Chapter : 02

BRAKES
a) Functions of Brakes.
1)To stop or slow down the vehicle in the
shortest possible distances in emergencies.
2) It is used to control the vehicle while
descending along the hill.
3) To park the vehicle and held it in
stationary position without the presence of
driver.
Classification of Brakes:
The brakes are classified according to following
consideration: (Any 04)
1) With respect to purpose:
a) Primary brake or Service brake
b) Parking brake or Secondary brake
2) With respect to application:
a) Foot brake
b) Hand brake
3) With respect to number of wheels:
a) Two- wheeler brakes
b) Four-wheeler brakes
4) With respect to the method of braking contact:
a) Internal expanding brakes
b) External contracting brakes
5) With respect to the method of applying the
braking force:
a) Single acting brakes
b) Double acting brakes
6) With respect to construction:
a) Drum brake
b) Disc brake
7) With respect to method of actuation:
a) Mechanical brakes
b) Hydraulic brakes
c) Air brakes
d) Vacuum brakes
e) Electric brakes
8) With respect to speciality:
a) Engine exhaust gas operated brake
b) Pneumatic-hydro brake
With respect to construction:
a) Drum brake
b) Disc brake
With respect to method of actuation:
a) Mechanical brakes
b) Hydraulic brakes
c) Air brakes
d) Vacuum brakes
DRUM BRAKE :-
https://youtu.be/qA1NKgU9SD0
Working of drum brake:
When the drum is rotating, the upper tips of
the shoes are pushed apart by the expander force
and rub against the inside surface of the drum.
The force F is applied by means of some brake
actuating mechanism, which forces brake shoe
against the revolving drum thereby applying the
brakes.
An adjuster is also to compensate for wear of friction
linings with use.
One or two retractor springs are used which serve to
keep the brake show away from drum when the
brakes are not applied.
DISC BRAKE :-
Working of Disc Brake:
In a disc brake, the fluid from the
master cylinder is forced into a calliper. where
it presses against a piston. The piston in turn
crushes two brake pads against the disc that
is being attached to wheel, making it to stop
or slow down. Main advantage of disc brakes
is their resistance to wear as the discs remain cool
even after repeated brake applications.
 DISADVANTAGES OF DISC
BRAKE :-

1) Initial cost is more.

2) Disc Brakes are much more prone to noise.
3) Disc Brakes are not self-energizing; they need
higher clamping forces, which require a power
booster.
Difference between drum-brake and disc brake:
 Classification of brakes on
the basis of Braking systems
1) Mechanical Braking system.
2) Hydraulic Braking system.
3) Air Breaking system.
4) Hydraulic operated air braking system.
5) Vacuum assisted Breaking system.
Mechanical Braking system.
Working:-

The cam is shown linked by means of a camshaft and a

lever.
The lever is operated with a rod by means of a pedal.
When the pedal is pressed, the cam rotates by a slight
amount because the links and it pushes the ends of the brake
shoes outward.
These brake shoes press against the inner portion of the brake
drum.
This stops the brake drum. Thus the rotating wheel is fully
stopped.
Hydraulic Breaking System :-
Working:
When the brakes are not in operation, the system
is filled with brake fluid under light pressure. When
driver presses the brake pedal for applying the brake, the
piston in the master cylinder moves forward and
compresses the fluid in cylinder. It increases the pressure
of the fluid in master cylinder and in entire hydraulic
system. This pressure is instantly transferred to all four wheel
cylinders (in case of disc brake this pressure is transferred to
callipers). Thus the piston in wheel cylinders moves outward
which moves brake shoes against brake drum to apply brakes.
When driver releases the brake pedal, the master
cylinder piston returns to its original position due to return
spring and the pressure is dropped. It releases brake shoes
from brake drum to their: original position and brakes are
released.
 Air Brake
• air brake or, more formally, a compressed air
brake system, is a type of friction brake for
vehicles in which compressed air pressing on a
piston is used to apply the pressure to the
brake pad needed to stop the vehicle. Air
brakes are used in large heavy vehicles,
particularly those having multiple trailers that
must be linked into the brake system, such as
trucks, buses, trailers, and semi-trailers in
addition to their use in railroad trains.
 Air Brake Components and their Functions :
• 1. Air compressor
• It is used to build-up and maintain air pressure.
• The function of the air compressor is to build up and maintain air pressure
required to operate air brakes and air-powered accessories.
• A compressor is designed to pump air into a reservoir which results in
pressurized air.
• The compressor is driven by the vehicle’s engine, either by belts and
pulleys or shafts and gears.
• The compressor is in constant drive with the engine. Whenever the engine
is running, so is the compressor.

• 2) Reservoir
• The reservoir is used to store the compressed air. Reservoirs are pressure-
rated tanks, which hold a supply of compressed air until required for
braking or operating auxiliary air systems.
• They must store a sufficient volume of air to allow several brake
applications if the engine stops or the compressor fails.
• The number and size of the reservoirs on a vehicle will depend on the
number of brake chambers and their size, along with the parking brake
configuration.
• 3. Air Dryer
• An air dryer may be installed between the compressor and
the wet reservoir to help remove moisture from the
compressed air.
• It may be partially filled with a high moisture–absorbent
desiccant and an oil filter, or it may be hollow with baffles
designed to assist in separating the moisture from the air.

• 4. Safety Valve(Unloader valve)

• A safety valve protects reservoirs from becoming over-
pressurized and bursting if the governor malfunctioned and
did not place the compressor in the unloading stage.
• The valve consists of a spring-loaded ball that will allow air
to exhaust from the reservoir into the atmosphere. The
valve’s pressure setting is determined by the force of the
spring
• 5. Foot valve.

• Foot Valve is used to draw compressed air from reservoirs when it is

needed for braking.
• This foot-operated valve applies air to operate the brakes.
• The amount of air delivered to the brakes is regulated by the driver
according to the distance the treadle or brake pedal is depressed.
Releasing it exhausts air in the service brakes through its exhaust port.
• The distance the treadle of the foot valve is depressed by the driver
determines the air pressure that will be applied, but the maximum
application will not exceed the pressure in the reservoir. Releasing the
foot valve treadle releases the brakes.
• When the driver applies the brakes, depressing the treadle partway, the
foot valve will automatically maintain the application air pressure without
the driver having to adjust the pressure of his foot on the treadle.
• Releasing the treadle allows the application air to be released through the
exhaust ports into the atmosphere. Air treadles are spring-loaded,
producing a different “feel” from hydraulic brake applications.
 Brake chamber.
• Brake chamber is used to transfer the force of compressed air to
mechanical linkages.
• Service-brake chambers convert compressed air pressure energy
into mechanical force and movement, which apply the vehicle’s
brakes.
• A brake chamber is a circular container divided in the middle by
a flexible diaphragm.
• Air pressure pushing against the diaphragm causes it to move
away from the pressure, forcing the push rod outward against
the slack adjuster.
• The force exerted by this motion depends on air pressure and
diaphragm size. If a leak occurs in the diaphragm, air is allowed
to escape, reducing the effectiveness of the brake chamber.
• A brake chamber is usually mounted on the axle, near the wheel
that is to be equipped for braking.
 https://youtu.be/3mrUMTP4thI

https://youtu.be/FDCaDGZKdTQ

https://youtu.be/FDCaDGZKdTQ
 Brake Assembly
• Brake assembly includes brake chamber and slack adjuster mounted
on the backing–plate because of the steering action.
• A brake chamber is usually mounted on the axle, near the wheel
that is to be equipped for braking.
• Air pressure is fed through an inlet port. The air pushes against the
diaphragm and the pushrod.
• The pushrod is connected by a clevis and pin to a crank arm–type
lever called a “slack adjuster”.
• This converts the pushing motion of the pushrod from the brake
chamber to a twisting motion of the brake camshaft and S–cams.
• When the air is exhausted, the return spring in the brake chamber
returns the diaphragm and pushrod to the released position.
 Working principle:
• As shown in the figure, in the air brakes the compressed air (around 700 kPa) is
used to actuate the brake mechanism.
• The figure shows the complete layout of the Air Brake System. It consists of Air
filter, unloading valve, Air compressor, Air reservoir, Brake valve, and 4 numbers
brake chamber.
• The compressor takes atmospheric air through the air filter and compresses the air.
This air is stored under pressure in the air reservoir.
• From this reservoir air goes to various accessories of the vehicle which operates on
compressed air. Part of the air goes to the brake valve.
• The control of the brake valve is done by a driver who controls the intensity of
braking according to an emergency.

• Pedal Depressed: When the brake pedal is depressed, compressed air from the
reservoir is transmitted through pipes equally in all directions to the brake
chambers through brake valve which further applies the brake.

• Pedal Released: When the driver releases the brake pedal, the master cylinder
piston returns to its original position due to return spring, and the pressure is
dropped. It releases brake shoes from brake drum to their: original position and
brakes are released
Advantages of Air brakes
Air brakes provide excellent stopping power for heavy-duty vehicles
and equipment, such as trucks and buses.
They are highly responsive, which makes them ideal for emergency
braking situations.
Disadvantages of Air brakes
They require additional components, such as an air compressor and
reservoir, which can add weight and complexity to the vehicle or equipment.
They require regular maintenance and inspection to ensure that they
are working properly and are not leaking.
Difference between air brakes and hydraulic brakes :
Air brakes Hydraulic brakes
1. Compressed air is used as a working 1. Hydraulic oil is used as a working
substance. substance.

2. Air brake has more powerful than a 2. Hydraulic brake has less powerful than
hydraulic brake. air brake.

3. Components: Air compressor, unloader 3. Components: Master cylinder, wheel

valve, brake valve, brake chamber. cylinder, oil reservoir.

4. The air brake system is used in trucks, 4. Hydraulic oil brake system is used for
buses, trains, etc. light vehicles such as cars, light-duty trucks,
etc.

5. Air compressor uses a certain amount of 5. No engine power is used.

engine power.

6. It is not self lubricating. 6. Hydraulic brakes are self lubricating.

 Vaccum assisted braking system

Any mechanism which adds to the driver's effort in applying the brakes is called a
power or servo mechanism, although that effort remains a considerable part of the total
braking effort required.
As the weight of the vehicle goes on increasing, more braking effort is needed
to stop the vehicle when a limit is reached above which it is not possible for an ordinary
driver to apply the effort needed conveniently.

This limit is normally reached at about three tonnes, the weight of the vehicle.
Beyond this, the help of the 'servo action' or self energization of the power brakes is taken.

The four most common types of power brakes are: vacuum suspended; air
suspended; hydraulic booster, and electro-hydraulic booster.
 Vacuum reservoir is connected - through a non -return valve to the inlet
manifold between the carburettor and the engine.

Vacuum reservoir is further connected to the servo cylinder on both sides

of the piston; on left side the connection is through the control unit, while on the
right side it is direct connection.
Control unit also contains a piston to which two valves are attached. The
upper valve controls the connection between the atmosphere and left side of the
piston in the servo cylinder.
The lower valve controls the connection between the vacuum reservoir
and left side of the servo cylinder piston. The piston in the control unit itself is
actuated by the brake pedal through the master cylinder
Vaccum assisted braking system
 The working operation of vacuum assisted power
brake with servo system. When the brake pedal is free, upper valve in the control
unit is closed and the lower one is open.

Thus both sides of the piston in the servo cylinder are exposed to the
engine vacuum. However, when the brake pedal is pressed to apply the brakes,
the pressure of the brake fluid pushes the piston in the control unit up, thereby
closing the lower valve there and opening the upper valve.

Thus left side of the servo piston is exposed to atmospheric pressure,

whereas vacuum acts on the right side. This causes the servo piston to move to
the right.

This movement is utilized to apply the brakes in the wheels through

some linkage which may be mechanical or hydraulic.

Thus the force to be exerted by the driver for applying the brakes is
considerably reduced and practically the whole of the breaking effort is supplied
by the engine vacuum.
 When the brake pedal is applied, the movement opens an air valve
which lets in atmospheric pressure air to one chamber of the booster.

Since the pressure becomes higher in one chamber, the diaphragm

moves toward the lower pressure chamber with a force created by the area of
the diaphragm and the differential pressure.

The equilibrium created by the low pressure in both chambers keeps

the diaphragm from moving until the brake pedal is depressed.

This force, in addition to the driver's foot force, pushes on the master
cylinder piston. The diaphragm will stop moving when the forces on both sides
of the chamber reach equilibrium.
https://youtu.be/pVWcH5049c0
Advantages of Power-assisted Brake
Power-assisted brakes provide additional braking power, making
them ideal for heavy-duty applications and high-performance vehicles.
They are easier to operate, which can reduce driver fatigue and
increase safety.
Disadvantages of Power-assisted Brake
They can be more expensive to manufacture and maintain than
traditional brakes.
They require additional components, such as a vacuum pump or
hydraulic booster, which can add weight and complexity to the braking
system.
 Antilock Braking System
Stopping a car in a hurry on a slippery road can
be very challenging. Anti-lock braking systems (ABS) take a lot
of the challenge out of this sometimes nerve-wracking event.
In fact, on slippery surfaces, even professional drivers can't
stop as quickly without ABS as an average driver can with ABS.
In this article, the last in a six-part series on brakes, we'll learn
all about anti-lock braking systems -- why you need them,
what's in them, how they work, some of the common types
and some associated problems.
 The theory behind anti-lock brakes is simple.
A skidding wheel (where the tire contact patch is sliding relative
to the road) has less traction than a non-skidding wheel. If you
have been stuck on ice, you know that if your wheels are spinning
you have no traction. This is because the contact patch is sliding
relative to the ice . By keeping the wheels from skidding while you
slow down, anti-lock brakes benefit you in two ways: You'll stop
faster, and you'll be able to steer while you stop.
There are four main components to an ABS
system:
• Speed sensors

• Pump

• Valves

• Controller
Speed Sensors
The anti-lock braking system needs some way of knowing
when a wheel is about to lock up. The speed sensors, which are
located at each wheel, or in some cases in the differential, provide
this information.
Valves
There is a valve in the brake line of
each brake controlled by the ABS. On some systems, the valve has
three positions:
In position one, the valve is open; pressure from
the master cylinder is passed right through to the brake.
In position two, the valve blocks the line, isolating that brake from
the master cylinder.
This prevents the pressure from rising further should the driver push
the brake pedal harder.
In position three, the valve releases some of the pressure from the
brake.
Pump
Since the valve is able to release pressure from the
brakes, there has to be some way to put that pressure
back. That is what the pump does; when a valve reduces
the pressure in a line, the pump is there to get the
pressure back up.
Controller
The controller is a computer in the car. It watches
the speed sensors and controls the valves.
ABS at Work
There are many different variations and control algorithms for ABS systems. We will
discuss how one of the simpler systems works.
The controller monitors the speed sensors at all times.
It is looking for decelerations in the wheel that are out of the ordinary.
Right before a wheel locks up, it will experience a rapid deceleration.
If left unchecked, the wheel would stop much more quickly than any car could.
It might take a car five seconds to stop from 60 mph (96.6 kph) under ideal conditions, but a
wheel that locks up could stop spinning in less than a second.
The ABS controller knows that such a rapid deceleration is impossible, so it reduces
the pressure to that brake until it sees an acceleration, then it increases the pressure until it
sees the deceleration again.
It can do this very quickly, before the tire can actually significantly change speed.
The result is that the tire slows down at the same rate as the car, with the brakes keeping the
tires very near the point at which they will start to lock up.
This gives the system maximum braking power.
When the ABS system is in operation you will feel a pulsing in the brake pedal; this comes
from the rapid opening and closing of the valves.
Some ABS systems can cycle up to 15 times per second.