7/15/2021

Automotive Brake system contents

Brake system  Introduction
 Booster
 Hydraulic brake
 Drum
 Disc

 Anti-lock brake (ABS)

Automotive Brakes Types of brakes

 Is responsible for the following activities
 Reduce the speed of the vehicle
 Bring the vehicle to a halt
 Prevent unwanted acceleration during
downhill driving
 Keep the vehicle stationary when it is
stopped
 Service or main brake
 is the main brake used to slow/ stop a
vehicle in motion
 Parking or secondary brake
 is used to hold the vehicle on a slop
 Retarders: (engine, exhaust, drive shaft)
 To slow a vehicle in down hill

1
 7/15/2021

Method of actuation Energy Conversion

 Mechanical brake

 Hydraulic brake

 Electric brake
The brake system converts the kinetic
 Vacuum brake energy of vehicle motion into heat

 pneumatic brake
6

Friction
 Is the resistance to slipping.
 Is the force of two surfaces in contact,
this keeps each tire from sliding off the
roadway
 Occurs whenever two surfaces rub
together.
Friction…
 It would be impossible to control a
vehicle without friction.
 Friction enables the vehicle to stop,
accelerate, and change direction.
Why is friction important for vehicle
control?

2
 7/15/2021

Stopping distance Stopping ….

 Total stopping distance  Reaction Distance
 is the distance your vehicle travels while you  How far the vehicle travels as the driver
make a stop. reacts and applies the brake
 Perception Distance  Brake Lag Distance
 How far the vehicle travels when the need to  How far the vehicle travels from the time
brake occurs and the driver recognizes that the brakes are applied and the vehicle
need. begins to slow down.

Factors that affect stopping distance

Thinking distance = Perception +Reaction
Stopping.. At 90 mph a car will cover 40 metres every second. Even if
your reaction time is as short as 0.5 s you will travel 20 m
 Braking Distance before you even hit the brakes! This is your thinking
 How far the vehicle travels from the brakes
distance.
starting to slow the vehicle and the vehicle tiredness
Alcohol
coming to a complete stop
 Total distance includes Thinking distance
eyesight
 Perception Distance drugs
 Reaction Distance Distractions
 Brake Lag Distance (posters,
people)
 Braking Distance

3
 7/15/2021

Factors that affect stopping distance

Braking distance Stopping distance on
The braking distance depends on the car and road conditions. a level road
Weather conditions  The equation for energy of motion is
Road surface Braking force
given by 1 2
conditions Wk  mv
braking distance
2
Mass of car  The work done in bringing the vehicle to
rest is given by
Speed of car
Tyre grip Wd  Fs

Stopping distance on a
slope
Stopping…
 When braking a moving vehicle to
standstill, the work done by the brake
must be equal to initial kinetic energy
possessed by the vehicle

 Where F is an average brake force

 In which condition is hard to stop a car
moving up hill or moving down hill? And why?

4
 7/15/2021

Example 1
 A car of mass 1000kg is travelling at
36km/h. Determine.
a) The kinetic energy it possesses
b) The average braking force to bring it to
rest in 30 meters.
ANSWER : A) 50KJ. B) 1.6KN
Example 2
 A station wagon is traveling at 30 m/s and
comes to a stop with an acceleration of -
60m/s2 .The driver has a reaction time of
0.5s.
 What is the reaction distance?
 What is the braking distance?
 What is the stopping distance?

15 m, 7.5 m and 22.5 m

Weight transfer during …acceleration

acceleration
 Acceleration force is opposed by inertia force
 weight will shift from the front onto the  Inertia force acts on CG & tends to lift the car
rear tires.
 The lifting effect reduces load on the front
axle and increases on the rear axle

5
 7/15/2021

…acceleration Example 1
A vehicle of mass = 1200 kg has a
Taking moment at the rear tire on the road
wheelbase of 2.5 m. The centre of
 Front, rear static load & load transfer gravity of the vehicle is at a height of
0.65m above ground level and 1.2m
behind the front axle. If the vehicle
 Front dynamic load accelerates at 5m/s2 calculate:
a. the amount of load transfer;
b. the dynamic loads on the front and rear
 Rear dynamic load axles.
Take g = 9.81m/s2 .
Wt = 1560N, Fl = 4561N, Rl = 7211N

Weight transfer during

deceleration
Example 2  During braking, the weight shifts from
the rear onto the front wheels
A vehicle with a wheelbase of 3.2m has
 Typical front to rear brake ratio is 70/30
its centre of gravity located midway
between the axles at a height of 0.75 m. % front/rear.
If the vehicle weight is 2 tonnes,  % of weight transfer = Wt/W*100
calculate the load transfer that occurs
when the vehicle accelerates at 5m/s2.
2.44KN

6
 7/15/2021

Weight transfer during cornering

 During cornering, the weight shifts from Braking efficiency
the inside tires to the outside tires
 Is the braking force produced as a
percentage of the total weight of the
vehicle
  Fb /W *100
Where:  = efficiency
Fb = braking force
W = weight of the vehicle

Braking efficiency.. Example

 If coefficient of friction is 1, Fb = W or
deceleration is same as gravity.
 Maximum theoretical limit for  is 100%
 Brake efficiency is generally 50% to 80%
 Minimum allowable limit is 50% for foot
brake and 30% for hand brake
 Determine the braking efficiency of a
vehicle if the brakes bring the vehicle to
rest from 60kmph in a distance of 15m.
94.4%

7
 7/15/2021

Pascal’s principle
Daniel Bernoulli  Pressure applied to an enclosed fluid is
Principle transmitted undiminished to every part of
 As the speed of a moving fluid (liquid or the fluid
gas) increases, the pressure within the  Pressure will act in all direction
fluid decreases.

Pressure and depth

P = gh

8
 7/15/2021

Brake system overview Hydraulic

circuit
Often used on rear-
wheel-drive
vehicles

Often used on front-

wheel-drive vehicles,
with high front-to-rear
brake ratio

Pedal mechanical advantage Stoplight Switch

 Operates the rear brake lights
 Normally open switch, usually mounted
on the brake pedal mechanism
 When the brake pedal is pressed, it
F1*A = F2*B closes the switch
Amount of movement
B/A = b/a

9
 7/15/2021

Determine the distances (X&Y), pedal Determine

force and force on slave cylinder; if the
pedal is moved by 5cm and has a  F1, P, F2, F3, F4
mechanical advantage of 4 to 1?

2000N

2000kpa

Brake not applied

Master Cylinder
 Foot-operated pump that forces fluid to
the brake lines and wheel cylinders
 Develops pressure to apply the brakes
 Equalizes pressure required for braking
 Keeps the system full of fluid as the
linings wear
 May maintain a slight pressure to keep
contaminants from entering the system

10
 7/15/2021

Brake applied Brake Warning

Light Switch
 Also called the pressure differential
valve
 Warns the driver of a pressure loss on
one side of a dual brake system
 If a leak develops in either the primary
or secondary brake system, unequal
pressure pushes the switch piston to
one side, grounding the indicator circuit

No leakage Leakage on primary circuit

11
 7/15/2021

Brake fluid level switch

Fluid Warning Light

 Turns on a dash light if the brake fluid in
the master cylinder becomes low
 Often mounts in the master cylinder lid
or cover
 Commonly operated by a float

Vacuum brake booster

Brake booster  Use vacuum for pressure differential
 Source of vacuum
 Provides power assist to the brake system
 Intake manifold
 It increases pedal force 2 to 4 times
 Vacuum pump
 Typically manifold vacuum (17-21in-Hg).
 The vacuum hose has check valve
 Are three types
 Vacuum
 Hydraulic
 Electro hydraulic

12
 7/15/2021

Control valve closed

Construction

Construction
Control valve open

13
 7/15/2021

Brake not applied Brake applied

Brake applied Pedal released

14
 7/15/2021

Pedal depressed with no

vacuum
Disc brake
 Disc brakes create braking power by
forcing flat friction pads against sides of
rotating disc
 Modern vehicles always equipped with
disc brakes on at least the front two
wheels.

Disc brake caliper Pad wear indicator

 Bolted to vehicle axle housing (steering  Used to warn the user and/or owner of a
knuckle) vehicle that the brake pad is in need of
 Are three types replacement.
 Fixed  There are two different types of pad wear
 Floating sensors,
 Sliding  Mechanical and
 Electric.

15
 7/15/2021

Wear indicator.. Wear indicator…

 The mechanical type generates a  The electric type turns on a warning
screeching noise when the metal clip lamp on the instrumental panel of the
attached to the pad comes in contact car when the pad needs replacement
with the disc.

Drum brake
 Is a brake in which the friction is caused
by a set of shoes that press against the
inner surface of a rotating drum.
 The drum is connected to a rotating
wheel
 Usually used on rear wheel brake

16
 7/15/2021

Anti-Lock Brake
System
 Address two conditions related brake
application;
 wheel lock up
 vehicle directional control
 Without ABS when brake is applied with
enough force to lock the wheel
 Vehicle slides uncontrollably….no traction
 With skidding wheel no steering control

Tire traction

17
 7/15/2021

ABS components

18