The document discusses vehicle braking systems. It begins with session objectives on understanding proper braking system selection, braking material selection for efficiency, and the role of electronics in ABS and traction control systems. It then covers topics like introduction, brake classification, ABS, and traction control systems. The introduction section defines brakes and their functions, and discusses braking principles, factors like pressure, friction, surface area, geometry. It also covers braking force calculation, weight transfer during braking, and stopping distance calculation. Drum and disc brake components and types are described. [END SUMMARY]
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Vehicle Braking Systems Explained
1. SRI KRISHNA COLLEGE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHATRONICS ENGINEERING
Session: Vehicle Braking System
11/24/2020 16MT407 - Theory of Automobile Engineering 1
MODULE 1
2. SESSION OBJECTIVES
11/24/2020 16MT407 - Theory of Automobile Engineering 2
On the completion of this session, the students might
be able to understand,
Proper selection of Braking system for your vehicle.
Good chosen of braking material for better braking
efficiency.
Role of electronics in Anti lock Braking system &
Traction control system.
3. Topics
Introduction
Classification of Brakes
Ant locking braking system
Traction Control System
11/24/2020 16MT407 - Theory of Automobile Engineering 3
4. INTRODUCTION
11/24/2020 16MT407 - Theory of Automobile Engineering 4
INTRODUCTION :
Causes the vehicle decelerate or stop
Hold the vehicle in position while stationary.
What happens when brakes applied?
By applying the brakes to a moving vehicle, the
kinetic energy of the vehicle is transformed into
heat generated by the friction.
Then the heat energy is dissipated to surrounding
air.
5. INTRODUCTION
11/24/2020 16MT407 - Theory of Automobile Engineering 5
Function of brakes : Purpose
Stop the moving vehicle in minimum possible
time.
Controls the speed, in turning & Crowded
places.
Holds the vehicle in stationary position,
without the presence of drive, after it has
been brought to stop.
6. INTRODUCTION
11/24/2020 16MT407 - Theory of Automobile Engineering 6
Principle of Brake Operation:
Generally Kinetic energy provided by the engine,
keeps its accelerate from standstill to a desired speed.
While applying brake, the energy of motion or Kinetic
energy is converted into heat energy generated by the
friction.
Kinetic energy of the vehicle during braking is,
𝐾 𝐸 =
1
2
𝑚 𝑢2
− 𝑣2
=
𝑊 𝑢2 − 𝑉2
2𝑔
∴ 𝑊 = 𝑚𝑔 𝑜𝑟 𝑚 =
𝑤
𝑔
w = Weight of the vehicles N = mg
m = Mass of the vehicle
u = Initial velocity of the vehicle m/s
V = Final Velocity of the vehicle m/s
g = acceleration due to Gravity = 9.81 m/s2
4 time KE = 4 times Brake Power
7. INTRODUCTION
11/24/2020 16MT407 - Theory of Automobile Engineering 7
Principle of Brake Operation: Frictional Force?
Opposes the vehicle motion
Consume power & Produce heat.
It occurs b/n Tyre & Road surface when the wheels
are locked by brakes.
To stop vehicle, it mainly rely on co-efficient of friction
b/n the contacting surfaces.
The amount of energy absorbed by the brakes
depends up-on
Pressure exerted on brakes
Co-efficient of friction of brake material
Brake surface area
Brake geometry.
8. INTRODUCTION
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Factors Governing Braking: Pressure exerted on the braking surface
When the pressure applied to two
frictional surfaces, then they grip each
other harder and resist any movement
between them.
9. INTRODUCTION
11/24/2020 16MT407 - Theory of Automobile Engineering 9
Factors Governing Braking: Coefficient of friction b/n braking surface
On the same surface, for moving different
material required different force.
Each material has different frictional
characteristics or Coefficient of friction (μ).
If “μ” is too high – Brakes may be grab or
cause wheel to slide.
If “μ” is too low – too much pressure is
required on brake pedal to stop the
vehicle.
𝜇 =
𝐹
𝑅 𝑁
F – Tangential braking force or frictional force acting at the contact surface block & Wheel
RN – Normal Reaction
10. INTRODUCTION
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Factors Governing Braking: Frictional Contact Surface
The bigger brakes stops a vehicle more quickly than
the smaller brakes used on the same vehicle.
Four wheel brakes stop a vehicle faster than a two
wheel brakes on same vehicle.
11. INTRODUCTION
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Factors Governing Braking: Brake Geometry (Heat dissipation Capability)
During braking, friction cause heat generation on Pad
& Disc.
It should be properly dissipated by air. (Absorb by air)
Mass & Potential speed of the vehicle determine the
size of braking mechanism and the friction surface
area of the pad or shoe.
No proper heat dissipation - leads to brake fade during
hard or continuous braking.
What will be happen?
Lining pad or shoe become glazed
Disc & Drum becomes hardened
Now the μ reduced, leads to excessive pressure must
be applied to produce desired braking effect.
12. INTRODUCTION
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Braking Force: FB
It is the force of resistance applied to stop the vehicle
or reduce the speed..
It depends on weight of a vehicle & rate of
deceleration which it is stopped.
Neglecting the following thing FB Calculated.
Air & gradient resistance
𝐹𝐵 =
𝑊. 𝑎
𝑔
𝑎 =
𝑔 . 𝐹𝐵
𝑊
W – Weight of the Vehicle
a – Rate of Deceleration
g – Acceleration due to gravity = 9.81 m/s2
Sum of Braking forces of all wheel equal to weight of the vehicle.
13. INTRODUCTION
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Braking Force: FB
The limiting value of the braking force depends upon
the adhesion of wheel on the road surface.
The ratio of adhesion to the weight of the vehicle is
called the Coefficient of friction.
𝜇 =
𝐹𝐵
𝑊
𝑜𝑟 𝜇 =
𝑎
𝑔
14. INTRODUCTION
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Maximum Retardation Point
Brakes applied – Wheels will either roll or skid.
Depends upon the relative value of Friction b/n
braking surface and friction b/n the tyre & road.
Jamming of braking surface, increase the friction &
cause wheel skid & more tyre wear.
The maximum retardation is reached means, wheel
lock condition during braking.
At this point friction/n Braking surface should equal to
the friction b/n Tyre & Road contact surface.
In case the friction b/n braking surface is more than
the friction b/n tyre & road, then the brake will lock &
the tyre will start skidding.
15. INTRODUCTION
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Weight Transfer During Braking:
Effective braking force occurs on the
Ground
During Braking vehicle weight & Kinetic
energy of the vehicle act through its center
of gravity.
When applying braking to moving vehicle,
It experience pitching.
This tendency of the vehicle is known as
“Brake dip”
Height of Center of gravity of vehicle
above ground level, in relation to the
wheel base & suspension characteristics.
16. INTRODUCTION
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Weight Transfer During Braking:
When applying brake, results in increase
weight on front wheel & decrease weight
on rear wheel.
Therefore, front brakes absorbs more
kinetic energy than the rear brakes.
Maximum amount of weight transfer
𝑊𝑇 =
𝜇 ℎ 𝑊
𝑏
When deceleration of vehicle is considered
𝑊𝑇 =
𝜇 ℎ 𝑎 𝑊
𝑏. 𝑔
WT – Weight transferred.
μ – Coefficient of friction
h – Height of center of gravity
from the ground level.
W – Gross weight of the vehicle
b – Wheel Base
a – deceleration of the vehicle
g – Acceleration due to gravity
17. INTRODUCTION
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Weight Transfer During Braking:
During braking, weight is added to the
static weight on the front wheels and
subtracted from the static weight on the
rear wheels.
The front wheel static weight is normally
55% of the vehicle weight.
The front brakes are designed to absorb
extra braking effort by selecting suitable
braking system.
Because, front wheel locks ahead of rear &
cause the vehicle to go straight & not to
spin.
18. INTRODUCTION
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Stopping Distance:
Distance required to stop a
vehicle during application of the
brake
By considered a 100% Brake
efficiency, the stopping distance
may calculated.
𝑆 = 𝑢. 𝑡 −
1
2
𝑎. 𝑡2
𝑉2 − 𝑈2 = −2𝑎𝑠
V = 0 (at end of stop)
𝑆 = 𝑢2/2𝑎
s = Distance moved by the vehicle in m
u = Initial Velocity of the vehicle in m/s
v = Final velocity of the vehicle in m/s
t = Stopping time in s
a = Deceleration of the vehicle in m/s2
19. INTRODUCTION
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Braking Efficiency:
Ratio of braking force produced to the weight of
the vehicle.
ȠB =
𝐹 𝐵
𝑊
× 100
Generally less than 100% because of
insufficient road adhesion & Ineffective braking
system.
Braking efficiency equal to Coefficient of friction.
If ȠB = 100% means, μ = 1
Total braking force produced at wheel = equal
to the vehicle weight.
100% brake efficiency lead injury to passenger
It generally vary from 50 to 80%
20. CLASSIFICATION OF BRAKES
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Classification of Brakes: According to the purpose of the brakes
Service Brakes/Foot Brakes :
Operated by foot pedal
Used while in vehicle moving to stop it.
21. CLASSIFICATION OF BRAKES
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Classification of Brakes: According to the purpose of the brakes
Hand Brake or Parking Brake :
Operated by Brake lever or Pedal
Used to hold the vehicle in position
while stationary
Helps in parking, Prevent vehicle
rolling @ Different road gradient/Fast
blowing wind.
Act as Emergency brake, while service
brakes fail or prove ineffective.
22. CLASSIFICATION OF BRAKES
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Classification of Brakes: According to the construction of brake
Drum Brakes Disc Brakes
23. CLASSIFICATION OF BRAKES
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Classification of Brakes: According to the Method of operation
Mechanical brakes
Hydraulic Brakes
Vacuum Brakes
Air Brakes
Electric Brakes
24. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Components
Brake Drum : Acts as a braking surface
on wheel side
Wheel Hub : The part which Wheel &
Brake drum is attached
25. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Components
Back Plate : Holds all the brake
components together
Brake Shoe : This will be pushed against
the inner surface of the drum
26. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Components
Brake Lining :
Provides friction b/n Brake shoe &
Inner surface of drum.
Causes to slow down the wheel
Hold Down Spring : Holds the Brake
shoe towards the Back plate
27. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Components
Retaining Spring : Retaining the brake
shoe to its Resting position
Wheel Cylinder : Hydraulic Part which
pushes the brake shoe
28. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Components
Self Adjuster Mechanism :
Modern drum brakes uses self adjuster
mechanism
Which means when the lining wear's
out, the system aligning the brake shoe
to keep the clearance b/n drum surface
& Brake lining
29. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Working
To operate the brake, the brake pedal is
pressed,
Brake shoes are pushed outwards,
So the lining is forced against the
drum,
The force comes from hydraulic wheel
cylinder or from the mechanical linkage
of the parking brake.
When the brake pedal is released, it
causes the brake shoes to return to
their original position, through the
action of the brake springs.
30. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Leading & Trailing Shoe
Shoe which extends in the same direction as
the rotation of the brake drum is known as
leading shoe.
Shoe which extends in opposite direction is
known as trailing shoe.
Leading shoe pushed up against the inside of
the drum, and pulled along by its rotation,
causing it to expand out wards.
Now brake shoe push harder against the drum
by applying even stronger braking force
Known as self-servo action or self energization
action
31. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Leading & Trailing Shoe
Trailing shoe pushed by the brake drum &
apply weaker braking force.
During trailing shoe pressed against the drum,
the friction caused by the drum rotation
subjects the shoe to forces which are centering
on the anchoring pins.
Those forces press the shoe inside.
Thus weakening the pressure on drum.
Now drum rotation de-energizes the trailing
shoe by forcing it inside.
In this way the drum speed reduced & Stopped
32. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Types
Leading & Trailing shoe Type :
Pivoted at bottom by anchor
Opened by Wheel cylinder at
Top.
One leading & Trailing shoe
provide constant braking force at
all time to stop vehicle.
Used in Small rear wheel drive
cars & Front wheel drive cars
33. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Types
Two Leading Shoe : Single acting type
Unidirectional wheel cylinders are
mounted in top & bottom of the brake
drum.
Both shoe can have self servo action
during vehicle forwarding
High degree of braking force is generated.
But it will reduced during vehicle
reversed.
Because now both the shoe experience
trailing
Used in front brakes, before the use of
disc brakes
34. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Types
Two Leading Shoe : Double acting type
Bidirectional wheel cylinders are
mounted on the top & bottom of the
brake shoes
Provide high degree of braking force @
forward & Reverse direction of Vehicle.
35. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Types
Duo Servo Type:
Similar to Leading & Trailing shoe type
Here brake shoes are not connected to backing
plate,
Rather they are connected each other by a shoe
adjuster
Advantages is both shoe act as a leading shoe.
Disadvantage, does not provide constant braking
force
36. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Brake Shoes
Made of two parts of pressed steel
Shoe rim & Shoe web
Shoe rim curved profile closely match with drum inner surface
Brake lining is attached to the rim Surface
It has series of bent areas on the edges, where the shoe rest against the
backing plate
Shoe web welded to the rim for
reinforcement to rim
The other part of the brake drum like anchor,
return spring, parking brake attachment, and
adjusting mechanism are attached to the
shoe web
Al – Shoe - good Heat dissipation, less weight
37. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Brake Lining (Bonding Attachment)
Made up of Friction material.
Two methods followed to attached with brake shoe.
Bonded lining is attached to shoe by high temperature
adhesive.
Procedure
First cleaning the break shoes
Lining surface roughened by sanding
The adhesive then applied to both liner & Shoe
Then placed into the high temperature oven (150oC
to 200oC
After curing the brake shoe is removed & allowed to
cool
Bonded lining is preferable
38. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Brake Lining (Riveting Attachment)
Attached to the Brake shoe by a series of Brass or
Aluminum rivets.
The rivets are pass through countersunk hole on lining
The rivets are flattened inside the shoe rim to hold the
lining tightly in place
39. CLASSIFICATION OF BRAKES
11/24/2020 16MT407 - Theory of Automobile Engineering 39
DRUM BRAKES : Brake Lining Material
Function :
Designed to produce heat from friction.
As it rubs against the rotating drum surface.
Also known as friction material.
Not to cause excessive wear to drum & Disc surface.
Able to operate at high temperatures without failure.
Made by Organic or metallic material.
40. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Organic Lining
Moulded Type :
Made of mixed compound asbestos, filler material, Powdered resin.
Asbestos – Silicate mineral called as rock forming minerals
Form from Serpentinite/Amphibole rocks
Filler material - Improves coefficient of friction & Gives good
bonding b/n asbestos & resin
To reinforce the brake lining.
Generally Barium sulfate (barytes) used as filler material.
Resin – Mixtures of organic compounds.
BLR 140 - melamine resin add with Brake lining to improve
thermal & mechanical properties of friction material
Melamine formaldehyde – organic compound (Thermosetting
plastic)
Asbestos
Serpentinite
Rocks
41. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Organic Lining
Moulded Type :
The mixture organic compound is Moulded in dies to
form into shape & is placed under heat & pressure until
hard
To get a state like Board
After it will cut into individual segments & attached with
Brake shoe
42. CLASSIFICATION OF BRAKES
11/24/2020 16MT407 - Theory of Automobile Engineering 42
DRUM BRAKES : Organic Lining
Woven Type :
Form from strands of Asbestos & Threads of Other
material
And impregnated (Soak) with rubber compound
To form organic lining for brake shoe.
43. CLASSIFICATION OF BRAKES
11/24/2020 16MT407 - Theory of Automobile Engineering 43
DRUM BRAKES : Metallic Lining
Sintering Method :
Process of compacting & Forming of solid mass of material by heat or pressure,
without melting it to the point of liquefaction.
Made of sintered metal has a composition of fine powdered Copper or iron,
Graphite and some amount of inorganic fillers and friction modifier
Inorganic Fillers – Silicon Carbide,Clacium carbonare, Dolomite, etc
Graphite (Crystalline Carbon), Carbon – Friction modifier
Finally lubricating oil is added for avoid segregation of different materials.
Required form of Lining is formed by some special process like heat treatment,
etc.
Frictional qualities is more constant than organic lining
It can be used in Police cars, Fire brigade vehicle, Sport cars
44. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Backing Plate
It is the base unit, where all the component is
attached,
It is fixed with rear axle or steering Knuckle.
The anchor pin is a steel pin welded or riveted solidly
to the backing plate or threaded into steering
Knuckle through the backing plate
It has various projection, where it holds the position
of Brake shoe & Drum.
It also contains holes and bosses for attaching wheel
cylinder, shoe hold-down spring, and parking brake
lever
45. CLASSIFICATION OF BRAKES
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DRUM BRAKES : Brake Drum
Made of cast iron
Requires, Good strength, Wear Resistance, It
should Absorb heat.
For improves heat dissipation, fins added with its
circumference
46. CLASSIFICATION OF BRAKES
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DISC BRAKES : PRINCIPLE
PASCAL’S LAW :
The system works based on Pascal’s Law
“Pressure Exerted anywhere in a contained
incompressible fluid is distributed equally in all
direction
50. CLASSIFICATION OF BRAKES
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DISC BRAKES : COMPONENT
Disc Rotor :
Part of the disc brake
Squeeze by Brake pads
During braking, heat will generate
because of friction,
That decelerate the wheel
Stud holes helps to dissipate heat
from disc by allowing more air
into it.
Optimum cooling performance is
achieved.
52. CLASSIFICATION OF BRAKES
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DISC BRAKES : COMPONENT
Housing Part :
Also called as Caliper
Mounted on steering Knuckle
Through Banjo Fitting The fluid
enters into the housing
Causes the piston to come out
with great force
To squeeze the pads against the
Rotating Disc
Comes in two types
Floating Caliper design
Fixed caliper Design
53. CLASSIFICATION OF BRAKES
11/24/2020 16MT407 - Theory of Automobile Engineering 53
DISC BRAKES : COMPONENT
Housing Part : Floating Caliper Type
Either comes with one piston or two
piston
During outer pad squeeze the disk,
the caliper can slide along vehicle
frame.
In general floating type single piston
is used on light cars.
54. CLASSIFICATION OF BRAKES
11/24/2020 16MT407 - Theory of Automobile Engineering 54
DISC BRAKES : COMPONENT
Housing Part : Fixed Caliper Type
Caliper solidly fixed to the steering
Knuckle.
It uses a pair of piston.
Located on both side of caliper
providing equal force each pad.
It’s also incorporate one or two
piston on each side (depends on
vehicle)
The inboard piston applies pressure
to the inner pad
Outboard piston applies pressure to
the outer pad
55. CLASSIFICATION OF BRAKES
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DISC BRAKES : COMPONENT
Brake Pad :
Consists of a block of friction material attached to
a stamped steel backing plate.
The brake pad material is bonded to the backing
plate with a high temperature adhesive.
A slit is provided on the face of the pad to indicate
the allowable limit of the pad wear.
It also provide a path for brake dust and gas to
escape .
56. CLASSIFICATION OF BRAKES
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DISC BRAKES : COMPONENT
Brake Pad wear indicator :
Some times attached to the one of the pads.
Simple steel plate
Helps the drive to notice about pad replaceable
time
Via a screeching Noise.
If he not notice it properly, leads to irreparable
damage to disc.
57. CLASSIFICATION OF BRAKES
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DISC BRAKES : COMPONENT
Pad to Disc Clearance Adjustment :
Similar to self adjuster mechanism in drum brake.
Automatic adjustment of the pad to disc clearance
is done whenever the brake is operated
A deformable seal is placed inside the machined
groove in the housing.
60. CLASSIFICATION OF BRAKES
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Brake Fade :
Brake drums and discs are forced to absorb
a significant amount of heat during braking..
It describes heat generation is faster rate
than a capable of heat dissipation to
atmospheric air.
Happen during repeated hard stops,
Overheating
Leads to Ineffective braking or even brake
failure.
Two causes for brake fade
Mechanical fade
Lining Fade
61. CLASSIFICATION OF BRAKES
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Brake Fade :
Mechanical Fade:
Due to brake drum over heats & expand
away from the brake lining.
Results increased brake pedal force during
travel.
Lining Fade:
Affects both drum & Disc brake.
Affects when the friction material overheats
to the point where the co-efficient of friction
drops off.
In this moment Friction is reduced and
brake ability to convert added heat is
reduced
62. CLASSIFICATION OF BRAKES
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Disc Brake vs. Drum Brake :
DISC BRAKE Drum Brake
Non – energized, Non servo Brakes Self energizing , Servo brakes
Brake pad pressure is directly proportional to
brake pedal pressure
Not directly proportional
More stable Less stable
Brake disc generally stays cleaner
Drum collects all the contaminants due to
centrifugal force
Remains cooler under repeated severe
braking
Heat increase under repeated severe braking
Clamping action of disc brake pad causes no
distortion of the disc
Spreading action of drum brake shoes cause
the drum to elongate into elliptical or oval
shape
Brake pad can easily replaced Not be easily replaced
More cost Less cost
High pedal pressure is required No high pedal pressure required
Difficult to install parking brake Easy to install parking brake
63. CLASSIFICATION OF BRAKES
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Hydraulic Braking System:
Brakes which are operated by means of
hydraulic pressure known as Hydraulic Brakes
Works on the principle called “Pascal’s Law”
All modern automobile brake systems use a
hydraulic system to transmit the forces from
the brake pedal to brake shoe or Brake pad
Main Components :
Brake Pedal
Master Cylinder
Drum Brakes – PCV & Wheel Cylinder
Disc Brakes
64. CLASSIFICATION OF BRAKES
11/24/2020 16MT407 - Theory of Automobile Engineering 64
Hydraulic Braking System: Master Cylinder
Major components of Hydraulic braking system.
Converts the pressure applied to the brakes into
hydraulic pressure.
Maintains the constant volume of the fluid in the brake
lines, since it has a reservoir.
Reservoir cap equipped with float sensor about the fluid
level in the tank
Master Cylinder
Single Master
Cylinder
Tandem Master
cylinder
65. CLASSIFICATION OF BRAKES
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Hydraulic Braking System: Master Cylinder
Single Master Cylinder : Construction
Consists two portion, Namely Cylinder &
Reservoir.
In reservoir Filer cap contains air vent, so
fluid can expand & Contract and still at
atmospheric pressure.
Main cylinder has piston, Primary cup &
Secondary rubber cups, Return Spring,
Outlet check valve & a rubber seat.
Rubber boot covers the push rod end of
the cylinder, to prevent dirt into the
cylinder.
66. CLASSIFICATION OF BRAKES
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Hydraulic Braking System: Master Cylinder
Single Master Cylinder : Working
i. When brake pedal is pressed?
Piston inside the cylinder forces the
fluid into the brake line.
Fluid pressure built up in the brake
system.
The fluid pressure acts at the piston in
the wheel cylinder or caliper.
The outside movement of piston
causes brake pad to come into contact
with brake shoe & disc
There by brakes applying
67. CLASSIFICATION OF BRAKES
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Hydraulic Braking System: Master Cylinder
Single Master Cylinder : Working
i. When brake pedal is Released?
Piston return spring move the piston
very rapidly.
This cannot compensate by fluid
movement.
So partial vacuum creates inside the
cylinder.
Now fluid from intake port moves via
hole in the piston & fill the vacuum in
the cylinder.
In contrast, fluid pressure in the line
open the outlet check valve.
68. CLASSIFICATION OF BRAKES
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Hydraulic Braking System: Master Cylinder
Tandem Master Cylinder :
Construction
Tandem means – inline
Master cylinder contains two
piston in it’s inline to each other
with in a single cylinder.
Primary piston contains two
rubber cups.
Secondary piston contains three
rubber cups.
Secondary cups on secondary
piston slightly different.
69. CLASSIFICATION OF BRAKES
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Hydraulic Braking System: Master Cylinder
Tandem Master Cylinder :
Working
i. When brake pedal is
pressed?
Primary piston operation is
same as single master
cylinder.
Secondary piston operates
by pressure built up in the
primary section
Here the hydraulic
pressure delivered to two
independent brake lines
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Hydraulic Braking System: Master Cylinder
Tandem Master Cylinder :
Working
i. When brake pedal is
released?
Primary piston returns to
the retaining ring at the
end of the cylinder.
Primary & Secondary
spring length & strength
determines the secondary
piston position during
returning.
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Hydraulic Braking System: Master Cylinder
Tandem Master Cylinder :
Working
i. When brake pedal is
released?
The piston stop bolt
ensure the secondary
piston return & its position
after brake release.
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Hydraulic Braking System: Master Cylinder
Tandem Master Cylinder :
Advantage:
If any leakage on any one
piston side also ensure the
brake pressure on non failure
side.
Front wheel drive cars use a
diagonal split system.
One piston supply pressure for
front right brake & rear left
brake
Similarly other piston supply
pressure in opposite manner.
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Hydraulic Braking System: Master Cylinder
Tandem Master Cylinder :
Advantage:
In diagonal split system ensure
the 50% of the braking power
on one line, even failure in the
system.
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Hydraulic Braking System: Proportional control valve (PCV)
During braking, the weight of the
vehicle transfer to front portion of
the vehicle.
Increase load on front portion,
makes the front brakes less prone
to locking.
Meanwhile, rear wheel side load is
reduced, which increases the
possibility to lock the rear wheels.
It causes the rear wheel to skid &
the vehicle is spin.
The PCV is provided to reduce & maintain the rear brake pressure & maintain
with its limit.
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Hydraulic Braking System: Proportional control valve (PCV)
Construction :
Input port receive brake fluid from
master cylinder.
A plunger actuated valve body held
open by spring force.
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Hydraulic Braking System: Proportional control valve (PCV)
Working :
When apply brake pedal, the brake
fluid pressure is transmitted to the
rear brakes via PCV
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Hydraulic Braking System: Proportional control valve (PCV)
Working :
When pressure on rear brake line
increase.
It over come the spring force inside
the valve.
& make it move downward.
Now the plunger is contact with the
lip seal.
Closing off the brake line.
In this moment equal pressure on
Master’s & Rear wheel brake’s
No pressure is transmitted to the
rear wheel
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Hydraulic Braking System: Proportional control valve (PCV)
Working :
When pressure is increased in
master side.
Plunger is pushed up against the
spring
Open valve to rear brake line.
Now pressure is transmitted to rear
line’s.
This cycle is continued & prevent
pressure surges on rear side
Also prevent wheel lock
For maintain the stability of the
vehicle.
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Hydraulic Braking System: Wheel Cylinder
Construction :
Cylinder Body made of cast iron or
Aluminum
It is mounted on backing plate, inside the
brake drum.
Cylinder body contains two holes
Inlet port
Bleeder valve
Inlet port : Give hydraulic pressure to
extend the cylinder piston for apply brakes
Bleeder Valve : Helps to remove air from
the system.
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Hydraulic Braking System: Wheel Cylinder
Construction :
From the expanded view,
It has two pistons with push rod
Piston cups
Piston cup expanders,
Piston expanders
Retain Spring
Dust Boot
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Hydraulic Braking System: Wheel Cylinder
Working :
When the brakes are applied, pressure is
transferred to the wheel cylinder.
The fluid pressure behind the piston cup,
expands the piston with the help of
expander
Now the push rod on the piston pushes the
brake pad against the drum inner surface
To stop it’s rotation motion.
When brakes released, the piston retracts
with the help of return spring.
Now brake is released.
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Pneumatic Braking system: Air Brakes
Working :
In larger vehicle, even a hydraulic brakes
with vacuum booster not give effective
braking.
It requires high power braking
Air brakes resolves in heavy vehicles such
as, Trucks, Highway vehicle, etc.
The air pressure is required about 900 Kpa.
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Pneumatic Braking system: Air Brakes
Construction :
It consists of a Air compressor unit,
Air reservoir tank, brake valve, series
of brake chambers, unloader valve,
pressure gauge and a safety valve.
Compressor is driven by engine.
It stores the air at reservoir
Brake valve is operated by foot pedal.
It is further connected to the brake
chamber
Each brake shoe contains separate
brake chamber
It has cam mechanism to apply brake
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Pneumatic Braking system: Air Brakes
Working : Hand Brake on
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Pneumatic Braking system: Air Brakes
Working : Hand Brake Release
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Pneumatic Braking system: Air Brakes
Working : Pedal Brake Applied – Service brakes on
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Pneumatic Braking system: Air Brakes
Working : Pedal Brake Release – Service brakes off
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Antilock Brake system
Prevents of the wheels of a vehicle from locking, when the brakes are applied.
Maintain ability to steer the vehicle.
Locking of front & Rear wheels of a vehicle is extremely dangerous.
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Antilock Brake system
Hard brakes applied while Vehicle’s moves on slippery road surface
Tends to front wheel locks.
Now driver loss his control of direction and vehicle still move in a current
direction.
Impact happens - It hit obstacle.
If Rear Wheel locks – vehicle
starts to spin
Now the stability of the vehicle
is affected.
ABS Intelligently works on
such a way to prevent wheel
lock at panic situation.
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Antilock Brake system
Amount of Tyre slip is known as slip factor.
ABS works on this principle to control the brake pressure.
Always maintain the Ideal slip factor.
It can be derived from Vehicle speed & Wheel speed.
𝑆𝑙𝑖𝑝 𝑓𝑎𝑐𝑡𝑜𝑟 =
𝑉𝑒ℎ𝑖𝑐𝑙𝑒 𝑆𝑝𝑒𝑒𝑑 − 𝑊ℎ𝑒𝑒𝑙 𝑠𝑝𝑒𝑒𝑑
𝑉𝑒ℎ𝑖𝑐𝑙𝑒 𝑆𝑝𝑒𝑒𝑑
Automatically controls the brake to keep the wheels in rotating condition.
Helps the inefficient drive to apply brake safely, during hard situation.
Driver get Steerability control of vehicle.
Braking force limiting the performance characteristics of the vehicle.
But ABS does not enhance it.
It ensure that brakes operate with maximum efficiency to stop the vehicle at
minimum distance.
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Antilock Brake system : Working
Speed Sensor : Provides wheel lock up
information to ECU unit.
Modulator : Controls the brake fluid
pressure to each wheel.
Electronic Control Unit :
Controls the complete system
operation.
Receives the signal from the wheel
sensor & controls the modulator.
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Antilock Brake system : Working
At panic situation, the wheel sensors
detects any sudden changes in wheel
speed.
ECU – constantly monitor the vehicles
speed and compares signals received
from four wheel speed sensor.
Calculate the slip ratio of each wheel
Instruct the modulator to provide
optimum brake pressure
Resulting in, wheel speed recovers to a
level which locking does not occur.
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Antilock Brake system : Working
Then ABS ECU – give signal to
modulator to reapply brake by
increasing the fluid pressure.
Now the wheel speed drops to a level
which the locking can occur.
This cycle continuous until the vehicle
stop with a minimum distance
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Traction Control System : Tractive effort
Traction is a force used to generate
motion between a body and a
tangential surface using dry friction.
Accelerating of a vehicle is limited by
two factors
Power of the engine
Traction force b/n tyre & road
surface
What happen if traction loss in
vehicle?
Increase the risk of skidding
Loss of control
Collision
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Traction Control System : Tractive effort
What factors derive traction loss to a vehicle?
Ice or snow roads
Standing water on road
Mud near farm entrance, Construction sites,
Truck crossings,
Wet leaves on roads
Broken or uneven road surface
Sand or gravel found in rural areas, while
approaching curves
Accelerating & braking too hard
Steering too much or Quickly steered
Enter curve with too much speed
These factors leads to vehicle skid
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Traction Control System : Need
Thus it necessary to have traction control in order to maintain the vehicle
motion in adverse conditions like slippery or in climbing hills.
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Traction Control System vs. ABS :
TCS ABS
In TCS apply brakes when the wheels
try to spin and loose traction
An ABS releases the brakes, when
wheel go into locking
It increases the traction force &
provides acceleration to the vehicle
Provides good steering, while braking
in slippery surfaces
It is active vehicle safety feature designed to help the vehicle make effective
use of all the traction available on the road. When accelerating in slippery
condition.
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Traction Control System : Working
Compares the rotational speed of the
drive wheels of the vehicle with the help
of speed sensors of ABS.
If any wheel encounter slippery surface
means, rotate with exceptionally high
speed.
Then it considered as spinning wheel
TCS immediately sends the signal to
apply brakes to cut of the power
delivered to the vehicle.
Therefore opposite wheel on that same
axle produce more torque to drive the
vehicle.
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Traction Control System : Other ways
Brake force apply to one or more wheel
Reduction or suppression of spark sequence to one or more cylinders.
Reduction of fuel supply to one or more cylinders.
Closing the throttle, if the vehicle is fitted with drive by wire
In turbocharged vehicles, a boost control solenoid is actuated to reduce the
boost power, thereby to reduce the engine power for wheels.