MODERN AUTOMOTIVE DESIGN

Le Van Nghia., PhD

Faculty of Transportation Engineering
Chapter 05: Braking systems

• Aid the designer to understand the legal

requirements of braking systems.
• Understand the basic requirements for braking
systems to be successful.
• Understand the design process for achieving an
efficient braking system.
• Appreciate the material requirements for efficient
braking systems.
• Understand current developments in braking control
systems.

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Chapter 05: Braking systems

• Definitions
• Structures of braking system
➢Braking mechanism
➢Braking driver
• Braking system calculation
➢ Determination of needed braking torque
➢ Calculation of braking mechanism
➢ Calculation of braking driver

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Chapter 05: Braking systems

• Definitions
• Function of braking system:
• Deacceleration
• Long Vehicle Stop on hill (20% -QCVN –09/2011)
• Classification
• By function: main brake, stop brake, auxiliary brake,
backup brake
• By structure of brake mechanism : drum brake, disc
brake
• By structure of brake driver: mechanical, hydraulic,
pneumatic, electric, combine

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Chapter 05: Braking systems

• Definitions
• Requirements:
• Max. Deacceleration (legal requirement)
• Stability of braking progress (legal requirement)
• Highly sensitive of Brake drive (legal requirement)
• Low control force (legal requirement)
• Optimal Distribution of braking force
• No self-tightening phenomenon (drum brake)
• Good heat dissipation brake mechanism
• Hight friction coefficient on using process
• Linear relationship between control force and braking torque
• Long stop on hill (legal requirement)

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Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – drum brake

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Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – drum brake
• SIMPLEX

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Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – drum brake
• DUPLEX and DUO-DUPLEX

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Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – disc brake

Fixed caliper Moving caliper

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Chapter 05: Braking systems
• Structures of braking system
➢Braking mechanism – comparing
Drum mechanism
- Hight weight
- Hight stability of brake torque
- Small clearance between brake disc
and brake pad → low time of braking
action
- brake pad – flat →uniformly
distributed pressure →uniformly wear
- Open type → good heat dissipation
- Hight cost
Disc mechanism
- Low weight
- Low stability of brake torque
- Big clearance between brake disc and
brake shoe→ Hight time of braking
action
- brake shoe – curved →infirmly
distributed pressure →infirmly wear
- Closed type → poor heat dissipation
- Low cost
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Chapter 05: Braking systems

• Structures of braking system

➢Braking mechanism – comparing

T: Friction force
P: Driver force

Force transmission coefficient

of brake mechanism

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Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – hydraulic type

Main components of system?

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Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – pneumatic type
Main components of system?

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Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – comparison
hydraulic type pneumatic type
- Low delay - Long delay
- Big control force caused by making - Small control force for opening or
working pressure closing valves
- Hight cost - Low cost

Pneuma-hydraulic type

- Small delay of system caused by reduction pneumatic line

- Control force on pneumatic valve

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Chapter 05: Braking systems

• Structures of braking system

➢Braking driver – pneuma-hydraulic type

Pneumatic lines
Hydrauic lines

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 Chapter 05: Braking systems

• Braking system calculation

➢ Determination of needed braking torque
Max. braking force Max. braking torque:

Static vehicle
position

Vehicle braking
moment

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Chapter 05: Braking systems

• Braking system calculation

➢ Determination of needed braking torque

Max. braking torque at axles

Max. braking torque on

front axle:

Max. braking torque on

rear axle:

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Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Main geometrical
parameters

Chooses: rt, a, b, h, beta

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Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Forces on drum brake: Drum
1. Drive forces: P’ and P’’
2. Reaction force from brake
latch U’ and U’’
3. Reaction force from drum R’
and R’’
Calculation Method:
1. Brake force graph
2. Using Approximate formulas

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Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 1 Total brake torque

For squeeze shoe For release shoe

K= 0.85-0.9 – regulator factor

Hydraulic

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Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 1

Hydraulic Self squeeze

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Chapter 05: Braking systems

• Braking system calculation Self squeeze

➢ Drum brake mechanism design

Relationship between driver Forces and brake torque:
Method 2

Hydraulic

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Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 2
A and B coefficients will be depended on the rule of the surface force distribution
Uniform distribution Sinewave distribution

Note: all angles are measured in Rad

Self squeeze:
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Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 3 Brake force graph

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 Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 3 Brake force graph

Rule of distribution:

Position of force R

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 Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Method 3 Brake force graph

Direction of force R

Determine the cross section of all forces → direction of force U

Build the force triangle → determine the force value

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Chapter 05: Braking systems

• Braking system calculation

➢ Drum brake mechanism design
Relationship between driver Forces and brake torque:
Brake force graph
Method 3

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Chapter 05: Braking systems

• Braking system calculation

➢ Disc brake mechanism design
• Brake torque:

• di – diameter of brake cylinder

• pt – working pressure

Choose the pt and calculate the di

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Chapter 05: Braking systems

• Braking system calculation

➢ Disc brake mechanism design
• Brake pad calculation:
• Special Friction work:

• G= m*g – vehicle weight

• V – initial speed before braking, with V=60 km/h, [l]=400-1000 J/cm2
• AΣ – total brake pad area
• Surface pressure:

• For brake pad: [q]=5 Mpa with using new materials

• P ratio:
For passenger vehicle

For bus
For truck
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Chapter 05: Braking systems

• Braking system calculation

➢ Disc brake mechanism design
• Brake pad calculation:
• Heat dissipation :

• G= m*g – vehicle weight

• V – initial speed before braking, with V=30 km/h, [t]=15 degree of celcius

• At – total heat dissipation area of drum or disc

• kt – coefficient of heat transmission

• C - specific heat , for steel c=500 J/kg.degree

• T – braking time

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Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver
Master cylinder

ib=a/b

Brake pedal Brake cylinder

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Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver
Pi is calculated from needed brake torque, and
chosen pt

Choose Qb<[Q], and choose

a, b, nhuy_b

Number of piston Disc brake

Piston motion
Drum brake
compression
coefficient limit wear

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Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver
Working pressure Recommendation on choosing
Brake without power assistant
Brake with power assistant
Brake with pump assistant
Cylinder diameters:
Drum brake

Disc brake

Master cylinder
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Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver with vacuum booster
Vacuum booster
Master cylinder

ib=a/b
Brake pedal Brake cylinder
air vacuum

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 Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Hydraulic driver with vacuum booster
Without Without
Vacuum booster Vacuum
booster
With Vacuum booster

With VB
Ignore spring force and friction
With

Driver characteristic

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Chapter 05: Braking systems

• Braking system calculation

➢ Brake driver design
Pneumatic driver design
➢ Pedal valve design
➢ Chamber design (by standard)
➢ Chamber with accumulative spring

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Chapter 05: Braking systems

• Electronic control integrated on Braking system

➢ Anti-lock Braking System - ABS

➢ Braking force distribution -EBD

➢ Emergency brake assist - EBA

➢ Traction Control System - TCS

➢ Anti-Slip Regulation – ASR

➢ Electronic stability program - ESP

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THANK YOU !

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