Brake System Fundamentals: Brakes

Brake System
Fundamentals
BRAKES C Copyright Gautam Malik 2007
Brake System Principles
• Kinetic Energy
• Mass
• Weight
• Speed
• Inertia and
Momentum

Friction Principles
• Kinetic and Static
Friction
• Friction and Pressure
• Friction and Surface
Area
• Coefficient of Friction
• Brake Fade

Friction Materials Characteristics
– Resist Fading with
increased temp
– Resist fading when wet
– Recover quickly
– Wear gradually
– Quiet
Bonded or Riveted

Braking Dynamics
• Weight Transfer
• Weight Distribution
• Braking Power
• Friction Efficiency
– Brake to Wheel
– Wheel to Road Surface
• Traction Efficiency
– Skidding

Braking System

Types of Brakes
• Mechanical Brakes (uses string & cam arrangements
eg. scooters, bikes)
• Hydraulic Brake (Cars & jeeps)
– Drum Brakes
– Disc Brakes
• Vacuum Assisted Brakes
• Pneumatic Brakes using compressed air (Bus/truck)
• Antilock Braking System (ABS)

Mechanical Brakes

HYDRAULIC BRAKES

Hydraulic Braking System

Hydraulic Principles
• Fluids cannot be compressed
• Fluids can transmit Movement
– Acts “Like a steel rod” in a closed container
– Master cylinder transmits fluid to wheel
cylinder or caliper piston bore.
• Fluids can transmit and increase force
– Force Pressure
Area

The amount force is calculated
by multiplying the pressure
times the area
P X A = Force
Hydraulic pressure is distributed
equally in all directions

The hydraulic pressure is the same, but the
applied force can be changed by changing
the piston size.

Advantage by Hydraulics
1. As oil is used, so fluid link assists in braking even

longer wheel distances compared to mechanical
brakes.
2. The braking effort is also comparatively reduced
3. No abrupt failure
4. Robust construction (works well in rough
conditions)

Disadvantages
• Prone to leakages
• It uses a closed system of fluid movement
so is restricted to longer wheel distances

Brake Pedal
• First Mechanical
Advantage is Driver’s
foot
• Length of Lever
determines force
applied
• Uses Fulcrum
• Pedal Ratio
10
5:1 2.5 inches 0.5 inch
2 5
Brake Plumbing
• Rigid steel brake lines
are double wall
• Flexible hoses connect
rigid lines on vehicle
to each wheel
• Transmits hydraulic
fluid to each wheel

DRUM BRAKES

Drum Brake System

Two different categories
of drum brakes
• Non-servo • Servo

Non-Servo

Servo Action
The rear shoe does most of the work

• Non Servo brake
lining
• Servo Brake lining

– Primary
– Secondary
It is very important that the Primary shoe
is always facing toward the front of the
car
The Secondary shoes must always face

toward the rear of the car

DRUM WEAR
Worn Drums
• Scored
• Bell Mouthed
• Concaved

Drum Size
Why is this important?
Because of the surface
area for the friction for
a particular power
transmission.
BRAKE DRUM

Master Cylinder

Pressure Control Valves

System in Conjunction

Wheel Cylinder
• Wheel cylinder or
caliper pistons are
“slave cylinders”
• Change hydraulic
pressure back into
mechanical force
• Can use one or two
cylinders at each
wheel

Wheel Cylinders

Axle Seals
• Inside Leak
• Outside Leak

Emergency Brake
Parking or “Emergency” Brake

Parking Brake Systems
• Foot or Hand Brake
• Are cable controlled
– Several Styles
• As shown
• Drum in hat
• Driveline

Combination of Disc & Drum

Automotive Disc Brakes

Disc Brakes
Disc brakes are fairly simple to work with,
once you know the parts and their
functions. Typically, there are 4 main parts
of a system:
• Mounting Bracket
• Rotor Disc
• Caliper
• Pads

Disc Brake Caliper Assembly

Sliding Caliper
• Applies pressure to
two pads on opposite
sides of rotor
• Caliper
– Sliding
– Fixed
• Friction Material
exposed to air

Fixed Caliper
• Applies two pistons to
opposite sides of rotor
• Caliper stays
stationary
• Disc Brakes require
higher hydraulic
pressure

Mounting Brackets
Mounting Brackets are used to

hold the Caliper in place.
Other than keeping the surface
clean and free of rust and road
grime, there is very little to be
done with this part

Rotors
Rotors are metal discs supported by

the suspension. The Calipers
clamp on to them to slow their
rotation, and then slow or stop the
car

Vented Rotor
These are
the VENTS

Vented Rotors
Vented Rotors have Fins in the spaces
between their machined surfaces.
These spaces allow air to pass through,
which helps to carry heat away.

Non vented Rotor
Non Vented Rotors are used on smaller
vehicles, and have no cooling fins

Non Vented Rotor

Calipers
Calipers are the housings that contain
the Pistons and the Brake Pads. The
Calipers are connected to the Hydraulic
System, and hold the brake pads to the
Rotor

Caliper Types
There are 2 types of Calipers
• Fixed
• Floating

Fixed Caliper
Fixed Calipers are disc brakes that use a
caliper that is FIXED in position and does
not slide. They have pistons on both sides
of the disc. There may be 2 or 4 pistons per
caliper

Fixed Caliper
Motorcycles and
some import trucks
and cars use this
type

Sliding Caliper
• Much more common
• Single Piston
• Easier to work with
• On “inboard” side of caliper

Clean, Floating Caliper

Floating Calipers

Operation
Caliper
Brake
Piston applies Line
pressure to
Inboard pad. As Brake Pads
the pad contacts
the rotor, the
Piston
caliper slides
along the pins, Rotor
pulling the
outboard pad into
contact.
Sliding caliper in operation

Parts of a Caliper

Seal
The rebuild kit will have a new
O ring, and a Dust Seal

Piston
The Piston surface should be smooth and
clean. This one is pitted, and needs
replaced.

Fixed Caliper
Fixed
caliper
2
piston
Fixed
caliper
4
piston
Floating
Caliper
Vacuum Assisted Brakes
Where effort required is comparatively
higher we make use of engine vacuum to
assist braking.

Location of components

Released position

Applied position

Vacuum
Check valve
optional
location

12 volt vacuum booster
for low vacuum engines

AIR POWERED BRAKES
• In air powered brakes, air instead of
incompressible oil as in case of hydraulic
brakes is used as the working medium.
• Air is abundantly available , free & hence can
be discharged into atmosphere without any
concerns after utilizing.

Advantage by Pneumatics
1. As air can be used in an open loop, so can easily be
discharged after assisting in braking at even longer wheel
distances compared to hydraulic brakes.
2. Can be utilized where braking effort is more as manual
effort is assisted by the pressure of compressed air from
reservoir via a compressor which takes its power from the
compressor.

Disadvantages
• Noisy
• Costly compared to hydraulic system

(Antilock Braking System (ABS))

Why Required???
During extensive field trails of Braking System some
serious facts came out.
1. While impulse/sudden braking the tires gets locked due
to braking action as a result vehicle doesn’t stops due to
momentum & starts skidding.
2. This skidding makes the vehicle get out of control of
driver.
3. Also if there has been a situation in which wheels do not
lock up, the stopping distance reduces compared to a
situation in which wheels are locked & do not skid &
therefore remains in control of driver.

ABS System

In antilock braking System this skidding of the
vehicle is checked. There are load Speed &
acceleration sensors installed which provides useful
data to the ABS Control Module about the tractive
effort & the speed of the wheels. Before locking up
of the wheel, the ABS controller allows the
alternate barking & releasing action on the wheel
cylinders/braking pads of calipers which prevent the
wheels from locking. With this system the vehicle
remains in the control of the driver.

Advantages
• No skidding
• Better Control
• Less stopping distances
Disadvantages
• Costly

Diagnosis of Brakes
Several different types of Complaints
1. Noise
2. Pulsation
3. Pedal travel etc..

Brake Noise
Wear
Indicator

Brake Pulsation
Usually a
warped Rotor
Rotor needs
trued on a
brake lathe

THANK YOU

Brake System Fundamentals: Brakes

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Brake System

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

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BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

1. As oil is used, so fluid link assists in braking even

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

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• Servo Brake lining

The Secondary shoes must always face

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

BRAKES C Copyright Gautam Malik 2007

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BRAKES C Copyright Gautam Malik 2007

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Parking or “Emergency” Brake

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Mounting Brackets are used to

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Rotors are metal discs supported by

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There are 2 types of Calipers

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