BRAKE

BALANCE
BAR
AND TWIN MASTER
CYLINDER HYDRAULIC
BRAKING SYSTEM :
MAJOR PROJECT REPORT
 SUBMITTED TO : University Institute Of Technology , RGTU
Bhopal (M.P.)

(Department of Automobile Engineering)

October - 2019
SUBMITTED BY:

Md Hasnain Saleem 0101AU141032

Hamza Meher 0101AU161017
Jay Yadav 0101AU161020
Jitendra Bopche 0101AU161021
Under the supervision of
Mr. Aditya Pratap Singh Sir
CONTENT
 Abstract
 Introduction
 Coefficient of friction
 Braking performance
 Construction
 Material used
 Working
 Analytical Calculations and Design
 Conclusions
 References
ABSTRACT

 Biasing is the most important concept in case of dual master cylinder brake
system. Bias Bar with a spherical bearing is designed to execute the function
of biasing operated by single pedal i.e. mechanical system. Practical
simulation of bias bar/balance bar is done in static condition using Pressure
Gauge on any vehicle. Different pressures are obtained at various positions
of balance bar which gives the correct setup of the system as per the
required biasing. Pushrod position is decided as per theoretical knowledge
and experience.
INTRODUCTION
 In the vehicle when brakes are applied by the driver, vehicle slows down
with gradual weight transfer from rear to front. The harder the vehicle is
braked more the load is transfer at the front wheels. This weight transfer is
also seen in case of cornering of the vehicle, where the weight transfer takes
place in lateral direction. This leads to change in the required braking force
at different wheel. In case of hydraulic disc brake system, hydraulic cylinder
i.e. master cylinders are used to pressurize the fluid. With the use of same
bore of master cylinder, with the same caliper piston area it becomes
difficult to distribute the braking force at different wheels. This makes it
troublesome to lock all the four wheels or stop the vehcle. Hence it is
important to compensate with the change in the weight transfer.
 To provide the more relative braking force at front we can increase the front
disc diameter, pad area, caliper piston area or by reducing the bore diameter
of front master cylinder than rear.
 This paper emphasizes the importance of using brake bias bar (also
commonly known as balance bar) in the car. We fine tune the brake balance
with the bias bar. This allows us to make rapid adjustments to suit varying
track conditions, tire compounds or driver
preference.
 The optimum brake bias
depends on track to track
and driver to driver.
COEFFICEINT OF FRICTION OF
TYRE ROAD AND DISC-PAD
 Here, the coefficient of friction between friction
pad of caliper and the disc are normally known to
great approximation along the variation of disc
temperature, but the main problem is that the
coefficient of friction between the road and tyre is
not well known to accurate value. It depends on
tire & road surface and road condition. Normally
the values are taken as (Ref. 5)
BRAKING PRFORMANCE CONCEPT

 Here we are going to introduce the various concepts used in braking analysis viz.
 1. Weight transfer: A variable brake effort ratio is required to provide ideal braking.
Factors affecting load transfer during braking are:
 i. Change in vehicle weight
 ii. Change in weight distribution
 iii. The effect of gradients (positive and negati ve)
 iv. Cornering (also lateral forces)
 v. Varying road surfaces and weather conditions
 vi. Split friction surfaces where the coefficient of adhesion changes from front to rear
 
 2. Pedal ratio: It is the ratio of force applied by driver to actual force given to master
 Cylinder Piston using mechanical lever advantage.
CONSTRUCTION AND WORKING:

 The construction of the balance bar is as shown in fig. . It consists of a solid

threaded bar of specific diameter with a spherical bearing fitted on it. This
assembly slides in the housing of the pedal with predetermined length.
 The balance bar takes the force applied to the pedal and distributes it to the
front (right) and rear (left) master cylinders. The percentage distribution of
force that goes to each master cylinder depends on the balance bar position.
 If the spherical bearing (located in the pedal housing) is positioned exactly
in the centre of the two master cylinder pushrod clevises, then each master
cylinder transfers the same amount of pushrod force.
ANALYTICAL CALCULATIONS AND
DESIGN:

 Frmc- Force on rear master cylinder

 Ffmc- Force on front master cylinder
 l- Effective length of Balance Bar
 x- Distance of spherical bearing from left.

Frmc = [ Total pedal force* dimension(x) ]/dimension (l)

Ffmc= Total pedal force - Frmc

 fig.(b) shows the force analysis of the balance bar. Balance bar can be set to
the different positions. With the change in the position of spherical bearing
various pressure changes can be obtained at different wheels.
MATERIAL USED

 Materials used in manufacturing of brake balance bar can

be stated as below: 
 Mild steel
 En 24
 Al 6063 T6
 In these various materials, we used mild steel of 9.8 grades
which has good weldebility, ductility and can be recycled.
PROS
 Biggest advantage is the ability to bias the brakes, a bit of rear bias and left
footing,by doing so we can get better traction in any weather. Adjsutment
like using huge calipers can be done by only having a small master cylinders
for any side of wheel

 It made it much easier to select master cylinders to balance brake pressure

front to rear. And having the adjuster/balance bar allows fine tuning front to
rear brake balance

 balance bar between front and rear master cylinders (it uses two master
cylinders for the brakes). This gives the best kind of adjustability for front
to rear bias.
BASIC NECESSITY

 Typically, brake failure injury victims have similar injuries to passengers in speeding accidents.
This is because, without proper brakes, the driver cannot mitigate the accident with lower speeds.
 Broken bones Injuries to the head, neck and back, including whiplash, concussions, or other
traumatic brain injury Facial injuries caused by airbag deployment. If you were in a car crash due
to brake failure, it’s advisable to seek medical attention as soon as possible. Because automobile
accidents are traumatic events, our bodies are flooded with adrenaline. As a result, accident victims
may not notice common car accident injury symptoms until several hours after the accident. Even
minor symptoms, such as a headache, could be a sign of a severe traumatic brain injury.
 In fact, brake failures only cause about 5% of the car crashes in the US every year. Of course, there
are 5.6 million car crashes in America every year, so brake failure accounts for about about
300,000 crashes per year.Nov 7, 2015
 Thus to reduce the accident rate , biasing of brake is required for efficient braking and to do so
brake balance bar is used .
CONS
 Proportioning valves do not works properly,since
it is conventional mechanical design ,100%
reliability does not found till date.
 Anti lock breaking system can not be used in break
balance bar
FUTURE ASPECT
 Brake balance bar can be used in articulation with
 Anti lock braking system(ABS)
 Electronic brake force distribution (EBD)
 Conventional braking system .
 Brake assist system
CONCLUSION:

 The position of balance bar should be straight but not tilted, when brake
pedal is in full pressed position ,which gives the correct and efficient
working of the balance bar .
 With theoretical and practical examination, pressure loss takes place in the
lines.
 Both clevis position should be within range of 3-5mm from the housing.
 Biasing by the balance bar can be done with the help of Remote brake bias
adjuster according to ergonomics.
REFERENCES:

 Carroll Smith,”Tune to Win”,year 1978.

 William F. Milliken, Douglas L. Milliken, “Race Car Vehicle Dynamics”,
year 1995.
 Subhash Mishra, Sagar Janghu, “Balance Bar Design And Motion Analysis
o f Pushrod”, year 2014.
 Tilton Engineering, www.tiltonracing.com
 AP racing, www.apracing.com
 Wilwood , www.wilwood.com
THANK YOU