Nam Nadu

2011-2012
MECHANICAL ENGINEERING | Mr.Vaibhav V Naik

AUTOMOBILE
ENGINEERING
BRAKES
Automobile Engineering
Module No 02 2 Vaibhav Vithoba Naik
BRAKES
1. Requirements of the brake
2. Classification of Brakes
3. Mechanical Brakes
4. Hydraulic Brakes
5. Electro and Vaccum brakes
6. Disc brakes
7. Braking of the front wheel
8. Rear wheel and four wheel brakes
9. Brake trouble shooting
10. Introduction Antilock braking system

Q1. - List the functions of the brake? State its essential requirement?
Answer: -
BRAKE :-
It is a device used for slowing, stopping & controlling the vehicle.
In braking operation, the kinetic energy of vehicle is converted into heat,
which is dissipated to atmosphere.

FUNCTIONS OF VEHICLE BRAKING

There are two main functions of brakes:

1) To slow down or stop the vehicle in the shortest possible time at the
time of need.
2) To control the speed of vehicle at turns and also at the time of driving
down on a hill slope.

REQUIREMENTS OF THE BRAKE

1) The brakes should stop the vehicles in shortest possible distance and
time.
2) The brake should work equally good on fair or bad road.,
3) Paddle effort applied by the driver should not be more so as not to
strain the drivers.
4) Brake should work equally good in all weather.
5) It should have less wearing parts
6) It should require less maintenance.
7) Brakes, when applied should not disturb steering geometry.
8) There should be minimum sound when brakes are applied.

Q2. - Define the principle on which brake works? Classify the brakes
Answer: -
PRINCIPLE OF VEHICLE BRAKING
Braking of a vehicle depends upon the static function that acts between
tyres and road surface.
Brakes work on the following principle to stop the vehicle:
The kinetic energy due to motion of the vehicle is dissipated in the form of
heat energy due to friction between moving parts (wheel or wheel drum)
and stationary parts of vehicle (brake shoes).
The heat energy so generated due to application of brakes is dissipated
into air. Brakes operate most effectively when they are applied in a
manner so that wheels do not lock completely but continue to roll without
slipping on the surface of road.

Q2. Give the Classification of the brakes?
Answer: -
CLASSIFICATION OF BRAKES
Brakes may be classified in the following ways.
a. With respect to application: -
1. Foot brake :- service brake
2. Hand brake :- parking brake

b. With respect to number of wheels to which brake is applied
1. Two wheel brake
2. Four wheel brake

c. With respect to construction
1. Drum brake
2. Disc brake

d. On the Basis of Mode of Operation
1. Mechanical brakes
2. Hydraulic brakes
3. Air brakes
4. Vacuum brakes
5. Electric brakes.

Q3.: - Explain the Drum Brake /Internal Expanding brakes ?
Answer: -MECHANICAL BRAKES
DRUM BRAKE: -
1. In this type, a brake drum is attached concentric to axle hub.
2. Two brake shoes are anchored on the back plate as shown in figure.
3. Friction linings are mounted on the brake shoes.
4. One or two retractor springs are used to keep the brake shoes away
from the drum when the brakes are not applied.

5. The brake shoes are anchored at one end, whereas on the other end
force F is applied by means of some brake actuating mechanism,
which forces the brake shoe against the revolving drum, thereby
applying the brakes.
6. An adjuster is also provided to compensate for wear of friction lining
with use.

Q4.: - Explain the Hydraulic brake working with its principle ?
Answer: HYDRAULIC BRAKES
Principle: -
Force applied on the brake pedal is transmitted to brake shoe through a
confined liquid known as brake fluid.
OR
Hydraulic brakes work on the principle of Pascals law which states that
pressure at a point in a fluid is equal in all directions in space. According
to this law when pressure is applied on a fluid it travels equally in all
directions so that uniform braking action is applied on all four wheels.

Construction: -
Hydraulic braking system consists of
1. Master cylinder
2. Wheel cylinder
3. Brake drum
4. Brake shoes
5. Brake fluid with brake lines.

1. MASTER CYLINDER: -
a. It consists of two main chambers, fluid reservoir & compression chamber.
b. Reservoir supplies fluid to brake system through two ports.
c. Larger port is called as intake port whereas smaller port is called as
d. By pass port.
e. To prevent leakage, there are rubber seals on both sides of piston in the
compression chamber.
f. Towards the break line side of compression chamber, there is a fluid
check valve with a rubber cup inside. It serves to retain residual pressure
in the brake lines even after the brakes are released.

2. WHEEL CYLINDER :-
a. Wheel cylinders are provided to force the brake shoes against the drums.
b. Each wheel cylinder is provided with piston, rubber seal, and rubber seal
spreaders, springs etc.
c. The brake line from the master cylinder is attached to the inlet port of
wheel cylinder.
d. A bleeder port is provided to bleed the air whenever necessary.


WORKING: -
1. The master cylinder is connected by brake lines to wheel cylinder at each of
four wheels.
Each wheel cylinder consists of a cylinder brake drum, which is mounted
on inner side of wheel & revolves with it.
Inside the brake drum, two brake shoes are fitted with friction brake lining
on their surfaces.
2. When the brake pedal is pressed, which is connected to master cylinder by
means of piston rod, it causes the piston of master cylinder to move. It
increases the pressure of fluid inside the master cylinder & in entire
hydraulic system. This pressure is instantly transferred to all four wheel
cylinders.
3. As soon as the pressurized oil comes inside the wheel cylinder through inlet
port, the pistons in the wheel cylinder moves outwards moving the brake
shoes out against the brake drum. Thus the brakes are applied.
4. When the driver releases the brake pedal, the master cylinder piston returns
to its original position due to return spring, dropping fluid pressure. Brake
shoe retracting springs contract & pulls the brake shoes out of contact with
brake drum to their original position & brakes are released.

Q5.: - Give the advantages and disadvantages of Hydraulic brake ?
Answer: -
ADAVANTGE OF HYDRAULIC BRAKE SYSTEM
The advantages of hydraulic brake system are,
1. Mechanical linkages, joints etc. are eliminated so as to have simple
construction.
2. Equal braking effort at all points to all four wheels.
3. Self lubricating
4. High mechanical advantage i.e. less effort required to operate brake
5. Differential braking action can be permitted by using wheel cylinders of
different sizes for front & rear wheels.
6. It gives higher efficiency than any other hydraulic system.

DISADVANTAGES OF HYDRAULIC BRAKE SYSTEM
The disadvantages of hydraulic brake system are,
1. Fails the whole system when there is leakage or damage to any part of
system.
2. Due to leakage of fluid, damage to brake shoes & linings happens.
3. This system is used to apply brakes intermittently. For parking purposes,
separate mechanical linkage has to be used.

Q8. - Explain the construction and working of Master Cylinder?
Answer: MASTER CYLINDER:
Construction of Master Cylinder
1. The Master Cylinder is the heart of the hydraulic brake system.
2. It consists of two main chambers.
3. The fluid reservoir which contains the fluid to supply to the brake system,
and the compression chamber in which the piston operates.

4. The reservoir supplies fluid to the brake system through two ports.
5. The larger port is called the filler or intake part and is connected to the
hollow portion of the piston between the primary and secondary cups
which act as piston seals.
6. The smaller port is called the relief, bypass or compensating port which
connects the reservoir directly with the cylinder and lines when the
piston is in the released position.

Working of Master Cylinder

1. When the brake pedal is depressed, the master cylinder piston moves
forward to force the liquid under pressure into the system. The relief port
is sealed out of the system. The liquid pressure is conducted to the
wheel cylinders, where it forces the wheel cylinder pistons out wards.
These pistons force the brake shoes out against the brake drums.
2. When brake pedal is released, the return spring quickly forces the
master cylinder piston back against the piston stop. Because the fluid in
the lines returns rather slowly, a vacuum tends to form in the cylinder in
front of the piston. This causes the primary cup to collapse to allow the
liquid to flow from the reservoir through the filter port past the piston to fill
the vacuum.

Q8.: - Explain WHEEL CYLINDER ?
Answer: WHEEL CYLINDER :
1. Wheel cylinder is the second important hydraulic brake system. It
consists of two pistons which can move in opposite directions by the fluid
pressure. It is rigidly mounted on the brake shield or backing plate. The
boots protect the cylinders from foreign substances. Bleeder valves are
provided in the cylinder to permit air and liquid to be pumped out of the
system during of the bleeding operation .

2. Piston cup fits tightly in the cylinder against each piston and seal the
mechanism against leakage of the brake fluid. A Spring serves to hold
the cups against the piston when the pressure is decreased.
3. When the brakes are applied the brake fluid enters the cylinder from a
brake line connection inlet between the two pistons. It causes to force
out the two pistons in opposite directions. This motion is transmitted to
the brake shoe. Directly or through links force them against the brake
drum, thus applying the brake.

Q8. - Explain the Pneumatic brake?
State its advantage and disadvantages?
Ans: PNEUMATIC BRAKE
Construction of Pneumatic brake

The pneumatic brake system consists of the following parts.

1. Air compressor
Generally the reciprocating compressor is used to build the air pressure in
the reservoir. The compressor is driven by the engine.

2. Unloaded valve
It maintains the constant pressure in the reservoir.
The excess of the pressure is relieved by the unloaded valve.

Figure: Block Diagram of Pneumatic Brake

3. Reservoir
It is the tank in which the air at high pressure is stored.

4. Brake Valve
It is located between air reservoir and air line of the brake cylinder.
Brake valve is used to control the braking action.
Brake valve may be operated by the brake pedal.

5. Brake Chamber
It is the housing in which brake shoe linkages are connected to the
diaphragm.
The movement of the diaphragm due to high pressure air actuated brakes
shoes towards brake drum.

6. Quick release valve
Quick release valve is used in from of brake liners to accelerate the quick
release of the pressure.

7. Relay valve
It speeds up the braking action and release of the air from brake chamber.
It supplies the air to the brake chamber directly from the reservoir and also
retains the air from rears brake chamber directly into atmosphere.

Figure: Air Brake

Working of the Pneumatic brake

1. In pneumatic brake, the brake shoes are operated by means of air
pressure.
2. Engine drives a compressor, which is used to compress the air and
stores in air reservoir.
3. Brake cylinder is connected to air re4servious by means of the flexible
linkages.
4. When the brake pedal is pressed, the compressed air enters in wheel
cylinder to push the diaphragm which in turn pushes the brake shoe to
apply the brake.
5. When the pressure is released from the brake pedal, it comes back
with retracting spring as result in closing of the brake valve and
releases the pressure inside the brake chamber.

Advantage of Pneumatic Brake

1. These are very powerful as compared to the mechanical or hydraulic
brakes.
2. Its location and working is very easy and simple.
3. Available compressed air also used for wiper.

Disadvantage of Pneumatic Brake

1. Compressor consumes the part of the engine power.
2. Construction of each component is complicated.
3. System is costly.

Q9. - Explain the Power brake?
Ans: ELECTRO AND VACUUM BRAKES (POWER BRAKE)

Construction of the Vacuum Brake

1. POWER BRAKE is designed to reduce the pedal effort required to stop
the vehicle.
2. Power brake used engine manifolds to assist the driver in applying the
brakes.
3. Power brake consist of the three basic parts

4. The vacuum of engine manifolds or separate exhauster can be used in
vacuum or power brake.
5. System consists of vacuum reservoir connected through the non return
valve to inlet manifolds of engine.
6. The two connections from vacuum reservoir go to the servo cylinder and
control unit.
7. The control unit has two valves.
8. The lower valves control the connection between the reservoir and right
sides of servo cylinder piston.
9. The other side of the piston of control unit is actuated by pedal by means
of master cylinder.

Working of the Vacuum Brake

1. When the brake pedal is OFF position, the lower valve of control unit is
open and upper valve is closed. This disconnects the atmospheric air
and vacuum form the reservoir is created on the both side of the piston
of the servo cylinder.
2. When the brakes are applied, it closes the lower valve of control unit and
opens the upper valve of atmospheric air to push piston in servo cylinder
towards the right to apply brakes. In these ways driver effort are utilized
to control the position of the drive in the control unit.
3. If failure occur in vacuum power system because of stalled engine, the
brake should still be applied to stop the car, but by greater effort.

Q10.: - Explain the construction and working of disc brakes?.
Answer: -DISC BRAKE:
Construction:
1. It consists of a cast iron disc bolted to the wheel hub & stationery
housing called as the caliper.
2. The caliper is connected to some stationery part of vehicle like stub axle.
3. This caliper is cast in to two parts each containing a piston.
4. In between each piston & the disc there is a friction pad held in position
by retaining pins or springs.
5. The passages are drilled in the caliper for the fluid to enter or leave in
each housing.

Working :
1. When the brakes are applied, hydraulically actuated pistons make the
friction pads into contact with the disc, applying equal & opposite forces
on the disc, causing the friction & hence slowing it down.
2. When brakes are released, hydraulic pressure on the friction pads is
released. The piston moves inwards & breaks their contact with the disc.

Q11.: - Explain the advantages of disc brakes over drum brakes.
Ans: -
ADVANTAGES OF DISC BRAKES OVER DRUM BRAKES
The advantages of disc brakes over drum brakes are,

1. In case of disc brakes, friction surfaces are directly exposed to air,
whereas in drum type, the friction occurs on the internal surfaces, so
heat dissipation problem occurs.
2. The friction pads in case of disc brakes are flat as compared to curved
friction linings in case of drum brakes. Therefore there is uniform wear of
friction pads in case of disc brakes. This helps in easy selection of
material for pads.
3. The design of disc brake is such that there is no loss of efficiency due to
expansion. In case of drum brake, as the system becomes hot, the
expansion of a drum of internally expanding shoe type brake tends to
move the friction surfaces apart, causing a loss of effective pedal travel.
On the other hand, disc expansion merely changes the relative positions
on friction surface causing no loss.
4. Disc brakes weigh less than drum brake.
5. Design of disc brakes is very simple & involves less number of parts to
wear.
6. Easy replacement of friction pads.

Q12. - Short notes on Brake Bleeding.
Answer: -
BLEEDING OF BRAKES
When air enters, into the brake system and any brake line is
disconnected, bleeding of brakes has to be done.
Since air is compressible so any presence of air inside brake lining does
not allow to transmit brake force to apply brakes.
Therefore, the system must be free from presence of air.
Bleeding is the process of removal of air from the braking system.

Bleeding Procedure
Following steps are followed for bleeding of brakes

1. Remove all dirt from the master cylinder filler plug. Then fill the master
cylinder up to lower edge of the filler neck by removing the filler plug.
2. Clean all the bleeding connections provided on all wheel cylinders.
3. After this bleeder hose and fixture is connected to that wheel cylinder
which has longest brake line. The other rend of bleeder hose is placed in
a glass jar, and submerge this end in the brake fluid.
4. How bleeder valve is opened by half to three quarter turn.
5. Then press the foot pedal and allow it to return back slowly.
6. This pumping action must be continued till all the air along with some
brake fluid comes out through bleeding hose.
7. After this bleeding operation is carried out on all wheel cylinders.
8. This completes the bleeding operation. At the end master cylinder is
filled with brake fluid to required level.

Q13.: - Short notes on Brake Setting or Brake Adjustments
Answer: -
ADJUSTMENT OF BRAKES

1. When pedal is pressed to apply brake, there should be atleast 1/2 inch
free pedal movement before breaking action starts. This may vary from
company to company.
2. The brakes are adjusted as per the above mentioned recommendation
before they are ready to use. This is done by following a definite
procedure.
a. List the wheels by screw jack.
b. Loosen the lock nut for the forward brake shoe and keep it in this
position.
c. Turn the eccentric with other wrench towards the front of automobile
till the brake shoe touches the drum.
d. Release the eccentric while turning the wheel with one hand, till
wheel turns freely.
e. Hold the eccentric in this position and tighter the lock nut.
f. Repeat the same operation to adjust other shoe, but turn the
eccentric if the backward direction of the vehicle.
g. Above procedure is repeated for all the four wheels.

Q14.: - Short notes on Parking brake or Emergency Brake?
Answer: -
PARKING BRAKE OR EMERGENCY BRAKE

1. Parking brakes or emergency brakes are essentially mechanical brakes
operated by hand.
2. These are used to prevent the motion of vehicle when parked at a place
or when parked on slopes.
3. In cars, these brakes are generally attached to rear wheels.
4. In this type, a cable connects the hand lever to the brake.
5. Brakes are applied by pulling the lever and released by pushing a button
(provided on lever) and pressing the lever down.

Q15.: - Short notes on Brake Adjusting Mechanism?
Ans: -
Brake Show Adjustment Mechanism

1. There are various methods to adjust the brake shop,
2. The most common types important ones are the
A. Micram adjuster
B. Screw adjuster.


A. MICRAM TYPE ADJUSTMENT OF BRAKE SHOES

1. This system is very effective and simple in construction as shown in
figure.
2. The mechanism consists two scroll members provided one for each
brake shoe to adjust them. each scroll member is mounted between the
brake shoe and the member M is fixed to the actuating plunger.
3. The brake shoe bears on the pin of the scroll member and the scroll
member itself bears on a locking tooth or ridge of the member M.

4. The scroll member is provided with toothed cam and can be turned by a
screw driver when there is desire to the shoe adjustment. The position of
the adjustment is locked by securing the tooth of the cam in the ridge of
the member M. this system is generally used in hydraulic brakes.

B. TAPER SCREW ADJUSTER

1. In this system the shoes are adjusted by a screw which is known as 'star
adjusting screw'.
2. The upper ends of the shoes are pivoted in the projections of the anchor
pin ant the lower ends are connected by the 'star adjusting screw' as
shown in the figure.
3. The expander Unit is provided just below the anchor pin and shoes are
held with the unit by the return sprigs.

Figure : Taper Screw Adjuster

4. Another helical spring is provided at the lower side to hold the shoed on
the ends of the adjusting screw.
5. Whenever the brakes are required to be adjusted then the adjusting
screw is turner with the help of a lever or screw driver through the
window provided in the back plate
6. This results in the expansion of the shoes out wards and thus reducing
the clearance between the linings and the drum .
7. Screw type adjuster is used in mechanical as well as hydraulic

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2011-2012

MECHANICAL ENGINEERING | Mr.Vaibhav V Naik

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