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HYDRAULIC BRAKES
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CONTENT
Introduction
Purpose
Condition of Operation
Principle
Hydraulic Brake Specification
Line Diagram
Component Description
Case Studies


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INTRODUCTION
The hydraulic brake is an arrangement of braking
mechanism which uses brake fluid, to transfer pressure from
the controlling unit (pump) to the actual brake mechanism
(brake calliper assembly)

Brake calliper assembly usually consisting of one or two
hollow aluminium or chrome-plated steel pistons (called
calliper pistons), a set of thermally conductive brake pads and
a rotor (also called a brake disc).



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PRINCIPLE
In hydraulic system we get
the large output by applying
smaller effort/input & large
amount of energy is to be
transformed as shown in the
sketch
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PURPOSE
Hydraulic braking system is used for smoothly bringing the
rotor to a stand still condition for application of mechanical
rotor lock.
Operating the hydraulic unit generates pressure (130bar) at
the pistons and hence the brake pads hold the brake disc
rigidly for stopping the rotor.
Solenoid valve and pressure switches are used for
maintaining the pressure during the braking period.

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Hydraulic Brake Specification
Operation Pressure Max.160 bar
Drive Motor 230/400V, 3-phase, 50Hz, power about 370W
Electric-stop valve 230V AC10% dc coil and rectifier in the connection plug, open basic
setting (with no current)
Electric Connection Terminal strip, Motor contactor, Switch for opening/closure of the brake
as well as electr. Safeguard are included at the turbine side.
Pressure Limitation Set work side to 160bar and sealed
Pressure Switch Adjustable manually; opens if set pressure is reached
Protection Type IP55
Corrosion protection Seetight version, cover varnishing RAL5015 (blue)
Surround temperature -20...+60C
Oil filter In filling-support 10m, circular filter
Kind of Oil UKADOL 46 NG, PEG (Polyethylene Glykol)
Pressure Connection G
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LINE DIAGRAM

1 - Motor ( 3 Phase induction 0.37 KW ,
0.5 KW, 0.75 KW )
2 - Positive displacement gear pump

3 - Pressure relief valve
4 - NRV type check valve
5 ,6 - Solenoid valve ( electro-magnetic
operation )
7 - Oil level indicator
8 - Micron wire mesh type filter
9 - Pressure switch
10 - oil reservoir ( 2.5 L capacity )
11 - brake calliper left & right

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POSITIVE DISPLACEMENT PUMP
A positive displacement gear pump makes a fluid move by
trapping a fixed amount and forcing the trapped volume into
the discharge line. Positive displacement pumps are
constantly flow machines.
Positive Displacement Pumps has an expanding cavity on the
suction side and a decreasing cavity on the discharge side.
Liquid flows into the pumps as the cavity on the suction side
expands and the liquid flows out of the discharge as the
cavity collapses.
A Positive Displacement Pump must not be operated against a
closed valve on the discharge side of the pump because it has
no shut-off head.

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POSITIVE DISPLACEMENT PUMP
A relief or safety valve on the
discharge side of the Positive
Displacement Pump is therefore absolute
necessary.
It consists of two meshed gears that
rotate in a closely fitted casing. The tooth
spaces trap fluid and force it around the
outer periphery. The fluid does not travel
back on the meshed part, because the
teeth mesh closely in the centre.
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RELIEF VALVE
The relief valve (RV) is a type of valve used to
control or limit the pressure in a system or vessel
which can build up by a process upset, instrument
or equipment failure, or fire.
The pressure is relieved by allowing the pressurised
fluid to flow from an auxiliary passage out of the
system. The relief valve is designed or set to open
at a predetermined set pressure to protect pressure
vessels and other equipment from being subjected
to pressures that exceed their design limits. When
the set pressure is exceeded, the relief valve
becomes the "path of least resistance" as the valve
is forced open and a portion of the fluid is diverted
through the auxiliary route.

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NON-RETURN VALVE
A check valve, clack valve, non-return valve
or one-way valve is a mechanical device, a
valve, which normally allows fluid (liquid or
gas) to flow through it in only one direction.
Check valves are two-port valves, meaning
they have two openings in the body, one for
fluid to enter and the other for fluid to leave.
A ball check valve is a check valve in which
the closing member, the movable part to
block the flow, is a spherical ball. In some ball
check valves, the ball is spring-loaded to help
keep it shut.
A ball check valve in the
open position to allow
forward flow and closed
position to block reverse
flow.

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SOLENOID VALVE & PRESSURE SWITCH
A SOLENOID VALVE is an electromechanically operated
valve.
A solenoid valve has two main parts: the solenoid and the
valve. The solenoid converts electrical energy into mechanical
energy which, in turn, opens or closes the valve mechanically.
A Solenoid valve also has a rectifier which converts AC into
DC as our valve operated at 220V DC.

A PRESSURE SWITCH is a form of switch that closes an
electrical contact when a certain set pressure has been
reached on its input.

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Hydraulic Brake Calliper
The main components in Brake Calliper are-
Return Spring
Attachment Screw
Metal Plate
Brake Disc
Brake Calliper (Pistons, O-ring)
Brake Linings/Pads
NRV (Bleed nipple)


Attachment
Screw
Return
Spring
Brake
Calliper
Brake
Disc
Brake pads/
Linings
Metal
Plate
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Check and Renewal of Brake Linings
Check brake linings
Measure the distance between brake disc and
back plate of the brake lining to check the
thickness of the lining concerned. If below the
minimum lining thickness of 3 mm, renew both
brake linings of the calliper as a matter of course.
Renew brake lining
WARNING-Prior to the renewal of brake linings, the
rotor has to be locked and the main switch shut
off!
First remove the two return springs from the
calliper.
Dismount the top and bottom metal plate. This
involves unscrewing the corresponding
attachment screws (M 16) and taking out the
metal plate.
Fit new brake lining, mount metal plate and
replace both return springs.


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Bleed Brake Mechanism
Every time a repair involving the opening of the brake system is carried out on the stop
brake, air may get in to the brake mechanism and must be bled out. It is generally
quite sufficient to bleed the calliper in question.

Remove the protective cap from the air bleed nipple and fit a clear bleeder tube to
the nipple concerned. Hold the end of the tube in a suitable container.
Press the stop brake until the hydraulic fluid flows through the tube free of bubbles.

Warning: During bleeding make absolutely sure that the level of the hydraulic fluid
container is sufficient, or otherwise air will be sucked in through the header tank.
Only refill with fresh brake fluid of the Renolin PG 46 brand.

Once bleeding is completed, remove the bleeder tube and replace the protective
cap.

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Case Study-Hydraulic Oil Leakage From
Brake Calliper
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Case Study- Continue...
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Case Study- Continue...
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CONDITION OF OPERATION-
The Hydraulic motor brake will operate in following conditions
only-
1. Emergency push button actuate from Control Cabinet
2. Emergency push button actuate from Nacelle Control Cabinet
3. Rotor brake switch manual actuated from NCC
4. Rotor locking switch release

NOTE- Any of the above condition creates emergency shutdown
of machine.


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CONTINUE...
As soon as any of those conditions occur, immediately
contactor=015-K06 will operate and hydraulic motor will get
the 3 phase supply through main contacts of =015-K06
contactor and at the same time NC contact of =015-K06
contactor will clear the MSC which will immediately start
pitching out all the three blade to approx 90 and
simultaneously pressure starts building up in hydraulic unit
and brake pad will hold the brake disc.
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Case Study-1
NNormal Working of Brake

As shown in above dig . the oil flow path
will be as indicated by blue arrows for
normal working . As the motor is in
continuous operation the discharged oil
emerges in the brake calliper & start
building pressure. Once the pressure
reaches to130 bar , pressure switch actuate
& cut off the supply to electric motor . The
pressure built up in brake calliper remain
constants till the solenoid valve is in close
condition (see the encircle view ) .

In case of grid failure there will be no
supply to solenoid valve & it will open
resulting pressure falls to atmospheric value
(brake open) .

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Case Study-2
Motor continue in operation but no pressure built up .

Here the pressure will built up only when the oil emerges inside the brake calliper,
which in turn results in to the forward movement of piston inside brake cylinder &
exert force over brake disc .

We all know that pressure = force / area

Here area is constant so pressure built up is directly proportional to force exerted
over brake disc . So here the constraints is area should be constant. The area will
be constant only when the oil flow path is close i.e. no oil leakage.

So there should be no oil leakage through any hose pipe or brake calliper
or joint fitting .

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Case Study-3
After cross checking all above said
points, still no pressure built up

-For building up the pressure another
criteria is solenoid valve should be in
close condition , but in above shown
dig, it is in open condition & the oil
discharged by pump directly delivered to
reservoir , instead of going to brake
calliper .
-Check whether the rectifier is working
properly or not?
-Is the internal resistance of the valve
coil normal? Typically 1700 ohm-2700
ohm
So here check the operation of
solenoid valve & its electrical
connection .

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Case Study-4
Solenoid valve ok , no oil leakage even then no pressure built up.

Check the direction of rotation of motor (as indicated on its fan cover by direction
arrow )
Check the sufficient oil level in reservoir should be up to 70 % .
Electric motor operation

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Case Study-5
Brake applied ( pressure built up ) but motor keeps in continues operation .

Here the pressure switch does not sense the pressure built up to trip the motor
supply. Hence pressure switch is faulty .
Check the pressure switch setting (should be up to 130 bar only ) .

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Case Study-6
Brake applied ( pressure built up ) motor also stop. But sudden ON/OFF
after some interval of time .

Check the entire pipe line (hose pipe) , fittings , brake calliper , for oil leakage .
Air bubble inside the hose pipe / oil / reservoir here carry out the air bleeding.

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Case Study-7
On activating emergency off in the NCC or emergency stop in the CC, the
hydraulic brake does not operate

Is MCB=015 Q01 in the NCC switched on?
Does the pressure switch have low impedance? 0 ohm between =15X01.42 and
=15K01.Al
Is 230V AC supplied to terminal =015X01.36 and =015X01.37B?

NOTE:- After inspecting / troubleshooting all above said points even then
no problem is solved

Hydraulic unit (pump) is faulty & has to be replace

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Case Study-Hydraulic Brake Oil
Decolouration
Observation
It has been observed, during the maintenance found
the entire quantity of Hydraulic oil is in black colour
and low viscosity, Even on applying the brake by
switching on the brake, no pressure was built up to
hold the rotor disc, and at the same observed that the
pressure switch was also found faulty.

Action need to be taken
Replace the entire oil and the pressure switch with the
new one.
It has been observed that on replacing the pressure
switch, the brake was not functioning effectively, but
on replacing the oil also in place of black coloured oil
the brake was able to function effectively to hold the
rotor disc rigidly.
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ANY QUERIES?
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THANK YOU