Braking Systems

Braking Requirements
The brakes must be strong enough to
stop the vehicle with in a minimum
distance in an emergency.
It should also be consistent with safety.
The driver must have proper control over
the vehicle during emergency and the
vehicle must not skid.
The brakes must have good antifade
characteristics. i.e their effectiveness
should not decrease with constant
prolonged application.

Classification of Brakes
1.
2.
3.
4.
5.

Purpose
Location
Construction
Method of actuation
Extra braking effort

 Purpose
a) primary brakes
b) secondary brakes
Location
c) Located either at transmission
d) Located at the wheels
Construction
e) Drum brakes
f) Disc brakes

 Method of actuation
a) Mechanical brakes
b) Hydraulic brakes
c) Electric brakes
d) Vacuum brakes
e) Air brakes

Drum Brakes

In this type, a brake drum is attached concentric to the

axle hub whereas on the axle casing is mounted a back
plate.
The back plate is made of pressed steel sheet and is
ribbed to increase rigidity and to provide support for
the expander, anchor and brake shoes.
Two brake shoes are anchored on the back shoes.
Friction linings are mounted on the brake shoes.

Drum Brake Assembly

Brake cylinder assembly:

Handbrake cable
Brake shoe

Backing plate
Tension springs

Retracting springs
Brake shoe
Handbrake lever

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Brake Drum
The drum provides a friction surface
for the brake linings. It also
dissipates heat, and can support
wheel bearings
or road wheel.
Drum fits over
wheel hub or drive
flange.

Drums sometimes
have fins to aid
cooling.
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Disc Brakes

Comparison of Disc and Drum brakes

In disc brakes friction s/fs are directly exposed to the cooling
air, whereas in the drum type friction occurs on the internal
s/f.
Friction pads in case of disc brakes are flat as compared to
curved friction linings in case of drum brakes, in disc brakes
uniform wear of friction pads and not subjected to any
bending.
Disc brakes weigh less than their conventional drum type.
Disc
brakes
have
comparatively
better
anti-fade
characteristics.
Compared to the drum type, disc brakes are simple in
design. There are very small number of parts to wear.
It is very easy to replace the friction pads when required,
compared to the drum type where the brake linings have to
be either riveted or fixed with adhesives to the brake shoes.
Frictional area of pads in disc brakes is very less as
compared with conventional drum type brakes.

Introduction: Hydraulic Brakes

This system uses a brake fluid
(Preferably
ethylene glycol) to transfer the pressure applied
by the operator from the controlling unit to the
actual brake mechanism, which is usually at or
near the wheel of the vehicle.
Most vehicles in India prefer to have drum
brakes on rear wheels while disk brakes on the
front wheels attached to the hydraulic
controlling unit

Construction
Brake pedal or lever
A pushrod (also called an actuating rod)
A master cylinder assembly containing a piston assembly
(made up of either one or two pistons, a return spring, a
series of gaskets/ O-rings and a fluid reservoir)
Reinforced hydraulic lines
Brake caliper assembly consisting of one or two hollow
aluminum or chrome-plated steel pistons (called caliper
pistons), a set of thermally conductive brake pads and a
rotor (also called a brake disc) or drum attached to an axle
The system is filled with a glycol-ether based brake fluid

System Operation
As the brake pedal is pressed, a pushrod exerts force
on the piston(s) in the master cylinder causing fluid
from the brake fluid reservoir to flow into a pressure
chamber
This forces fluid through the hydraulic lines toward
one or more calipers where it acts upon one or two
caliper pistons sealed by one or more seated O-rings
which prevent the escape of any fluid from around
the
pistonis dissipated through brake pads which are
Heat
made up of special heat tolerant materials such as
kevlar or sintered glass

On releasing the brakes, the rubber sealing rings acts as

return springs and retract the pistons and the friction pads
away from the disc.

Important Considerations
Hydraulic systems are smaller and less
expensive than the air brake systems
Hydraulic fluid should be in-compressible. Also
the hydraulic system should be air tight such
that no vapor is introduced in the system
Hydraulic fluid must resist vaporization at high
temperatures
The fluid that is used should be non-corrosive
for the surrounding material
Elimination of Brake Fade

Below are the components in a hydraulic disc brake system.

Brake reservoir: Contains hydraulic brake fluid
Master cylinder: Device that pumps the fluid from the
reservoir to brake lines that run throughout the vehicle
Brake lines: Rubber or steel braided hoses that run from
the master cylinder to each brake caliper
Brake caliper: A steel housing that mounts on a fixed
point of the brake rotor that contains a piston and brake
pads
Brake piston: A round rod that extends and pushes
against a brake pad when hydraulic fluid is fed from the
master cylinder
Brake pad: A metal backing pad with a semi-metallic
overlay that grips the steel rotor
Brake rotor: A steel disc mounted to each wheel and hub
that the pads grasp to stop the wheels from rotating

Brake Fluid

Boiling point.
Viscosity.
Effect on rubber.
Corrosive action.
Storage stability.

Air Suspension
Generally two types of air springs
1. Bellows type spring
2. Piston type.

Working of Air Suspension

Four air springs, which may be either
bellows type of piston type are
mounted on the same position where
gradually the coil springs are
mounted.
Air compressor takes atmospheric air
and compresses it to a pressure of
about 240MPa, at which pressure the
air
in
accumulator
tank
is
maintained, which has a safety
valve.

 This high pressure air goes through

the lift control valve and the levelling
valves, to the air springs.
The lift control valve is operated
manually by means of a handle on
the control panel, through a cable
running from the valve to the handle.

Working of Anti lock brake system

The hydraulic unit is the central component
of an ABS system.
Each of the four wheels has a speed sensor,
which measures the rotational speed of the
wheel.
This information is monitored by ECU which
opens and closes the magnetic valves at the
right time.
If the wheel is about to lock under heavy
braking, the system continues to reduce the
hydraulic pressure on that wheel alone, until
the threat of locking is past.

Working of Anti lock brake

system
Once the wheel is turning freely again,

the hydraulic pressure is increased.

This increase and release of pressure
continues until the driver reduces the
force on the brake pedal or until the
tendency to lock is overcome.
ABS is incorporated in some of the cars
to prevent skidding and to rove braking.
Ex: Mercedes C200 CDI, Ford Monde,
Honda Accord.