper is rigidly
attached to the stationary car parts.

• In operation, the two or four pistons are forced outward from

their caliper bores by hydraulic pressure.

• This causes the two shoes to move in against the rotating disc
FLOATING-CALIPER DISC BRAKE
FLOATING - CALIPER
• The floating caliper, or swinging caliper can pivoted, or swinging in or

out. It is suspended from rubber bushings

• Which give enough to permit. The caliper has either one or two piston.

• In operation, hydraulic pressure from back of the piston forces the

brake pad on the piston side against the rotating disc.

• This produces a reaction force against the caliper that causes the
caliper to move inward slightly,

• So other side of the rotating disc. Now, braking action is the same as
with the fixed-caliper type.
 SLIDING- CALIPER
• The principle of operation of a sliding caliper is the same as
that of a floating caliper.

• The difference is in the method of attaching the caliper to

the mounting bracket.
• The grooves (or the sliding surfaces) in the caliper and
mounting bracket are called ways.
• The caliper is held in the ways by a retaining key, a spring, and a
lock screw.
• There is no sideward motion of the caliper when the brakes
are applied.
 ADVANTAGES OF DISC BRAKES OVER DRUM BRAKES

The following are the advantages of disc brakes over the drum brakes:

• Disc brakes provide better stability since these have uniform pressure distribution over the pads than that of

the brake linings in the case of drum brakes.

• Increased temperature does not affect the disc pads much compared to the brake linings of the drum brakes.

• The design of the brake adjusters becomes simple because when hot, the discs expand towards the pads

causing no loss in pedal travel.

 ADVANTAGES OF DISC BRAKES OVER DRUM BRAKES

• The application of brakes causes lesser bearing load since the overhang is lesser over the adjacent bearing

• Maintenance and repairs of disc brakes is easy

• Disc brakes weigh less than their conventional drum type counterpart a saving of approximately 20% being possible.

• Disc brakes have comparatively better anti fade characteristics

• Disc brake assemblies are costlier than drum brakes.

• The pads wear off fast compared to brake shoe linings of drum brakes. Disc brakes have higher brake pressures.

• The temperature operation of disc brakes causes evaporation of the brake fluid and deterioration of seals.

• Disc brakes offer difficulty in installing hand brakes.

BLEEDING OF BRAKES
 EFFECTS OF AIR IN HYDRAULIC BRAKE SYSTEM
• In hydraulic brakes, care must be taken that not even small quantities of the air enter into the

braking system

• The air gets compressed when the brake pedal is pressed

• The result is that fluid pressure is not transmitted to the brakes, which as a consequence are not
actuated

• This leads to total collapse of Braking system

 Bleeding of Brakes

Fig.1
BRAKE BLEEDING PROCEDURE
• A special bleeding valve is provided for this purpose on the
shoe expander or the disc caliper.
• For bleeding, the master cylinder is topped up completely
with the brake fluid and pipe is connected to the bleeding
valve nipple

• The other end of this pipe is dipped in the brake fluid

contained in some jar.
• One person sits on the driver’s seat and presses the brake
pedal
Brake Bleeding Procedure
• After which the bleeder valve is opened by the second person
with a spanner

• when some air bubbles will come out of the pipe and escape
through the brake fluid into the atmosphere.
• The bleeder valve is now closed and the brake pedal released
and pressed once more
• Then once again the bleeder valve is opened again some more
air bubbles will come out
• This procedure is repeated till on pressing the brake pedal, no
more air bubbles are noted
• When with the pedal in the pressed position the bleeder valve is closed.
• The reservoir is then topped up with the fresh fluid.
• This procedure is then repeated for all wheels
 WORKING RULES
Check the following things before bleeding of brakes :

• Check fluid level in the reservoir whenever the system is inspected. Note that on a disc brake system, a drop in fluid level can indicate severe pad wear

• Refill or top up the brake system only with the specified grade of brake fluid

• Do not re-use brake fluid which has been drained out from the vehicle

• Brake fluid must be renewed at fairly regular intervals ( i.e. at least once a year )

• Check drum brake lining thickness through the inspection hole, if provided: otherwise pull off the drum

• Clean lining dust out of the brake. Extract dust by suction, do not blow it out ( asbestos dust represents a health risk )

• All the brake linings on any axle must be renewed at the same time

• Prevent grease or oil from reaching any brake components

• Clean brake components only with alcohol spirit

 MERITS OF HYDRAULIC BRAKES
• The fluid exerts equal pressure everywhere in its circuit. For this reason equal braking effort is
obtained at all the four wheels.

• The system is simple in construction, due to the absence of brake rods, joints etc., inherent in the
mechanical system.

• Moreover, pipelines can be bent and shaped according to the underside of the body structure.

• Due to absence of joints compared to mechanical brakes, rate of wear is also less

• The system is mostly self lubricating

• Self compensating system

 DEMERITS OF HYDRAULIC BRAKES

• Even slight leakage of air into the braking system makes it useless.

• This system is suitable only for applying brakes intermittently. For

parking purposes separate mechanical linkage has to be used.

• The brake shoes are liable to get ruined if the brake fluid leaks out.
SERVO BRAKES
SERVO BRAKE SYSTEMS OR POWER ASSISTED BRAKES

• Servo Mechanism

Any mechanism which adds to the driver’s effort in applying the brakes is

called a Servo Mechanism

 9A404.30

95
Servo Mechanism
VACUUM SERVO BRAKES
• Another form of a servo brake system is the vacuum brake

• Where the suction from the engine inlet manifold is utilized for brake application

• There are two types of vacuum servo brakes, both incorporating a piston or a diaphragm operating in a cylinder

and provided with suitable linkage for brake application

• In the first type, both sides of the piston are exposed to atmosphere when brakes are in the released position.
Vacuum Servo Brakes
Vacuum Booster
 VACUUM SERVO BRAKES
• For applying brakes, engine vacuum is applied on one side of the piston subjecting the same to

differential pressure and thus operating the linkage.

• In the second type, however both sides of the piston are subjected to engine vacuum in the brakes

released position.

• To apply brakes, one side is exposed to atmosphere which provide the desired force on the piston.

• This second system is called “suspended vacuum” system and is preferred over the first system,

because this is comparatively more rapid in action.

 9A404.30

Vacuum Servo Brakes

100

Fig 3
 Vacuum Servo Brakes

Fig 4
Vacuum Servo Brakes

Master To inlet manifold

cylinder
Vacuum Servo Brakes
• A simplified diagram showing the suspended vacuum type of brake system is given in Figure.5

• Vacuum reservoir is connected through a non-return valve to the inlet manifold between the carburetor and
the engine.

• Vacuum reservoir is further connected to the servo cylinder on both sides of the piston.

• On left side the connection is through the control unit, while on the right side it is direct connection.

• Control unit contains a piston to which two valves are attached.

• The upper valve controls the connection between the atmosphere and left side of the piston in the servo

cylinder
Vacuum Servo Brakes
• When the brake pedal is free, upper valve in the control unit is closed

• And the lower one is open thus both sides of the piston in the servo cylinder are exposed to the

engine vacuum.

• However, when the brake pedal is pressed to apply the brakes,

• The pressure of the brake fluid pushes the piston in the control unit up.

• There by closing the lower valve there and opening the upper valve.

• Thus left side of the servo piston is exposed to atmospheric pressure, whereas vacuum acts on the
right side.
 Vacuum Servo Brakes

• This causes the servo piston to move to the right.

• This movement is utilized to apply the brakes in the wheels through some linkage which may
be mechanical or hydraulic.

• Thus the force to be exerted by the driver for applying the brakes is considerably reduced
and practically the whole of the braking effort is supplied by the engine vacuum
OBJECTIVES
On the completion of this session you would be
able to know :

Power brake
Layout of brakes
Components of air brakes

1) Air compressor
2) Air tank
3) Brake valve
4) Relay valve
5) Brake chamber
6) Pressure
POWER BRAKE SYSTEM

• The vehicle is braked exclusively by an external force generated by compressed air.

• The effort of driver serves only to control the system and can not generate any brake
force
• Heavy vehicles are equipped with power brake system
• Air brake uses air pressure to move brake shoe. It can get large brake force with small
pedaling force.
Therefore, this types brake is used in heavy vehicles
 Lay out of Air Brake

Fig.1
Air Brake System
• Air brakes are applied by the pressure of compressed air instead of foot pressure acting
against flexible diaphragms in brake chamber.
• The diaphragms are connected to the brake rods which connect to brake operating cams on
the wheel brakes.
• These diaphragms are controlled through a hand or foot operated valve.
• The brake valve controls brake operation by directing the flow of air from a reservoir against
diaphragms in the brake chambers when the brakes are applied.

• And from brake chambers to the atmosphere when the brakes are released.
 Components of Air Brake System
The air brake system contains the following components

1) Air compressor

2) Air tank

3) Brake valve

4) Relay valve

5) Brake chamber

6) Pressure regulator
AIR COMPRESSOR
• Engine drives air compressor
• In the cylinder head, there are plate type suction valve and delivery
valve.
• On the suction valve the un-loader valve is attached.
• When the air pressure in tank becomes high, by means of the
compressed air from the pressure regulator
• The un-loader valve opens the suction valve. The suction valve inhale
the air, therefore there is no air compression
• When the air pressure becomes low, the compressed air from the
pressure regulator is exhausted and the un-loader valve is returned
by spring force
• Therefore the air compressor start to compress the air again
 Unloader Valve
AIR COMPRESSOR
AIR TANK

• There are 3 kinds of tanks- wet tank, front tank and rear
tank. Wet tank is to remove moisture from compressed
air
• Front and rear tank accumulate the compressed air for
each front and rear system
 BRAKE VALVE
•The brake pedal operates this valve.
•It sends compressed air to relay valve according
to the depressing condition of the pedal.
•In this brake pedal and valve is directly
connected. The brake pedal pushes down valve via
plunger.
The body is apart into the upper part and lower
part.
• The upper part supplies compressed air to the
front system, the lower part supplies air to the
rear system.
• Each line has intake and exhaust valve.
 RELAY VALVE
• The relay valve is operated by the compressed air
from the brake valve.

• It opens or closes the airline from the tank to the

brake chamber and prevents the operational delay
on the brake.

• Each of the front and rear system has it.

• When the brake pedal is released, the compressed

air in the brake chambers is exhausted from this
valve
BRAKE CHAMBER
• It receives the compressed air from relay valve and makes to rotate the brake cam in the

drum brake.

• The brake chamber makes braking force by means of the air pressure from the relay valve.

• When the compressed air from the relay valve flows into the chamber case

• The diaphragm presses the pushrod.

• The push rod turns the brake cam via slack adjuster and the brake shoes are pressed to
the brake drum.
BRAKE CHAMBER
PRESSURE REGULATOR

• The pressure regulator adjusts the pressure in the

tanks. It works according to the air pressure in the
tank.
• When the air pressure is lower than the regulation,
the spring pushes the valve to the lower valve seat.
• The passage from air tank to the un-loader valve is
closed.
 AIR BRAKE SYSTEM
Air brake systems are classified according to type of transmission

1) Single circuit air brake system

2) Dual circuit air brake system

 Single Circuit Air Brake System

• In the simplest case the braking energy is transmitted to

total brakes through one single circuit
Single Circuit Air Brake System

Fig.2
 Single Circuit Air Brake System
• In this brakes are applied by the pressure of compressed air, acting against flexible
diaphragms in brake chamber
• All the brake chambers of front and rear axle are connected with a single pipe line.
• The diaphragms are connected to the brake rods which connect to brake operating cams
on the wheel brakes.
• These diaphragms are controlled through a foot operated valve.

• The brake valve controls brake operation by directing the flow of air from a reservoir
against diaphragms in the brake chambers when the brakes are applied and from brake
chambers to the atmosphere when the brakes are released.
 Demerits of Single Circuit Air Brake System

• If a defect occurs or any leakage in pipe line makes the

entire system inoperative.
• This makes vehicle operation unsafe
• These demerits are overcome in Dual circuit air brake
system
 DUAL CIRCUIT AIR BRAKE SYSTEM

• For increased safety the brake system design is dual circuit

• In commercial vehicles the front axle and rear axle brake cylinders are controlled by

an independent brake circuit.

• If there is a failure in one of the two bake circuits in dual circuit brake system, the

other intact brake circuit remains in operation providing it has sufficient effect

• The remaining circuit can serve as a secondary braking system.

 9A404.32

125 DUAL CIRCUIT AIR BRAKE SYSTEM

Front & rear systems work

separately.

In case there is leakage in one

system, the other system works

for safety.

Fig.3
Lay out of Dual Circuit Air Brake System
OPERATION
The main component in dual brake circuit is the
dual brake valve as shown in Fig. 5
• During the brake pedal is released, main piston and relay pistons are returned
by the springs and air pressure, therefore the way to the relay valve is closed.
• When the pedal is depressed, the plunger is pushed down.
• The plunger pushes down the main piston via main spring.
• The main piston compresses the return spring and closes the exhaust of the
upper valve.
• At the same time, the intake of the upper valve is opened
 Operation of Dual Brake Valve

Fig.5
Operation of Dual Brake Valve
• As a result, the compressed air from rear air tank passes through the upper valve to the rear relay valve.

• Then the exhaust of the lower valve is closed and the intake is open

• Like this, the valve for front relay valve is opened by the compressed air for rear relay valve.
• As the compressed air to the relay valves become high, the air pressure pushes up the main piston.
• When the pressure force and the main spring force are balanced, the upper and lower valves are closed.
• That means, in proportion to the pedal depressing condition, the compressed air is sent to the relay valves.
• When the pedal is released, the main piston is returned up by the return spring.
• The intake of the upper valve is closed and the exhaust is opened. The air for rear is released.
Operation of Dual Brake Valve

• For the lower valve, the compressed air on the upper side of the relay pistons is also gone,
therefore the relay pistons are returned up and the intake of the lower valve is closed and
the exhaust is opened.
• If there is leakage on the rear (upper) system, there is no air pressure on the relay pistons,
but the main piston pushes down the inner relay piston directly
• Therefore the front (lower) system is operated mechanically.

• In case of leakage on the front (lower) system, the operation is same as the normal.

• But there is no compressed air for the front (lower) system, just the lower valve is opened.
ANTISKID BRAKE SYSTEM
Why the ABS ?
ABS brings about a considerable increase in the safety of vehicles, when brakes are applied

• It stops the wheels from locking, which happens

- When the vehicle is over braked

- When the brakes are applied on slippery road surface

 COMPONENTS OF ABS SYSTEM

There are three main components to an ABS system

• Speed sensors

• Pressure control valve

• Electronic 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.

Wheel speed sensor with sensor ring

Electronic Controller

• The electronic controller process digitally the signals

from the wheel speed sensors
• The braking deceleration and brake slip of each
individual wheel or pair of wheels it calculate the
optimum brake pressure
• Which is then applied to the individual brake cylinders
by the solenoid operated valve
Pressure Control Valve
• There is a valve in the brake line of each brake
controlled by the ABS, 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.
 LAY OUT OF ABS

1.Brake booster, 2.Slenoid valves,3.Accumelator chamber, 4.rear axle

solenoid valve,5.Dual circuit return pump,6.Central valve
WORKING OF ABS
• 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 90 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 tyre can actually significantly change speed.
WORKING OF ABS
• The result is that the tyre slows down at the same rate as the car, with the brakes keeping the
tyres 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
• The vehicle retains its directional stability
• The vehicle retains its steerability
• Optimum deceleration values are obtained under emergency braking
• Fewer steering corrections are required when the road surface is slippery (ice)
 Anti-Lock Brake Types

• Anti-lock braking systems use different schemes depending on

the type of brakes in use.

• Refer to them by the number of channels -- that is, how many

valves that are individually controlled -- and the number of
speed sensors .
Four-channel, four-sensor ABS
Three-channel, three-sensor ABS
One-channel, one-sensor ABS
 Anti-Lock Brake Types
Mechanical Brakes: Used in almost all two wheeler like
mopeds and bikes. And these are also
used in Tractor, Cycles etc.,
Example :
Luna, TVS 50, scooters , Hero Honda, Yamaha,
Enfield etc.,

Hydraulic Brakes: Used in almost all light motor vehicles.

Example :
Jeep, Trax, Tata sumo, Ambassador car,
Maruticars, Matador van, etc.,
 Anti-Lock Brake Types

• Air Brakes: Used in almost al Heavy passenger and Heavy commercial vehicles also
Medium commercial vehicles
Example:
Ashok Ley land, Tata Buses etc.

• Power Assisted brakes: Used in some of the light motor & commercial vehicles.
Example :
Tata 207, Tayota etc.,