Automotive Braking Systems

The Basic Concepts

 Kinetic energy = heat
 F = ma
 Newton is always right!
 Do the calculations first
 When all else fails see rule 3.
Energy Conversion

The brake system converts the kinetic

energy of vehicle motion into heat
Overview
 Brakes convert kinetic energy into heat by
creating friction
 System must have very high reliability
 Types of brakes:
- Disk
- Drum
Basic System Model
System Basics
 Hydraulic actuation
allows multiplication of
pedal force.
 In this system, a 10lb
force on the pedal
produces 360 lbs of
force at the friction
surface.
Braking Dynamics
 Dynamic weight transfer
caused by braking shifts
the weight balance
towards the front of the
car
 Dynamic weight for the
front and rear can be
found using Newton’s
mgd ma h
Law W 
f  x
cd cd

mgc max h
W r 
cd cd


Braking Dynamics
 Because the maximum braking force is
equal to the coefficient of friction times the
normal force, the front wheels will have an
increased capacity to provide braking force
 Also, the system must be designed to
distribute the application of force between
front and rear
Typical Diagonal Split System

Right front Left front

left rear right rear
Disk Brakes
 Caliper squeezes pads to
create force on the
surfaces of the rotor.
 Used in most automotive
applications.
 Benefits:
 Simple design
 Self adjusting
 Rotor venting allows faster
heat dissipation
2 Types of disk brake calipers
 Floating caliper
 Piston pushes pad
against the inner rotor
surface, reaction force
causes the caliper to
slide and contact the
outer surface
2 Types of disk brake calipers
 Fixed caliper has at
least one piston on
each side
 Each piston drives it’s
corresponding pad
into contact with the
rotor
Drum Brakes
 Expanding shoes create
force on the inner surface
of the drum
 Used on the rear of some
trucks and SUV’s
 Self-energizing design
requires less activation
force
 Require periodic
adjustment
Tandem Master Cylinder
Master Cylinder
 Provides a reservoir for brake fluid and contains the driving
pistons in the hydraulic circuit
 2 Types
Front - Rear split
-One piston for front brakes and one for rear
-If a leak occurs you could lose front brakes
Diagonally split
-One piston drives one front wheel and one rear wheel
-Diagonal layout allows you to maintain directional control if a
leak occurs
Diagonally Split System
Power Assistance
 Power booster reduces pedal
force required to stop vehicle
 Engine vacuum is used to
actuate a large diaphragm
 When the pedal is depressed,
vacuum is applied to only
one side of the diaphragm
and force is applied to the
master cylinder push rod
 Booster stores sufficient
vacuum for several brake
applications if the engine
fails.
Power Booster in closed position
Anti-Lock Brakes
 A locked (sliding) wheel offers less braking
force than a decelerating rolling wheel
 The locked wheel also produces little lateral
force, preventing steering control
 Anti-Lock systems (ABS) monitor wheel
lock-up and modulate brake pressure to
provide controlled braking under most
circumstances
Anti-Lock Brakes
 System can have 2, 3 or 4 channels
 Trucks typically use 3 channel with only one
sensor for the rear axle
 Most modern cars use 4 channel system
 Wheel speed sensors monitor each wheel speed
 ABS controller and high-pressure pump increase
or reduce pressure to wheels in order to maintain
consistent wheel speeds
Typical 3 channel system
Valves and Switches
Pressure Differential Switch
-Senses a pressure differential between the two master
cylinder stages and warns the driver that the system
has a leak
Metering Valve
-Prevents the front brakes from engaging until the rear
drums have enough pressure to overcome the shoe
return springs (Front disk-Rear drum systems only)
Proportioning Valve
-Reduces the pressure to the rear wheels to balance the
effect of weight transfer to the front wheels.