Indian Institute of Technology Delhi

MCL-321 Automotive Systems

Practical No. 4 (Sessions: 2023-24)

Experimental Title: Experimental study of different Types of Brake Systems

Objective: The primary objective of this laboratory experiment is to provide Mechanical
Engineering students with hands-on experience and a comprehensive understanding of various
types of brake systems commonly used in vehicles. This experiment aims to familiarize
students with the working principles, components, and performance characteristics of double
band brakes, band and block brakes, disc brakes, and air servo brake systems.

Introduction:
Brakes are vital components in any vehicle, ensuring safe deceleration and stopping. Different
types of brake systems are utilized in automotive engineering, each with unique features and
operating principles. The main types of brake systems include:
Friction Brakes: These are the most common type of brakes found in vehicles and operate by
converting kinetic energy into heat through friction between brake pads and rotors or drums.
Drum Brakes: Drum brakes feature brake shoes that press against the inner surface of a drum
to create friction, thereby slowing down the vehicle.
Disc Brakes: Disc brakes use calipers to squeeze brake pads against a rotating disc or rotor,
generating friction to stop the vehicle.
Hydraulic Brake: Hydraulic brakes operate based on Pascal's law, utilizing hydraulic fluid to
transfer force from the brake pedal to the brake pads or shoes, thereby generating friction to
slow down or stop the vehicle. Components of a hydraulic brake system typically include a
master cylinder, brake lines, brake calipers (or wheel cylinders), brake pads (or shoes), and
brake fluid reservoir.

1. Double band brake system

A double band brake system is a type of mechanical braking system commonly used in various
applications, including automotive and industrial machinery. This system relies on the
frictional force between two bands and a rotating drum to slow down or stop the motion of a
vehicle or machinery. Here's an overview of the double band brake system:
 Fig 1: (a) Double band brake system and (b) systematic representation of components

Working Principles:
❖ Engagement: When the brake pedal is depressed or the control lever is activated, the
actuating mechanism tightens the bands around the drum.

❖ Friction Generation: As the bands make contact with the rotating drum, friction is
generated. This friction opposes the rotation of the drum, creating a braking force.

❖ Deceleration/Stopping: The generated friction slows down or stops the rotation of the
drum, and consequently, the motion of the vehicle or machinery.

❖ Release: When the brake pedal is released or the control lever is disengaged, the bands
are released from the drum, allowing the system to return to its non-braking state.

2. Band and Block Brake System

A band and block brake system is a type of mechanical braking system that utilizes the
frictional force between a flexible band and a stationary block to slow down or stop the motion
of a vehicle or machinery. This system is often employed in various industrial applications
where moderate to heavy braking forces are required. Below is an overview of the band and
block brake system:
 Fig 2: (a) Band and block brake system and (b) systematic representation of components

3. Disc brake system:

Disc brakes are widely employed in modern vehicles due to their superior braking performance,
reliability, and ease of maintenance. Unlike drum brakes, which operate by pressing brake
shoes against the inside surface of a drum, disc brakes utilize calipers to squeeze brake pads
against a rotating disc or rotor. This setup offers several advantages, including better heat
dissipation, reduced fading, and improved braking efficiency.

The basic components of a disc brake system include a brake rotor, brake caliper, brake pads,
and associated hardware.

Fig 3: Basic components of a disc brake system

Brake Rotor: The brake rotor, also known as a brake disc, is a circular metal disc attached to
the wheel hub. When the brake pedal is pressed, hydraulic pressure is applied to the brake
caliper, causing it to squeeze the brake pads against the rotating brake rotor.

Brake Caliper: The brake caliper is a housing that contains pistons and brake pads.

When hydraulic pressure is applied, the pistons within the caliper extend outward, pushing the
brake pads against both sides of the brake rotor.

Brake Pads: Brake pads are friction materials mounted on metal backing plates within the
brake caliper. When pressed against the rotating brake rotor, the brake pads create friction,
converting kinetic energy into heat energy.

Working Principle:

Explain the fundamental principles behind disc brakes, focusing on the conversion of kinetic
energy into heat through friction between the brake pads and the rotating disc.

Fig 4: Representation of the fundamental working principles behind disc brakes

Initial Stage: When the brake pedal is pressed, hydraulic fluid is forced through brake lines
from the master cylinder to the brake calipers. The hydraulic pressure causes the pistons in the
caliper to move outward, bringing the brake pads into contact with the brake rotor.

Friction Generation: As the brake pads clamp onto the spinning rotor, friction is generated
between the brake pads and the rotor surface. This friction creates resistance, converting the
kinetic energy of the rotating wheel into heat energy.

Deceleration: The frictional force generated between the brake pads and rotor causes the
rotation of the rotor to slow down. As a result, the vehicle decelerates, eventually coming to a
complete stop when the rotational motion of the wheel ceases.

Heat Dissipation: The heat generated during braking is dissipated through the brake rotor and
surrounding components. Vented or slotted rotors may be used to enhance heat dissipation and
prevent brake fade under high-stress conditions.

Advantages of Disc Brakes: Disc brakes offer superior stopping power compared to drum
brakes, particularly in high-speed or emergency braking situations. They provide better heat
dissipation, reducing the risk of brake fade and maintaining consistent braking performance.
Disc brakes are more resistant to water and debris buildup, ensuring reliable braking even in
adverse conditions.

4. Air (Pneumatic) Brake Systems

Air brake systems utilize compressed air to transmit force from the brake pedal to brake
components, enabling efficient braking in heavy-duty vehicles. These systems are widely
adopted due to their reliability, effectiveness, and ability to provide consistent braking
performance over extended periods.

Components Analysis:

Disassemble a pneumatic brake system to illustrate its various components, including air
compressor, air reservoir, brake valves, brake chambers, and brake drums or rotors.
 Fig 5: Illustrate its various components of brake system

Working Principle:

Air brake systems, commonly used in heavy-duty vehicles such as trucks, buses, and trains,
operate on the principle of utilizing compressed air to transmit force from the brake pedal to
the brake components. The primary components of an air brake system include an air
compressor, air reservoirs, brake valves, brake chambers, and brake drums or rotors. Explain
the fundamental principles behind pneumatic brake systems, focusing on the use of compressed
air to transmit force and activate brake components. Emphasize the role of brake valves in
controlling air pressure and modulating brake application.

Fig 6: Emphasize the role of every component in working principle

Compressed Air Generation: The system begins with an air compressor that is driven by the
vehicle's engine. The compressor draws in atmospheric air and compresses it, storing it in the
vehicle's air reservoirs.

Storage of Compressed Air: Compressed air is stored in the air reservoirs, which act as a
source of pressurized air for the brake system. The reservoirs ensure that a sufficient supply of
compressed air is available to actuate the brakes when needed.

Brake Activation: When the driver presses the brake pedal, it triggers the release of
compressed air from the reservoirs. The released air travels through brake lines or hoses to
various brake valves located throughout the vehicle.

Brake Valves: Brake valves control the flow and distribution of compressed air to the brake
chambers. There are different types of brake valves, including relay valves, quick release
valves, and modulating valves, each serving specific functions in the brake system.

Brake Chambers: Brake chambers, also known as brake actuators, are responsible for
converting the compressed air pressure into mechanical force to actuate the brakes.

When pressurized air enters the brake chamber, it pushes against a diaphragm or piston, causing
it to expand and apply force to the brake components.

Brake Application: The force generated by the brake chambers is transmitted to the brake
shoes or pads, which press against the brake drums or rotors to create friction and slow down
the vehicle. The amount of braking force applied depends on the pressure of the compressed
air supplied to the brake chambers and the design of the brake components.

Release of Brakes:

When the brake pedal is released, the brake valves close, cutting off the supply of compressed
air to the brake chambers. The residual pressure in the brake chambers is vented, allowing the
brake components to retract and release the brakes.

Advantages of Air Brake Systems:

Air brake systems are highly reliable and offer consistent braking performance, especially in
heavy-duty applications. They are less prone to brake fade compared to hydraulic brake
systems, making them suitable for prolonged braking situations.
Conclusion:
Summarize the key findings of the experiment and their significance in the field of mechanical
engineering. Reflect on the importance of understanding different brake systems for designing
and optimizing braking systems in various applications.

Some viva voce questions

1. explain the primary differences between hydraulic, pneumatic (air), and regenerative
braking systems?
2. How does the working principle of disc brakes differ from that of drum brakes?
3. What are some common causes of brake fade in hydraulic brake systems, and how can
it be prevented or mitigated?
4. Can you explain the fundamental working principles of double band brakes and band
and shoe brakes? How do they differ in terms of their design and operation?
5. Compare and contrast double band brakes and band and shoe brakes in terms of their
effectiveness, application, and suitability for different vehicles or machinery.
6. How do brake systems manage and dissipate heat generated during braking?
7. What are the main components of a disc brake system, and how do they work together
to facilitate braking?
8. How is air pressure regulated in pneumatic brake systems, and why is it important to
maintain proper pressure levels for effective braking performance?