THE BRAKE BOOSTER OF TOYOTA CROSS HV

WHAT IS BRAKE BOOSTER ?

 A brake booster is a device that increases the force
applied from the brake pedal to the master cylinder

 The booster is what separates a power-assisted

braking system from a manual one.

Brake booster
 BRAKE BOOSTER IN
AUTOMOBILE VEHICLES
 Used only on power brakes, not manual brakes
 Give more braking power with minimum pressure on the brake pedal
 Located between the brake pedal and the master cylinder
 The booster's size and whether it has a single or more than one diaphragm depend on the year,
make and model of the vehicle
 STRUCTURE OF BRAKE
BOOSTER
 The brake booster is made of 5 parts:
 Body
 Booster piston
 Booster return spring
 Reaction valve
 Control valve

 The body has 2 chambers:

 The variable pressure chamber
 The constant pressure chamber
 WORKING PRINCIPLE
 When you press your brake pedal, that force is transmitted to
the brakes through a liquid. But then, the actual brakes require a
force still bigger than what your leg applies for its effectiveness;
this force multiplication which is generally 2-4 times the size of
the diaphragm, is achieved in two different ways- leverage
(mechanical advantage) and hydraulic force multiplication.
 As you press the brake pedal, a shaft is pushed forward which is
attached to the power brake booster which uses the engine
vacuum to help give the pedal increased force, helping in
turn to balance the high pressures of the braking system.
Together with your foot effort on the pedal, this shaft then moves
to push a piston into the main brake cylinder, displacing as a
consequence, brake liquid through the braking system.
 This liquid enters forcefully into the brake cylinder through a
rationing valve such that correct liquid quantities reach the brake booster
respective wheels to act on the brake slave cylinders which
clamp the pads on the brake rotors, slowing down your
vehicle. For transmitting the force from the brakes to the tires
and then to the road, frictional force comes into play.
 VACUUM BRAKE BOOSTER

WORKS
A vacuum brake booster provides power assist to the brake system.
 The vacuum operated brake booster works much today as it did sixty-years
ago.
 A combination of atmospheric pressure pushing and vacuum pulling on a
diaphragm, multiplies the force a driver applies with the brake pedal.
 Most brake boosters, have two or more chambers, divided by flexible
diaphragms.
 The chamber is normally steel and the diaphragm is usually some form of rubber
 Vacuum, usually supplied by the engine and atmospheric pressure combine to
provide the assistance during braking.
 BOOSTER AT REST
When we are not applying the brakes, a two way valve
allows vacuum application on both sides of the
diaphragm. An equal vacuum on both sides, causes a
balance and the diaphragm remains stationery. In this
state, we say that the booster is at rest. The shell of the
booster acts as a reservoir, to store the engine vacuum. A
check valve, in the inlet fitting, helps to maintain a
vacuum when the engine accelerates.

Booster at rest
 APPLYING THE BRAKES
 When we press the brake pedal, the two way also moves. This
movement closes the passage to the rear of the diaphragm and vacuum
applies only to the front. Simultaneously atmospheric pressure flows
into the rear. Atmospheric pressure pushes the diaphragm and vacuum
pulls it forward. The push rod also moves to apply the brakes, through
the master cylinder, attached to the front of the booster.
 Releasing the brake pedal allow the internal spring to push the
diaphragm and push rod back and operates the two-way valve.
This valve blocks atmospheric pressure to the rear chamber.
Simultaneously, it opens the chamber to vacuum. This evacuates the rear
chamber and assist in returning the booster to a state of rest.
 The system is robust and inherently failure resistant. If the valve,
diaphragm or vacuum source fail, they have mechanically connected
the push rod to the brake pedal and master cylinder. A damaged
system reverts to manual brakes, with no power assist.

Applying the brake

 NEED FOR USING BRAKE
BOOSTERS
 Earlier, cars had mostly only drum brakes, not
needing any power braking features as it already
had some best advantages. However, when disc
brakes became the order particularly on the
front wheels, the need for power braking system
using boosters was keenly felt for helping the
drivers from strenuous exertion while applying
brakes.
 For constantly driving people and persons with
poor physique, applying more pedal force
frequently may become a nightmare resulting in
safety issues; so the Brake Booster have become Brake booster section view
a blessing in disguise for easy braking for
drivers applying just a little of pedal effort to
stop vehicles when needed.
 WORK EVEN UNDER BRAKE
BOOSTER FAILURE
 In such a failure condition, there will be no pressure difference between the constant
pressure chamber and variable pressure chamber. When the brake is “OFF,” the piston comes
back to the right by the action of the piston return spring.

 Upon the brake pedal being pressed, the valve operating arm extends to the left pushing the
reaction disc, booster push rod and the air valve. This action results in the master cylinder
piston applying the braking force on the braking system, still making the braking system
work, and stopping the vehicle.
 TEST FOR FUNCTIONING OF
BRAKE BOOSTER
 A test called “Air tightness test under load” for
confirming its working condition is described
here. When the engine is running, press the brake
pedal and then stop the engine, and wait for some
30 seconds. If no change is observed in the
position of the brake pedal, it indicates healthy
functioning of the brake booster.

pedal position
 ADVANTAGES OF BRAKE
BOOSTER
 A brake booster cares for cars making brake working great.
 Hydraulic boost is available whenever the engine is running and the hydraulic pressure
accumulator provides boost for 8–10 applications of the brakes with the engine off.
 In diesel vehicles (which do not generate vacuum), a vacuum pump is needed for pneumatic
(vacuum boosters) but these same vehicles usually have power steering and that pump
provides the needed hydraulic pressure so there’s no need for the expense or complication of
an additional vacuum pump.
CALCULATING THE MAIN
PARAMETERS OF THE
DESIGNED SYSTEM
4 5 6 7 8 9 10

3 11 12 13 14

2
B
1
I

A D
19 18 17 16 15

Vacuum booster
 CALCULATING THE MAIN
PARAMETERS OF THE
DESIGNED
• Vacuum booster design SYSTEM :
• Break booster coefficient:
 .D 2
'

From the formula determined on the pedal: l 1

Qbd  . pi . .
4 l 
• The pressure for the driver is:
4.Qbd l
 pi  . .
 .D 2 l '

Qbd - force exerted by the driver at the pedals.

D - main cylinder diameter
Pi - oil pressure generated in the system
l,l’ - brake pedal stroke size
 - drive coefficient
:
 CALCULATING THE MAIN
PARAMETERS OF THE
DESIGNED SYSTEM
 Pressure generated by the booster:

Pt - The maximum total pressure required to be produced during heavy braking

 Enhancement coefficient:

 Determining the size of the diaphragm:

 Force generated by the booster:

 Consider the equilibrium of the membrane: Qc  ( p0  p ' ).Fm  PLX

 Qc  p.Fm  PLX
 CALCULATING THE MAIN
PARAMETERS OF THE
 kG 
P 2 
DESIGNED SYSTEM Qc- force generated by the booster
 cm  P0 - atmospheric pressure
p’ - vacuum pressure

70 Δp - pressure difference between the front and

rear chambers
 .D 2 m
Fm 
Khi trợ lực
làm việc
Fm - the area of the diaphragm 4
Khi không có trợ lực

Plx - recoil spring force

So that:
0 5 30 Qbđ

Powertrain characteristic line

 CALCULATING THE MAIN
PARAMETERS OF THE
 Calculate DESIGNED
the booster spring: SYSTEM
 Diameter of spring wire: d
8.k .Plx .Dtb
 . c 
3

Dtb - average diameter of the spring ring

Plx - recoil spring force
K - stress concentration factor
 c  - torsional stress
.G.d 4
• Calculate the number of rotations of the spring: n0 
8.Dtb2 .Plx

 - displacement of the spring

G - elastic moment of material

• Calculation of the total loop of the spring:

CALCULATING THE MAIN
PARAMETERS OF THE
DESIGNED SYSTEM
 Calculate the step of the spring:

 Overall length of spring:

 Taper spring durability:

 CONCLUSION
A brake booster is an enhanced master cylinder setup used to reduce the amount of pedal pressure
needed for braking. It employs a booster set up to act with the master cylinder to give higher hydraulic
pressure to the brakes and or lower force applied on the brake pedal through a brake booster push-rod.
The brake booster usually uses vacuum from the engine intake to boost the force applied by the pedal
onto the master cylinder or may employ an extra vacuum pump to enable it. Without the engine running
the brake pedal feels very hard and ineffective on the braking capability. An "active" booster is a non
"conventional" booster where a solenoid is used to open the booster air valve to automatically push the
master cylinder forward to perform some forms of dynamic stability control. Brake boosters come in
either a single diaphragm or tandem diaphragm (which is generally used for bigger vehicles and
trucks). They can be "cabin-breathers" (taking clean filtered air from inside the cabin thus may be
noisier) or "engine- breathers" (less noisy but more at risk for becoming clogged with mud ice if not
protected properly).