Automobile Braking System

Braking Rules
• The car must be equipped with a braking system that acts on all four
wheels and is operated by a single control.

• It must have two independent hydraulic circuits such that in the case of
a leak or failure at any point in the system, effective braking power is
maintained on at least two wheels.

• Each hydraulic circuit must have its own fluid reserve, either by the use
of separate reservoirs.

• The brake system must be capable of locking all four (4) wheels during
braking test.
 Overall System
• http://auto.howstuffworks.com/auto-
parts/brakes/brake-types/brake3.htm
Conservation of Energy
Pedal Assembly
• Reverse Mount Pedal
• 6:1 ratio
• Adjustable
Master Cylinder
• Wilwood TM1 Tandem MC
• 5/8” Bore
• 1.31” Stroke
• Compact Design
• Lightweight
• Mounting Bracket
Proportioning Valve: refer book
• used in rear brake line of vehicles with
front disc brake and rear drum brake
•Weight transfer to front during hard
braking
• Lower pressure to rear caliper
• 62% Front 38% Rear
• Adjustable
 Brake Lines
• Withstand master cylinder pressure
Front • Flexible: pedals and front calipers
• Hard Line: rear caliper and to front flex
• Fittings
Master Cylinder

Proportioning Valve

Rear
• Wilwood PS1 Caliper
• 2 Pistons
• Piston Area: 0.79 in2
• Weight: 0.93 lbs
Brake Pads
Rotor
• Material: 420 Stainless Steel
• Dimensions: 7” OD 3/16” thick
• Mass: 1.22 lbs
• Floating Design
  The Basic Concepts
 Hydraulic layouts
 Component functions
 Brake Balance
 Stopping Distance and Fade

12
 Energy Conversion

The brake system converts the kinetic

energy of vehicle motion into heat

13
 Energy Conversion
A vehicle weighing 290 kg. (639 lbs.)
At 90 kph (55.9 mph) has kinetic energy of:

OR 90,770 N-M.

Stopping the vehicle at .9G takes 2.9 Seconds

This is equal to 31 kilowatts (42 HP).

14
 Kinetic Energy as a Function of Speed and Mass
180,000

160,000
200 kg
140,000 250 kg
290 kg
120,000
Energy N-M

100,000

80,000

60,000

40,000

20,000

0
30 60 90 120
Speed kph

15
 Basic System Model

Brake Force

16
 Hydraulic System Configurations
There are two layouts of hydraulic brake systems used in cars
and light trucks.
Front/Rear hydraulic split:
Also called axle by axle, vertical, and some times “black and
white”.
Diagonal Split:
Also called criss-cross.

The type of split is only significant in the event of a

hydraulic system failure.

17
 Front/rear Hydraulic Split

Primary System

Front Axle
Rear Axle

Secondary System

18
 Typical Diagonal Split System

Right front Left front

left rear right rear

19
 Brake Component Function

20
 Four Sub-systems

 Actuation sub-system
 Foundation sub-system

 Parking brake sub-system

 ABS & ESP (electronic stability

program) sub-system

21
 Actuation Sub-system

Brake Pedal
Master Cylinder
Proportioning Valves
Brake Lines

22 16
 The Brake Pedal
Output to master cylinder
4:1 Nominal
400 N and 36 mm Pedal Ratio

Driver Input
100 N and 144 mm

23
 Master Cylinders

A master cylinder is just a simple piston

inside a cylinder

Input Force

Output Pressure

24
 M/C Unapplied

25
 M/C Applied

26
 Primary System Failure
Pressure for
Normal
Secondary
System Function

Operated
Mechanically Bottoms Against
Secondary Piston
27
 Secondary System Failure
Bottoms at End of Cylinder Bore

Pressure for Normal Primary System Function

28
 Proportioning Valves

 Reduce the pressure to

the rear brakes T
Y
PI
CA
LP
R
OP
VA
L
VE
P
ER
FO
R
MA
NC
E
CU
8
0
0
 Diagonal systems
require two
 Split and slope are 6
0
0
changed to create Split Point
proper balance 4
0
0
RearBkePrsue Slope

2
0
0

Hard Stops
0
0 2
0
040060080
0
29 Fr
on
t
Bra
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eP
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s
su
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e
 • Brake Lines

 Double wall steel tubing (Bundy Tubing) is industry

standard.
 3/16” o.d. is standard size.
 Very robust, can take a lot of abuse
 Use SAE 45° inverted flare (J533 and J512) joints if you
can.

30
 Foundation Brake Sub-system

 Disc Brakes
 Linings

31
 Front Disc Brake

32
 Front Disc Brake

33
 Brake Linings
•Brake linings are probably the most mis-understood part of
a brake system.
•The output of any brake is directly related to the coefficient
of friction (µ) between the lining and the disc or drum.
•The challenge is knowing what the instantaneous value of µ
is during any given stop.
•Any design calculations you do, go right out the window if
the lining you use does not have the µ value you assumed.

34
 Brake Linings

Remember the equation for a disc brake

The best method for determining the actual value of µ for a

given lining is from a dynamometer test.

35
 Both Front Wheels Locked:

 You can’t steer

 The vehicle goes straight
 OK, if you must hit something
 Not good if you are on a curved road

36
 Both Rear Wheels Locked:
 The front wheels track straight ahead
 Then the rear wheels deviate to the side
 Until the vehicle can’t track straight any longer
and the rear starts to spin around the front

37
 µ vs. % Wheel Slip
Typical Dry Surface
1

0.9

0.8 Braking
0.7
Mu (Deceleration)

0.6

0.5

0.4
Steering
0.3

0.2

0.1

0
0 10 20 30 40 50 60 70 80 90 100
% Wheel Slip

38
 Front Lock
If there is more front brake torque than dynamic front weight

Brake torque Dynamic weight

distribution distribution

20%
80% 40% 60%
The front wheels will lock up before the rears

39
 Rear Lock
If there is more rear brake torque than dynamic rear weight;

Brake torque Dynamic weight

distribution distribution

40% 60% 20% 80%

The rear wheels will lock up before the fronts

40
 Optimum Braking

Optimum braking is achieved when brake torque

distribution matches dynamic weight distribution

No Braking Hard Braking

40% 20%
60% 80%
Weight Distribution

41
 Ideal Vs Actual Torque

Ideal
60/40 Actual
70/30 Actual
0.9 1.0 1.1
0.8
0.7
0.6
Rear Torque

0.5

0.4

0.3
With a prop valve
0.2

0.1

0.0

42 Front Torque
 Stopping Distance

Does not Depend on: Does Depend on:

• Type of brakes • Tire to road friction
• Size of brakes • Vehicle balance
• Skill of driver
• System Reaction Time

43
 µ vs. % Wheel Slip
Typical Dry Surface
1

0.9

0.8 Braking
0.7
Mu (Deceleration)

0.6

0.5

0.4

0.3

0.2

0.1

0
0 10 20 30 40 50 60 70 80 90 100
% Wheel Slip

44
 Brake Fade
Brake fade is the loss of performance resulting from
the lining friction decreasing as the lining and rotor
or drum rises in temperature

45
 Disc Brake Parts
• Rotor
• Caliper
• Brake pads
• Piston
• Square cut seal
• Dust boot
• Guide pins
• Mounting bracket
 Inspecting Disc Brakes

• Road test and function

checks
• Shop tests
• Disc brake pad
thickness
• Inspection of rotor.
(Miking)
 Shop Inspection
Caliper, Pads, Rotor & Hardware
• Inspect brake hose for
cracks.
• Inspect the brake pads
for there thickness.
The pad material
should be at least as
thick as the backing
plate.
• Look for any damage
to the mis. hardware.
• Mike the rotor.
Micrometer
 Disc Brake Service
• Disassembly and
Removal of Caliper
• C-Clamp
• Inspection of
Hardware
• Replacing Pads
• Disc Brake Quiet
• Reassembly
 Machining Rotors
• A limited amount of metal can removed from
the rotor because of heat dissipation.
• Thickness of rotor new.
• Machine to thickness.
• Discard thickness.
 Machining Rotors
• Measuring rotor
thickness
• Mounting on lathe
• Scratch cut
• Coarse Cut(s) .006”
• Fine Cut .004”
• Cleaning hub
Removing the Rotor
Mounting on the Lathe
Cleaning Wheel Bearings
Installing New Oil Seal
Installing the Rotor
BRAKES
 BRAKES
Friction is the resistance to motion between two objects in contact
with each other.

•Dry friction (Brakes)

•Greasy Friction (Wheel bearings)

•Viscous (Crank main bearings)

Friction varies with the roughness of the surfaces.

Kinetic (Motion) Friction

Static (Rest) Friction

 BRAKES
Friction between Drums & Shoes or Pads & Rotors slows the car.

Friction between TIRES and ROAD stops the car.

 BRAKES
•Air Brakes. (Pneumatic)

•Hydraulic Brakes use hydraulic fluid pressure to transmit power.

(Incompressible)

•Two pistons of same size will travel the same distance, with the
same force.

•If the small piston acts on a large piston,

the large piston will travel with more
force, but a shorter distance.

•If the larger piston acts on a small piston, the small piston will
travel a longer distance, but with less force.
 BRAKES
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 BRAKES
Brake Action

•Brake Pedal is connected to the Master Cylinder.

•Each wheel has a Wheel cylinder Or Caliper

(Rear) (Front)

•Each wheel has a brake Drum Or Disk

(Rear) (Front)

•Each wheel has Shoes Or Pads

(Rear) (Front)
Brake Action
BRAKES
When the Brake pedal is pressed, brake fluid travels from Master
cylinder to the Caliper or Wheel cylinder, pushing the pistons out.
In turn this action pushes the shoes against the drum or
the pads against the rotor.
 BRAKES
When the vehicle comes to a stop, most of the weight is shifted
to the front

70% - 80% of the work is done by the front brakes

 BRAKES
Brake Lining

Brake lining is made of various materials (Asbestos)

Some are bonded or glued to a metal plate.

Some are riveted to a metal plate.

Brake lining must be strong enough to absorb the heat and last
a long time, yet save the drums and rotors from wearing too quickly.
 BRAKES
Disk brakes found on front of most vehicles as well as at rear
of four wheel Disk brakes vehicles.

•Has a rotor/disk between two pads

•Caliper squeezes the pads against

the disk when the brakes are applied

•Disk brakes work much better then

the drum brakes, as they cool better
and apply more pressure.

CHOICES
•Metallic(last longer, but bad for rotor)
•Semi-metallic
•Ceramic
 BRAKES
Wear Sensors

Some pads have wear warning sensors.

•Squeals without stepping on the brakes.

•Replace when the pad is down to 1/8” at any point.

 BRAKES
Drum Brakes on the rear wheels of the vehicle.

•When brakes are applied, the wheel cylinder pushes the brake shoes
against the rotating drum.
 BRAKES

•Rear brakes are self adjusting.

•They adjust when the vehicle is
reversed and brakes are applied.

•Can be manually adjusted by

turning the star-wheel.

•Primary shoe sits at the front (smaller/thinner),

and secondary shoe sits towards the rear
(bigger/thicker).

•Replace shoes when they are down to 1/16” at any point.

BRAKES
 BRAKES
Parking brakes are part of the rear brakes and are operated
mechanically with the help of a leaver and cables.
BRAKES
 BRAKES
Master Cylinder

•Reservoir for brake fluid.

•Connected to the brake pedal.

•Pressurizes the system when

brakes are applied.

•Cheaper to replace.

•Bench bleed when installing

new.

PROBLEMS
•Internal leak – Pedal slowly goes down to the floor when stopped at a
red light. (No visible leak)

•External leak – Between Master cylinder and power booster.

 BRAKES
Dual Brake system
•Is a safety feature. If one system fails the other will still work.
•Front brakes are on different lines then the rear.
•Master cylinder has two compartments for brake fluid.
•Bigger for front and smaller for rear.
 BRAKES
•Power Brakes assists in braking when the pedal is pressed.

Hydraulic booster hydraulic pressure is applied by power-steering pump

Vacuum Booster works with the vacuum from the vehicle’s manifold.

To Check press on the brake pedal

and start the vehicle, if working
properly the pedal should go down.
 BRAKES
Pressure Differential Valve

Warning light (Dash mounted) will light up, in case difference

of pressure is detected in either system due to a leak.
 BRAKES
Metering Valve

•On vehicles with front disk and rear

drum brakes.

•In hydraulic line to front brakes.

•During light brake application, metering valve prevents front

brakes from applying until after the rear brakes shoes are in
contact with the drums.
 BRAKES
Proportioning Valve

•ON front disk & rear drum system.

•Installed in hydraulic lines to the

rear brakes.

•Reduces pressure to the rear brakes during hard braking

•During hard braking, vehicle weight is transmitted to the front,

resulting in the need of more braking at front.
 BRAKES
Combination Valve

Pressure Differential Switch, Proportioning Valve & Metering Valve

are all combined in one.
 BRAKES
Brake Fluid

•Use the one recommended by the manufacturer.

•DOT3
•DOT4
•DOT5

Brake parts can be cleaned

with brake fluid.

Properties

•High Boiling point

•Water Tolerance
•Low Freezing Point
•Non-corrosive (rubber, plastic, metal).
•Lid should be always covered in order to prevent moisture in the
system.
 BRAKES
Problems

•Spongy brakes are caused if air gets in the system, hence brake
bleeding is required.

•Dragging brakes are caused if vehicle is driven with partially

brakes applied and overheated. (Seized parking brake cables)

•Bent or run-out rotor can be ground to make it true.

•Loss of brake pedal

•Master cylinder
•Leak in the system
 BRAKES
Problems

•One rear wheel locks up

•Adjustment
•Oil on the brake lining
•Seized brake cable

•Pull to one side

•Seized brake caliper
•Blocked brake line
•Bad tires (alignment)
Power Brake Systems
 Power Brake Systems
• Most all modern vehicles use power assisted
brakes.
• A vacuum line from the intake manifold to the
brake booster provides a source of vacuum.
• A brake booster check valve prevents loss of
vacuum during wide open throttle.
Power Brake Systems
• Vacuum in the intake manifold
is applied to a rubber
diaphragm on the vacuum side
of the booster chamber (red
speckled area)

• The piston rod (7) is pushed in

when the brakes are applied
and vacuum is supply to the
brake booster assembly rear
section through the bell valve.
 Power Brake Systems
• When the engine is running and the brake are not
depressed there is vacuum on both sides the booster
diaphragm (vacuum Suspended)

• As brake are applied atmospheric pressure is allowed

to enter the rear of the booster through an air
control valve increasing pressure on the master
cylinder.
 Intake manifold vacuum

Brake Booster Brake Booster rear When the brake pedal is

front chamber chamber depressed the air valve moves
Vacuum supply to forward allowing atmospheric
rear chamber pressure to enter the rear of
Air Valve the brake booster assembly.
assembly
The higher pressure in the
rear forces the diaphragm to
move forward increasing the
pressure applied to the
master cylinder.
A spring in the front chamber
forces the diaphragm
Spring rearward when the brake
NOTE: Vacuum is closed off pedal is released.
to the rear chamber when
brake are applied
 Power Brake Systems
• Most automotive repair shop do not repair or
rebuild brake boosters. Its usually more cost
efficient to replace defective brake booster
assemblies.
• It is important to understand how a power
brake booster operates before diagnosing a
defective booster assembly.
 Power Brake Systems
To diagnose a power brake assembly
1. Pump the brake several times with the engine off to
remove vacuum from the booster.
2. Start the vehicle the brake pedal should move downward
slowly as vacuum begins to build.
3. A hard brake pedal can be caused by:
A. Defective brake booster diaphragm
B. Low vacuum to the brake booster.

NOTE: In case the engine should stall while driving, Vacuum booster are design to
maintain vacuum providing the operator time to stop safely.
 Power Brake Systems
• There are very few adjustment on
power assisted brakes. If necessary
brake pedal free travel can be checked
using a ruler.
Master cylinder Caution: Only in rare
Firewall circumstances will it
Brake pedal be necessary to adjust
brake pedal free travel
Ruler
 Power Brake Systems
• If a push rod is adjusted to short it will cause
excesses brake pedal free travel
• If a push rod is adjusted to long it could cause
brake to:
– Heat up due to dragging
– Lock-up due to brake expanding caused by
excesses heat.
 WORKING OF HYDRAULIC BRAKE
COMPENSATING CHECK
INLET PORT PORT VALVE

MASTER CYLINDER

BRAKE ON WHEN THE DRIVER

DEPRESSES THE BRAKE PEDAL, THE
MASTER PISTON MOVES FORWARD
CUTTING OFF THE FLUID SUPPLY FROM
THE RESERVOIR . HYDRAULIC PRESSURE
MOVES THE PISTONS OF THE WHEEL
CYLENDER
 TYPES OF BRAKES

MECHANICAL BRAKES
HYDRAULIC BRAKES
VACUUM-ASSISTED BRAKES
AIR PRESSURE ASSISTED BRAKES
AIR PRESSURE BRAKES
HYDRAULIC DISC BRAKES
MECHANICAL BRAKES
HYDRAULIC BRAKES
VACUUM ASSISTED BRAKES
1. POWER CYLINDER
ASSEMBLY
2. DIAPHRAGM
3. MASTER
CYLINDER
4. VALVE
5. BRAKE PEDAL
6. LINKAGES
7. LINKAGES
AIR PRESSURE ASSISTED BRAKES
 AIR PRESSURE BRAKES
UNLOADER
VALVE AIR TANK
AIR-COMPRESSOR

PRESSURE
HOSE
BRAKE VALVE GAUGE
HAND CONTROL VALVE
BR.OPR.
ROD

SLACK
ADJUSTER

BRAKE
CHAMBER
HYDRAULIC DISC BRAKES
TANDAM MASTER CYLINDER
BRAKING SYSTEM
PRINCIPLE OF HYDRAULIC BRAKE