BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

BRAKING SYSTEM
1

INTRODUCTION Brakes are employed to stop or slow-dow t!e speed o" a #e!$%le depe d$ & 'po t!e dr$#$ & eeds( When braked, each wheel of the vehicle builds-up a certain braking force. For this reason, greater the number of wheels braked, greater will be the braking effort, and sooner will the vehicle come to halt. Modern vehicles are therefore equipped with brakes on all the wheels. Brak$ & Re)'$reme ts* The following requirements are e pected of an efficient braking s!stem. "t must stop the vehicle with in a smallest possible distance. "t must act instantaneousl! in case of an emergenc! braking. "t must be strong enough to sustain braking force. "t must neither slip nor should cause an! skid to the vehicle. The brake linings should have longer life b! possessing higher anti-fading qualities. "t must operate with the least effort b! the driver. +RINCI+,E O- BRAKING The brake is a friction-creating device, which caused speed reduction of the vehicle at a faster rate than the speed reduction obtained b! changing the gears #top to $rd, to %nd, to 1st& and closing-down the accelerator. 'owever, this rate cannot be high enough to stop the vehicle instantaneousl!. "t is because a vehicle of weight w moving at a speed v possesses kinetic energ! whose value is given b! 1 W (.). * --- --- +% % g TY+ES O- BRAKES ,ifferent t!pes of brakes are used on various categories of vehicle. These can be classified according to following considerations. .( O T!e Bas$% o" A%t'at$ & Met!od Mechanical brakes '!draulic brakes -neumatic #or air& brakes /a0 .ompressed air brakes /10 +acuum brakes )lectric brakes

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

2( O 3( O 4( O

T!e Bas$% o" Co str'%t$o ,rum brakes ,isc brakes /and brakes T!e Bas$% o" A%t$o o" Brake S!oes "nternal e panding brakes ) ternal contracting brakes T!e Bas$% o" Com1$ at$o s ,rum and ,isc combination brakes Mechanical and '!dro combination brakes

5YDRAU,IC BRAKES The modern cars are mostl! equipped with h!draulic brakes on all the four wheels. The braking s!stem of $-wheelers also use h!draulic brakes but on rear wheels onl!. Their front wheel is equipped with a mechanical brake. Wide popularit! of h!draulic breaking s!stem can be attributed to its several advantages, which it has over the mechanicall! operated /01()2. 2ome of these advantages are )qual braking on all the wheel. .omparativel! lesser braking effort required b! the driver. 'igher multiplication of brake pedal effort. 3uieter operation due to the absence of too man! links, rods and shafts. 0educed loss of effort between brake pedal and brake shoes on account of fewer frictional parts. The h!draulicall! operated brakes are suitabl! used on both the drum and the disc brakes. 'owever, there is a basic difference in these two s!stems. "n h!draulicall! operated drum brakes, some h!draulic pressure has to be alwa!s maintained with in the s!stem whereas in h!draulicall! operated disc brakes it is not so. 5YDRAU,IC DRUM BRAKES The assembl! of a brake drum. "t consists of the following main components. /a0 /rake ,rum /10 /ack plate or torque plate /%0 /rake shoe /d0 /rake lining /e0 ) pander /"0 1nchor /&0 0etracting spring /!0 1d4uster The brake drum is mounted on the a le hub and the whole assembl! is housed concentricall! with in the wheel. 1 back plate made of pressed steel sheet is mounted on the a le causing. "t is meant for supporting the brake shoes, e pander and the anchor. "t also serves to protect the assembl! from dust, dirt and mud.

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

Two brake shoes age hinged or fulcrumed on the back plate b! means of anchor pins towards heel end of the shoes. The toe-end of the shoes is connected to the e pander. The brake linings made of friction materials are riveted on the brake shoes on their conve faces, which remain near to he brake drum. 1 retracting spring #ma! also be two in number& is attached to the two brake shoes for the purpose of pulling-back the shoes, awa! from the brake drum when the brakes are released. The e pander attached to the toe end of the brake shoe, ma! be a cam, toggle lever, or wedge in mechanical brake, or a wheel c!linder in case of h!draulic and pneumatic brakes. "t is operated b! foot pedal or hand lever through mechanical, h!draulic, or pneumatic linkage. The brake linings do wear in due course of their working and need to be ad4usted from time to time. Therefore an ad4uster is used for this purpose. ,ayo't a d Compo e ts* - 2implified la!out of a t!pical h!draulic brake s!stem. "n consists of the following mains parts. Master c!linder, operated b! foot pedal Wheel c!linder /rake fluid #or brake oil& pipelines Master Cyl$ der* - 1 Master c!linder is the most important component of h!draulic brake s!stem. "t remains connected to the brake pedal on one end and to the wheel c!linder through the pipings, houses and their unions on the other end #output side&. "n effect it is a plunger t!pe pump, which delivers oil at about $56-566-k-a pressures during /raking. The Master c!linder assembl! alwa!s remains full of brake oil so that instantaneous braking ma! be done when desired. Co str'%t$o * - "t consists of the following main parts in its assembl!. .!linder bod! integral with the brake oil reservoir having inlet and b!-pass ports. 0eservoir cap having air vent. -lunger connected to a push rod, which is attached to the brake foot pedal. -lunger return spring attached with in the pressure chamber. .heck valve with a rubber cup and valve seat to prevent back flow of brake oil from wheel c!linder to pressure chamber. -lunger seals7 primar! and secondar!. 0ubber boot for protection against the dust and dirt. -iston stopper. The washers, circlips and rubber cups and also be prevent leakage. The plunger is of var!ing having the least area in its middle portion. 6ork$ &* - When the brakes are applied the effort e erted on the brake pedal forces the plunger outward b! the push rod. .onsequentl!, the plunger compresses upon the brake oil stored in the pressure chamber against the pressure of return spring. This initiates pressure stroke, which opens the check valve to allow oil to flow into the brake lines. When the brakes are released the plunger return spring pushes back the plunger towards the boot end. The oil brake pipelines returns back and raises the check valve from its seat. When the oil pressure falls to a required minimum value, the return spring helps the valve to reseat.

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

Types o" Master Cyl$ der* - 2everal designs of master c!linder are emplo!ed on auto vehicles of different makes and models. These are7 .( 2ingle Master c!linder ,rum brakes ,isc brakes 2( ,ouble Master c!linder 3( Tandem Master c!linder

6!eel Cyl$ der* - "t consists of the following main parts. Two pistons, one each connecting to the left and right brake shoes. -iston return spring. Wheel c!linder bod! enclosing the pistons and the spring. 1 h!draulic pipeline is connected to wheel c!linder. When the fluid is forced into the c!linder, piston move awa! from the center and force a part shoes. The shoes pivot on pins and press against the internal surface of brake drums secured on the wheels, thus slowing down the rotation of the wheel. When the pressure in the h!draulic s!stem drops, the shoes are drawn to each other b! spring and the pistons return to their initial position.

Brake -l'$d* - The s!stem is filled with a fluid consisting of Caster O$l a d Al%o!ol #other combinations are also used&. This is known as Brake "l'$d or 1rake o$l. Its "' %t$o s $ !ydra'l$% 1rak$ & are s$m$lar to t!e "' %t$o o" 1lood $ !'ma 1ody(

DISC BRAKES 1s compared to the drum brakes, the disc brakes are the development of later !ear. /asicall! the! are also friction brakes but with practicable differences. The! had been used on aircraft in the past, have been successfull! used on racing cars and are now used as standard equipment on various vehicles. 1dvances in disc brakes are seen as a sign of ousting of drum brakes.

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

Co str'%t$o * - 1 ,isc /rake resembles a flat clutch fitted on each wheel. The generall! adopted t!pe disc brake is referred as spot brake. "t consists of the following main parts. /a0 .aliper or c!linder casing * outer and inner /10 0otor disc /%0 -iston /d0 Friction pad /e0 -ad supporting plate /"0 /leeder plug /esides above, the disc brake assembl! also enclose piston seal, dust boot, pad wear indicator, anti squeal shim etc. The c!linder casing is made in two halves named outer and inner c!linder and resembles a caliper. That is wh! the disc brake is named caliper-t!pe. The caliper is attached to the a le housing in a rear-wheel brake and to the steering knuckle in a frontwheel brake. The rotor disc is connected to the road wheels through a le shaft. The assembl! houses two friction pads, one on each side of the disc. These pads are held in position b! steel pad plates.

6ork$ &* - The ,isc brakes are operated h!draulicall!. When the vehicle is to be braked the brake fluid #or oil& pumped b! the Master .!linder-brake pedal s!stem #see topics on h!draulic brakes& enters into the caliper through inlet tube. "t then flows through the oil passages provided their in and e perts pressure on the pistons. There are four pistons and each of them forces the friction pads against the rotating disc. The pressure of pads stops rotation of the disc and hence the a le shaft #i.e. the wheels mounted on them& stops. When the brakes are to be released, the compression springs force back the piston to release pressure from the friction pads.

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

COM+ARISON BET6EEN DRUM BRAKES AND DISC BRAKES

1lthough ,isc brakes are getting increasing applications on Modern 1uto vehicle, !et the ,rum brakes are not out of favour. "n fact both t!pes have their own merits and demerits and therefore suit well on one or the other vehicles. 1 comparison between them is made in the chart given below. S(NO( .( DESCRI+TION :ife of friction material DRUM BRAKE 0easonable #about 1566 km& DISC BRAKE 0easonable #about %566 km& 2( 3( 4( 7( 8( +isibilit! of wear from outside 'eat dissipation 0eplacement of friction material Weight .ooling <ot possible "nferior Troublesome and time taking /ulk! +er! slow .an be seen at a glance /etter )as! and rapid :ighter #b! * %5>& )fficient due to e posure to atmosphere 9( :( ;( Water and dirt collection /reaking effect Temperature effect 1ccumulates =enerall! inconsistent 2elf cleaning .onsistent

,rum e pands, tends to separate ?naffected out from linings

.<( ..( .2(

2elf energi;ing action /rake pedal effort

) ists 'igher

1bsent -roportional to retardation <o h!draulic pressure on the piston

/ehavior of h!draulic s!stem in 2ome pressure alwa!s e ists released stat.

.3( .4(

0esistance to fading Force needed to appl! brake

Fair .omparativel!

) cellent More, since brakes are not self-energi;ing

.7( .8(

<ature of wear 2hape of friction lining

<on uniform .urved

?niform 2traight

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

+NEUMATIC /OR AIR0 BRAKES

T!e p e'mat$% $(e( a a$r-operated 1rak$ & system $s employed predom$ a tly $ med$'m a d !ea#y tr'%ks 1e%a'se o" t!e "ollow$ & ad#a ta&es( The pressure of pre-compressed air allows practicall! an! force required for braking to be developed with a ver! small effort applied b! the driver to the brake pedal. .ompressed air can also be used to inflate the t!res to drive the windshield wiper, to actuate the steering gear booster, to open and close the doors in buses and to operate pressure horns etc. 1n air-operated brake is the most convenient and dependable device for braking fulltrailers and semi-trailers. -eat'res o" A$r Brakes "t is powerful than the mechanical and h!draulic brakes. "ts components can be mechanical located an!where on the chassis, therefore the chassis design is simplified. 6ork$ & o" A$r Brakes When the pedal is depressed the brake valves change their position and compressed air is admitted into the wheel brake chambers. "n the chambers the air acts upon fle ible diaphragms moves them and pushes out the rods connected with the lever of the brakes gear cams. The cams turn and separate the shoes, thus braking the wheels. When the brake pedal is released, the suppl! of compressed air is cut-off from the brake chambers and the! are connected to atmosphere. The pressure in the chambers drop, the brake shoes are return b! springs to their initial position and the wheels run free. The brake valve is equipped with a servomechanism, which ensure that the braking force on the shoes is proportional to the force applied to the pedal. The compressor is run b! engine power, which is tapped b! means of a belt-pulle! arrangement. The atmospheric air enters into the compressor via an air filter, and then the compressor delivers compressed air to the reservoir through an unloader valve. 1n air pressure gauge mounted on the dashboard indicates air pressure in the s!stem. 1 safet! valve is provided to release air into the atmosphere when the pressure e ceeds its safer limit. 1ir brakes are also emplo!ed on man! self-powered and -owered vehicles. Ma$ +arts o" A$r Brakes 1ir receiver Tank with -ressure relief +alve /rake -edal /rake +alve /rake ,rum 2ervo Mechanism

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

=ACUUM BRAKE "n this s!stem, the operation of brakes utili;es the power of partial vacuum e isting in the inlet manifold of a running engine. This vacuum, via a vacuum reservoir, is applied on one side of a large piston whose other side is e posed to the atmospheric pressure. 2ince atmospheric pressure is 1.6$$% kgBcm% #166 kpa& and the partial vacuum is less than this pressure, therefore difference in the pressure on two sides of the piston causes it to move with in a c!linder. This movement of the piston through a suitable mechanism can be used to appl! the brakes. 1n air breather port is provided in the c!linder through which the atmospheric air escapes-out when the brakes are released. 1 vacuum brake has been used on some vehicles such as /edford, in the past. "t is not much popular as an independent unit i.e. as a purel! vacuum unit. "t is therefore being used in combination with other t!pes of brakes. The vacuum unit can be used with a mechanical or with a h!draulic braking s!stem b! interposing suitable between the brake pedal and the linkage. <ow-a-da!s, the vacuum units are almost universall! adopted on power brakes.

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

16

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

MEC5ANICA, BRAKES
11

Mechanicall! operated service brakes on 8-wheeled auto vehicles are realit! of the past. The! have been replaced b! h!draulic and pneumatic brakes since decades. Their stud! stands for academic interest onl! since the! have least practical utilit! now, 'owever, the mechanical brakes are still used on 8-wheelers for parking and emergenc! uses along with the h!draulic brakes as service brakes. "n such cases, the mechanical brakes are installed onl! on the rear wheel. "t is operated b! hand and foot both. The hand operated is suitable for use as parking and emergenc! brakes while the foot-operated brakes are suitable for al the four wheels. "n an alternative arrangement, there can be a foot pedal instead of hand lever for application of effort b! the driver. 1 mechanical brake s!stem mainl! consists of the following sub-s!stems7 Mechanical linkage for multiplication of input effort. Mechanical e pander for operating the brakes shoes. .ompensator or equali;er for dividing the pedal force between front and rear, and left and right side wheels.

BABA FARID COLLEGE OF ENGINEERING & TECHNOLOGY

Department of Mechanical En ineerin

C,UTC5ES
INTRODUCTION
The clutch is an intermediate mechanism, which is placed in between the fl!wheel and the gearbo for the purpose of allowing or discontinuing the power flow from engine to the transmission s!stem. "n normal conditions, the clutch remains in engaged position and allows flow of power from engine to the gearbo . 'owever, when the flow of power is to be interrupted for an! reason, it is disengaged and hence the power flow discontinues temporaril!. The disengagement of the clutch is required when the gear position is to be changed, or when the vehicle needs to kept in neutral position #i.e. engine running but the vehicle stationar!&. The control for disengaging the clutch is imparted b! a foot-pedal in 8-wheelers and b! a hand-lever in %-wheeler through control linkages.
1%

RE>UIREMENT O- A GOOD C,UTC5

While discharging its functions, the following requirements are desirable in a clutch. Grad'al E &a&eme t* - 1 clutch should take on the power drive smoothl! without undesired 4erks whenever it is re-engaged. This helps in increased driving comfort, less effort on the driver, and prolonged life of the clutch. E""ortless Operat$o * - The operation of clutch disengagement should be easier so that the driver does not feel tired. 1 hard #uneas!& clutch operation will cause erratic running. S$?e* - The si;e of a clutch should be such that it occupies minimum space. 1lthough the si;e is governed b! the designed value of frictional surface area of the clutch facing, even through this area can be accommodated efficientl! b! providing two or more clutch plates, such as in multiplate clutch. SING,E +A,TE -RICTION C,UTC5 2uch clutches use a single -late having friction facing on both the sides. .ushioning effect in them is obtained b! installing springs of different designs. ,epending upon the t!pes off springs the! use, the single plate clutches ma! be classified into following two t!pes7 'elical spring t!pe single plate clutch ,iaphragm spring t!pe single plate clutch.