Seminar Report 2018 - 19 Retarder Brake System

ACKNOWLEDGEMENT

I feel very fortunate to have the support and encouragement of

number of key individual of department of Mechanical Engineering of this
institution.

I would like to express my deepest gratitude to Mr. RAJEEVAN.T

(Head of Department, Mechanical Engineering) for the help rendered by
him to prepare and present this seminar in proper way. Moreover I am
very much indebted to Mr. VINODAN.M (Lecture, Mechanical Engineering),
Mr. RAMESAN.K (Lecture, Mechanical Engineering), Mr. SAMJYOTH
KUMAR.T.V (Lecture, Mechanical Engineering), SARATH LAL.M (Lecture,
Mechanical Engineering) for their advice.

I am also indebted to all my friends and classmates who have given

valuable suggestions and encouragement.

AKSHAY.P

Dept. of Mechanical Engg. 1 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

CONTENTS
1. ABSTRACT 3
2. INTRODUCTION 4
3. BRAKE 5
4. RETARDER 6
5. HYDRAULIC RETARDER 8
6. ELECTRICAL RETARDER 15
7. RETARDER ACCESSORIES 17
8. ADVANTAGES OF RETARDER 20
9. ENGINE COMPRESSION RETARDER 21
10. CONCLUSION 23
11. REFERENCES 24

Dept. of Mechanical Engg. 2 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

ABSTRACT
In case of Heavy vehicles insufficient braking is the huge problem. To provide
efficient braking, a secondary brake or brake assistance is provided. This brake
assistance is known as Retarder.

A Retarder is a device used to augment or replace some function of primary

brake or service brake. Retarders serve to slow vehicles, or maintain a steady speed on
declines, and help to prevent the vehicle ‘running away’ by accelerating down the
decline. They are not usually capable of bringing vehicles to a standstill, as their
effectiveness diminishes as vehicle speed lowers. They are usually used as an additional
‘assistance’ to slow the vehicle, the final braking done by a conventional friction braking
system. As the friction brake will be used less, particularly at higher speeds, their
service life will increase.
According to the working Retarders are classified as two, they are Hydraulic
Retarder and Electric Retarder.

Dept. of Mechanical Engg. 3 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

INTRODUCTION
Retarders, otherwise known as auxiliary braking systems, are essential devices
for the modern heavy emergency response vehicle (ERV). They have been proven to be
so important that NFPA 1901, Standard for Automotive Fire Apparatus, requires them
for any rig with a 36,000-pound gross vehicle weight rating (GVWR) and greater.

Retarders are not restricted to road motor vehicles, but may also be used in
railway systems. The British prototype Advanced Passenger Train (APT) used hydraulic
retarders to allow the high-speed train to stop in the same distance as standard lower
Speed trains, as a pure friction-based system was not viable. Retarders serve to slow
vehicles, or maintain a steady speed on declines, and help prevent the vehicle ‘running
away’ by accelerating down the decline. They are not usually capable of bringing
vehicles to a standstill, as their effectiveness diminishes as vehicle speed lowers. They
are usually used as an additional ‘assistance’ to slow vehicles, with the final braking
done by a conventional friction braking system. As the friction brake will be used less,
particularly at higher speeds, their service life
is increased. Retarders serve to slow vehicles, or maintain a steady speed on declines,
and help prevent the vehicle ‘running away’ by accelerating down the decline. They are
not usually capable of bringing vehicles to a standstill, as their effectiveness diminishes
as vehicle speed lowers. They are usually used as an additional ‘assistance’ to slow
vehicles, with the final braking done by a conventional friction braking system. As the
friction brake will be used less, particularly at higher speeds, their service life is
increased.

Dept. of Mechanical Engg. 4 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

BRAKE
Brake is a mechanical device that inhibits motion by absorbing energy from the
moving system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to
prevent its motion, most often accomplished by means of friction. Most brakes
commonly use friction between two surfaces pressed together to convert the kinetic
energy of the moving object into heat, though other methods of energy conversion may
be employed.
Friction brakes on automobiles store braking heat in the drum brake or disc
brake while braking then conduct it to the air gradually. When traveling downhill some

vehicles can use their engines to brake.

Dept. of Mechanical Engg. 5 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

RETARDER
A Retarder is a device used to augment or replace some function of primary
brake or service brake. Retarders of all types have been developed to remedy the
inadequacies of conventional brakes, of the natural braking power of the engine and of
the various resistances which normally oppose the movement of the vehicle. The
retarders are always used for heavy vehicles. Different types are presented. They cannot
be assimilated to a brake. It should be possible to stabilize the speed, the decelerations
obtained should be relatively small, but of long duration. The retarder should be
independent of the normal braking system, it should operate in conjunction with the
braked wheel and it should be possible to use even when de-clutching.

Retarders are not restricted to road motor vehicles, but may also used in Railway
systems. They are not usually capable of bringing vehicles to standstill, as their
effectiveness diminishes as vehicle speed lowers. They are usually used as an additional
‘assistance’ to slow vehicles, with the final braking done by a conventional friction
braking system. As the friction brake will be used less, particularly at higher speeds,
their service life is increased.

Types of Retarders are

 Hydrodynamic Retarders
Physical concept:

Torque converter

 Electrical Retarders
Physical concept:

Foucault current

Dept. of Mechanical Engg. 6 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

Hydraulic Retarder

Electric Retarder

Dept. of Mechanical Engg. 7 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

HYDRAULIC RETARDER
Hydraulic retarders use the viscous drag forces between dynamic and static
vanes in a fluid-filled chamber to achieve retardation. There are several different types
which can use standard transmission fluid (gear oil), a separate oil supply, or water.
A simple retarder uses vanes attached to a transmission driveshaft between the
clutch and road wheels. They can also be driven separately via gears off a driveshaft.
The vanes are enclosed in a static chamber with small clearances to the chamber’s walls
(which will also be vaned), as in an automatic transmission. When retardation is
required, fluid (oil or water) is pumped into the chamber, and the viscous drag induced
will slow the vehicle. The working fluid will heat, and is usually circulated through a
cooling system. The degree of retardation can be varied by adjusting the fill level of the
chamber. Hydraulic retarders are extremely quiet, often inaudible over the sound of a
running engine, and are especially quiet in operation compared to engine brakes.
Hydraulic retarders are mainly manufactured by Voith multinational corporation
in Germany.

Hydraulic Retarder Function

Dept. of Mechanical Engg. 8 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

Working of Hydraulic Retarder

 Two blade wheels in the hydrodynamic Retarder face each other.

 The rotor is connected to the propeller shaft of the vehicle via the Retarder input
shaft, the stator to the stationary housing of the Retarder.

 In braking mode, there is oil between the blade wheels. The oil is accelerated by
the rotor and decelerated in the stator.

 This also decelerates the rotor, thus braking the vehicle.

 The heat generated by the brakes is quickly and effectively dissipated via the
vehicle cooling system.

Hydraulic Retarder

Dept. of Mechanical Engg. 9 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

Heat Transfer in Retarder

1 Thermostat
2 Radiator
3 Fan
4 Heat exchanger
5 Temperature sensor Retarder oil
6 Temperature sensor water

The hydraulic retarder is the most stabilized auxiliary braking system of heavy-
duty vehicles. When the hydraulic retarder is working during auxiliary braking, all of
the braking energy is transferred into the thermal energy of the transmission medium
of the working wheel. Theoretically, the residual heat-sinking capability of the engine
could be used to cool down the transmission medium of the hydraulic retarder, in order
to ensure the proper functioning of the hydraulic retarder. Never the less, the hydraulic
retarder is always placed at the tailing head of the gearbox, far from the engine, long
cooling circuits, which increases the risky leakage risk of the transmission medium.
What's more, the development trend of heavy load and high speed vehicle directs the
significant increase in the thermal load of the hydraulic retarder, which even higher
than the engine power. Conventional engine cooling system could not meet the demand
of the hydraulic retarder heat rejection within the same installation space. In this

Dept. of Mechanical Engg. 10 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

research, independent two-phase evaporator was adopted to strengthen the coolant

heat absorption capacity from the transmission medium at the oil outlet of the retarder
and increase the thermo stability of heavy-duty vehicles during high working load
operating conditions by means of the vacuum flow boiling heat transfer. As a result, the
reliability during driving could be guaranteed. The basic idea of this study is
determining the thermal load characteristics and the transmission medium circular flow
by a heavy-duty vehicle operating conditions. Then, the geometric dimensions of the
evaporator are confirmed according to the optimal temperature range of the
transmission medium. Finally, analysis is conducted for the influence of the coolant flow
variation on evaporation system heat transfer power under different operating
conditions. The mathematical model of the coolant vapor fraction, the flow and the oil
temperature is obtained. The result shows that under different operating conditions, the
designed two-phase evaporation system could stabilize the transmission fluid in the
best operating temperature ranges. On the premise of the system's stability, the cooling
medium's vapor fraction variation could dynamically respond to the change of vehicle
driving conditions. Moreover, this mediates the variation of the recovery flow in the
cooling medium and reduces the volume flow significantly. Above all, this improves the
controllability of the two-phase evaporation system and decreases energy consumption
of this system in the meantime.

Dept. of Mechanical Engg. 11 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

Hydraulic Retarder System Main Components

1 Display

2 Retarder sequence switch

3 Cruise control operation

4 RECU (Retarder ECU)

5 Retarder

Dept. of Mechanical Engg. 12 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

Operation Of Retarder

Steps A:

When actuating the brake pedal, the Retarder

will be activated automatically (Retarder blending).

- The function “constant speed”

can be activated via the tip switch.

Steps 1-3:

- Manual Retarder braking steps

Step B:

- Step B = max. braking force.

- Stage B is only available in vehicles with automatized gearbox (I-Shift, Geartronic).

The "braking programme" is activated by actuating stage B. The Retarder sequence

Switch returns from stage B to stage 3. On activation of the braking programme, the
gearbox selects the speed where the additional brake is effective best.

The braking programme can be deactivated by shifting down from stage 3 or by

applying the accelerator pedal.

Dept. of Mechanical Engg. 13 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

Offline & Inline Retarder

Offline Retarders (peak-period retarder) work with a translation. In other words,
the retarder speed is higher than the drive shaft. Offline retarders are very compact and
exhibit great braking force even at low speeds.

Offline Retarder

Inline retarders are installed directly onto the transmission or freely to the
driveline. They are connected to the vehicle universal joint shaft.

Inline Retarder

Dept. of Mechanical Engg. 14 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

ELECTRICAL RETARDER
The electric retarder uses electromagnetic induction to provide a retardation
force. An
Electric retardation unit can be placed on an axle, transmission, or driveline and
consists of a rotor attached to the axle, transmission, or driveline—and a stator securely
attached to the vehicle chassis. There are no contact surfaces between the rotor and
stator, and no working fluid. When retardation is required, the electrical windings in the
stator receive power from the vehicle battery, producing a magnetic field for the rotor
to move in. This induces eddy-currents in the rotor, which produces an opposing
magnetic field to the stator. The opposing magnetic fields slow the rotor, and hence the
axle, transmission or driveshaft to which it is attached. The rotor incorporates internal
vanes (like a ventilated brake disk) to provide its own air cooling, so no load is placed
on the vehicle’s engine cooling system. The operation of the system is extremely quiet. A
hybrid vehicle drive train uses electrical retardation to assist the mechanical brakes,
while recycling the energy. The electric traction motor acts as a generator to charge the
battery. The power stored in the battery is available to help the vehicle accelerate.
The stator and the rotor are mounted coaxially, opposite to one another, and are
separated by a narrow gap, thereby avoiding any friction. The stator plays the role of
the inductor; it is made of pair of electromagnets, which generate electromagnetic fields
when electricity continuously flows through the stator coils, thereby producing eddy
currents in the mass of rotor.
Rotor act as induced current. Manufactured with a specially designed conducting
material, rotors are only subjected to eddy currents when passed through by magnetic
fields generated by the stator while being brought into rotation by the transmission
shaft.
By definition, eddy currents originate from conducting metallic masses when the
latter are placed in variable magnetic fields. In the case of induction braking systems,
the variability of the magnetic fields to which rotors are subjected is a result of the
rotation of the rotors. Eddy currents, also known as swirling currents, wrap around the
magnetic flow lines.
The generation of eddy currents in the mass of the rotor leads to the appearance
of Laplace forces that counteract with the rotation of the rotor. The braking torque that

Dept. of Mechanical Engg. 15 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

is thus generated and applied to the transmission shaft slows the vehicle. The eddy
currents produce a gradual rise in rotor temperature and the heat is then released into
the atmosphere through ventilation systems. With induction braking systems, it is thus
possible to effectively slow down a rotating shaft without friction and therefore without
wear.
Electrical Retarders are mainly manufactured by a multinational company
known as TELMA.

Electric Retarder

Dept. of Mechanical Engg. 16 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

RETARDER ACCESSORIES
IRCS
The iRCS (integrated Retarder Control System) is an electronic box designed by Telma
that integrates both the control and power functions into a single module.

The innovative electronic design of the iRCS's power function significantly reduces the
retarder's energy consumption and preserves its electric circuits.

The modernity of design and flexibility of the control part of the iRCS, as well as its
compatibility with CANBUS networks, allow for seamless integration of Telma retarders
in all vehicles equipped with electronic braking systems (ABS, ESP, EBS, speed control,
automatic transmission control...).

CAN adaptor
The CAN adaptor is an electronic box that interfaces with the CAN bus of the vehicle
according to IS0 11898. Among other things, it allows to multiplex the analog signals of
a hand lever, a pressure switch or even to pilot a light on the dashboard.

The CAN Adaptor ensures seamless integration of Telma retarders into all vehicles
equipped with any electronic braking system such as ABS or ESP®.

The CAN SAE J1939 protocol is available as standard. On special request, it is also
possible to develop other CAN protocols.The CAN Adaptor is specifically programmed
for each vehicle configuration prior to delivery to customers. It can also be used for
retrofit or industrial applications.

Dept. of Mechanical Engg. 17 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

CB
A CB (Contactor Box) ensures power supply switching through the retarder's various
power stages. The CB's design makes it a simple, effective and proven solution

LSC
The LSC (Low-Speed Cutoff) prevents the retarder from being unnecessarily fed when
the vehicle is stopped, thus preserving electric systems of the vehicle as well as of the
retarder.

Dept. of Mechanical Engg. 18 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

Hand Lever
A Lever allows the driver to directly control the retarder. It also allows activation of the
speed control function on downhill slopes. The various models of Telma Levers allow
for smooth integration into any dashboard configuration.

Pressure Switch
Integrated into the vehicle's pneumatic air brakes system, the pressure switch controls
the automatic and progressive activation of the retarder through the brake pedal.

Each pressure switch is specifically calibrated to perfectly adjust to the configuration of

the vehicle in which it is installed.

Dept. of Mechanical Engg. 19 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

ADVANTAGES OF RETARDER
 Reduce the braking distance.

 Smooth and quiet braking.

 Safer driving

 Reduce the service brake wear.

 Provide good control of vehicle on descending the hills.

 Reduce driver effort.

 Constant speed for downhill

 No interruption of braking force

COMPARISON
 Electrical

− Cheaper

− Easy to install

− Ratio decreases 10%-20% by heating

 Hydrodynamic

− Lighter

− Cooling system quicker

− Slower at the beginning

− More used

Dept. of Mechanical Engg. 20 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

ENGINE COMPRESSION RETARDER

The engine compression retarder uses the engine’s compression stroke to absorb
energy from the vehicle’s motion. Normally the piston compresses the cylinder air for
the next power stroke, and this compression of the cylinder air takes energy. That energy
is normally provided by another cylinder which is in its power stroke. The engine
compression retarder uses up vehicle motion energy during the compression stroke of
each piston because the other cylinders are not producing power during their power
stroke time interval. No (or insignificant) engine power is generated, because the throttle
must be at the idle position for the retarder to operate. During the retarder mode of
operation, when the piston approaches the top of the compression stroke, the retarder
system opens the exhaust valves for that piston, which vents the energy which was
absorbed from the vehicle’s motion. The retarder works by absorbing energy during the
compression stroke, and throwing away this energy through the exhaust valves as the
piston completes its compression stroke. The most popular engine compression retarder
is the Jake Brake. This retarder system is manufactured by the Jacobs Manufacturing
Company, and their product is available for Caterpillar, Cummins, Detroit Diesel, and
Mack engines, just to name a few. Refer to the diagram above. The electric signal
activates the solenoid valve. The active solenoid valve applies engine oil pressure to the
control valve. The engine oil pressure force moves the ported piston of the control valve
up until the piston port aligns with the high pressure oil passage to the slave piston. The
check ball in the control valve allows the engine oil pressure to fill the slave piston and
the master piston voids via the high pressure oil passage. As the cylinder completes its
compression stroke, the cylinder injector pushrod rises and lifts the master piston. This
forces the oil out from above the master piston into the slave piston. Remember, the
check ball in the control valve prevents the high oil pressure from bleeding back into the
lower pressure engine oil supply. As the injector pushrod moves upwards, the slave
piston pushes down on the exhaust crosshead which opens the exhaust valves. This
releases the compressed air which provided the retarder braking action. When the
retarder is deactivated, the solenoid valve vents the engine oil pressure, which allows the
control valve spring to lower its ported piston, which seals off the high pressure oil
passage. To activate the Jake Brake, four requirements must be met, as shown in the
diagram above. The dash switch must be on, the clutch must be engaged, the throttle

Dept. of Mechanical Engg. 21 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

must be at idle, and the driver and/or cruise control must have activated the retarder.
Engine RPM must be kept high for the most retarder effect.

Dept. of Mechanical Engg. 22 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

CONCLUSION

There are many retarder options available today. The retarder will normally
make your rig a safer rig on the road and will extend your service brake life. There is a
lot of arguing amongst drivers about whether or not to use the jake brake during
shifting. During the shifting double clutch, the conditions are correct for jake brake
activation. If your gear shifts are close together, then the jake brake will fight you on the
engine RPM match while shifting. However, if the gear shift result in large RPM drops, or
if the shift is on a steep grade which results in rapid truck speed loss, then use of the
jake brake may very well help you to grab that next gear quicker. In this situation, the
truck speed is falling rapidly, and the engine RPMs are falling normally, so during the
double clutch, the engine RPMs are yanked lower by the jake brake. This might be
helpful to get that next gear in place during a slow and steep grade climb.

Dept. of Mechanical Engg. 23 Govt. Polytechnic College, Mattannur

Seminar Report 2018 - 19 Retarder Brake System

REFERENCES

− https://en.wikipedia.org/wiki/Retarder_(mechanical_engineering)
− ht tp: / /www. zafr. com/ truck t com/retarder.htm.
− JakeBrake.com (http://www.jakebrake.com/), “A Manufacturer of Engine
Brakes”.
− Voithturbo.com(http://www.voithturbo.com/retarder_e.htm), A Manufacturer
of Oil- and Water–Base Hydraulic Retarders.
− https://www.telma.com

Dept. of Mechanical Engg. 24 Govt. Polytechnic College, Mattannur