S11 Brake System

S11 Brake System Introduction

Right brake lamp
ABS warning lamp
Left brake lamp
ABS master
ABS control module cylinder
Vacuum booster
Brake lamp switch

Left rear wheel speed sensor

ABS electronic
control module
ABS hydraulic
control unit

Brake switch

ABS wheel speed sensor

Composition of Ordinary Brake System

Parking brake control lever
Brake booster

Brake pedal
Proportioning valve

Brake master cylinder

Parking brake cable
Disc brake

Disc brake

Brake Booster

1. Usually, the brake booster can increase the braking force two to
four times.
2. Brake booster's performance varies with the actual atmospheric
pressure, vacuum degree and its active area. The bigger its active
area is, the stronger its boosting force is.

Brake Booster not in Braking

Vacuum

Constant-pressure chamber
- chamber B

Variable-pressure chamber
- chamber A

Cylinder sleeve
Relationship
between Fb + Fs
and Fa

To brake
wheel
cylinder
Valve
Brake master cylinder
Spring

Piston

Fb=Fa
Fs pushes the
piston to the right.

Brake Booster in Braking

Vacuum
Relationship
between Fb + Fs
and Fa
Fb + Fs < Fa
Fa pushes the
piston to the right
Valve
Hydraulic
pressure
Brake master cylinder

Air

Brake Booster Structure

Constant-pressure chamber
Diaphragm
Vacuum

Power piston

Check valve

Reaction disc

Valve body
Air
Valve control
lever
Brake master
cylinder

Air filter
Push rod

Booster housing
sealing member

Booster
housing
Diaphragm spring

Booster housing
sealing member
Variable-pressure chamber

1. Brake Booster not in Braking

Piston

Vacuum valve (opened)

Passage A
Control valve

Opened vacuum
valve & control
valve
A is connected
with B

Constant
pressure
chamber

Control valve spring

Valve body

Air valve
(closed)

Valve control lever

Passage B

Air filter element

Air valve return spring
Variable pressure chamber

When not in braking

2. Brake Booster in Braking

Piston
Control valve

Closed vacuum
valve & control
valve
A is not connected
with B
B is connected
with C

Constant
pressure
chamber
Air
Booster
push rod
Air valve
(opened)
Air filter element

Reaction disc
Passage B
Variable pressure chamber

When not in braking

3. Brake Booster in the Retained Position

Piston

Vacuum valve (closed)

Control valve

Closed vacuum
valve & control
valve
A is not connected
with B or C

Control valve spring

Constant
pressure
chamber

Stop
Air valve
(closed)

Valve control lever

Variable pressure chamber

When in the retained position (brake force)

4. Brake Booster in the Released Position

Piston
Passage A

Vacuum valve (opened)

Control valve

Opened vacuum
valve & control
valve
A is connected
with B and C

Air valve
(closed)
Valve control lever
Passage B

Air valve return spring

Variable pressure chamber

When in the released position (brake)

Purpose of Brake Master Cylinder

Brake master cylinder

Front/rear brakes

Brake pedal
Drum brake

Brake Master Cylinder Structure

Reservoir
Liquid lever sensor
RF/LR brake cylinders
RR/LF brake cylinders

Rubber piston cup

Second piston

Primary piston

Tandem brake master cylinder

1. Brake Master Cylinder not in Braking

Compensating port
Secondary return spring

Primary return spring

Inlet port

Piston cup is
located between
inlet port and
compensating
port
Primary piston cup
Stopper bolt
Secondary piston cup

When not in braking

2. Brake Master Cylinder in Braking

Compensating port
Inlet port

Piston cup

Both inlet port

and
compensating
port are closed
with the oil
pressure
increased
Secondary piston

Primary piston

When in braking

3. Brake Master Cylinder when Released (1)

Orifice

The orifice in the

piston is opened
and the brake
fluid flows back

Piston cup

to the piston-cup
side

When brake pedal is released (1)

Inlet port

4. Brake Master Cylinder when Released (2)

Compensating port

The
compensating
port allows
surplus fluid to
flow back to
the reservoir

When brake pedal is released (2)

5. Rear-end Leakage

In contact

Secondary piston

Primary piston

Rear-end leakage

6. Front-end Leakage
Piston contacts cylinder wall

Secondary piston

Front-end leakage

Primary piston

Proportioning Valve

Proportioning valve

Importance of Proportioning Valve

1. Loads on front and rear wheels are different
The front wheels of the vehicle bear more of the vehicle weight than its rear wheels. In
addition, its center of gravity will move forward when in braking, resulting in increased
load on front wheels and reduced load on rear wheels. The bigger the braking force is, the
more obvious this change is.

2. The risk of too early locking of rear wheels

When in braking, the load on rear wheels is light, and this causes them to be easily locked
too early, thereby resulting in lateral sway of the vehicle body's rear half.

3. Measure to prevent the above problem from happening

Proportioning valve: to automatically reduce hydraulic pressures delivered from brake
master cylinder to rear-wheel brake wheel cylinders. Pressure reduction is in proportion to
the stepping force on the brake pedal.

Pressure in rear brake wheel cylinder

Requirements on Rear-wheel Brake Force

Bifurcation point

Pressure in brake master cylinder

Proportioning Valve

RF wheel
LF wheel

RR wheel

RF wheel

Working Principle of Proportioning Valve

When the Pressure is zero

Proportioning
valve

Piston

Control valve
Spring

Rear

Working Principle of Proportioning Valve

Chamber A side

Piston

Small area

Large area

Chamber B side

When the Pressure is Low

Fa+Fs=Fb

Piston

Spring

Working Principle of Proportioning Valve

When the Pressure is high

Fa+Fs<Fb
When the pressure is
higher than some point,
the difference between
chambers A and B will
overcome the spring's
elastic force to make
the piston move until
the port C is closed.

1.When the Braking Pressure is Low

From brake master cylinder

Cylinder cup

Piston

Spring

To rear-wheel brake wheel cylinders

2.When the Braking Pressure is High

In contact

Piston

3.When the Brake Pedal is Released

Cylinder cup

When the brake

pedal is released,
the pressure drop
in the left chamber
will cause the
piston to move to
the left.

Piston

Spring

Disc Brake
Fixed caliper

Hydraulic pressure

Motion

Floating
caliper

Brake disc

Piston
Steering
knuckle

Brake lining
Rotor disc

Friction disc thickness sensor

Floating-caliper type

Front-wheel Brake

Rear-wheel Brake