BRAKE

A brake is a
mechanical
device which
inhibits motion.
WORKING OF BRAKES
• A COMMON MISCONCEPTION ABOUT BRAKES IS THAT BRAKES SQUEEZE
AGAINST A DRUM OR DISC, AND THE PRESSURE OF THE SQUEEZING ACTION
SLOWS THE VEHICLE DOWN. THIS IS IN FACT A PART OF THE REASON FOR
SLOWING DOWN A VEHICLE.
• ACTUALLY BRAKES USE FRICTION OF BRAKE SHOES AND DRUMS TO CONVERT
KINETIC ENERGY DEVELOPED BY THE VEHICLE INTO HEAT ENERGY.
• WHEN WE APPLY BRAKES, THE PADS OR SHOES THAT PRESS AGAINST THE BRAKE
DRUMS OR ROTOR CONVERT KINETIC ENERGY INTO THERMAL ENERGY VIA
FRICTION.

THUS BRAKES ARE ESSENTIALLY A

MECHANISM TO CHANGE ENERGY
TYPES
 TYPES OF BRAKES
 MECHANICAL BRAKES
• DRUM BRAKES
• DISC BRAKES
 HYDRAULICBRAKES
 POWER BRAKES
• AIR BRAKES
• AIR HYDRAULIC BRAKES
• VACCUM BRAKES
• ELECTRIC BRAKES
BRAKE SYSTEM COMPONENTS
 HYDRAULIC BRAKES

 Hydraulics is the use of a liquid under pressure to

transfer force or motion, or to increase an
applied force.

 The pressure on a liquid is called HYRAULIC

PRESSURE.

 And the brakes which are operated by means

of hydraulic pressure are called HYDRAULIC
BRAKES.

 These brakes are based on the principle of

Pascal’s law.
 PASCAL’S LAW

 The pressure exerted

anywhere in a mass of
confined liquid is transmitted
undiminished in all directions
throughout the liquid.

 Applied in hydraulic lifts,

hydraulic brakes etc.
 MASTER CYLINDER IN ACTION

 When we press the brake pedal, it pushes on primary

piston through a linkage.

 Pressure is built in the cylinder and the lines as the brake

pedal is depressed further.

 The pressure between the primary and secondary

piston forces the secondary piston to compress the fluid
in its circuit.

 If the brakes are operating properly, the pressure wll be

same in both the circuits.

 If there is a leak in one of the circuits, that circuit will not

be able to maintain pressure.
MASTER CYLINDER
 USE OF LIQUIDS INSTEAD OF GASES

 Liquids are used in hydraulic systems because liquids

are incompressible.

 If we use a gas, on increasing the pressure, the gas will

be compressed into a smaller volume due to which
there will be no transmission of force or motion.
 ADVANTAGES OF HYDRAULIC BRAKES

 Equal braking effort to all the four wheels

 Less rate of wear (due to absence of joints compared to

mechanical brakes)

 Force multiplication (or divisions) very easily just by changing

the size of one piston and cylinder relative to other.
 DISADVANTAGES OF HYDRAULIC BRAKES

 Even
slight leakage of air into the breaking system
makes it useless.

 The brake shoes are liable to get ruined if the brake

fluid leaks out.
 DISC BRAKES

 In a disc brake, the fluid from the

master cylinder is forced into a
caliper where it presses against a
piston.

 The piston in turn squeezes two

brake pads against the disc (rotor),
which is attached to wheel, forcing
it to slow down or stop.
 DISC BRAKE AND BRAKE OF A BICYCLE

 Similar to a bicycle brake where two rubber pads run against

the wheel rim creating friction.

 But in a disc brake, the brake pads squeeze the rotor instead
of the wheel, and the force is transmitted hydraulically
instead of through a cable.
 DRUM BRAKES

 The drum brake has a metal

brake drum that encloses the
brake assembly at each
wheel.

 Two curved brake shoes

expand outward to slow or
stop the drum which rotates
with the wheel.
 WORKING OF DRUM BRAKES

 Drum brakes work on the same principle as the

disc brakes.

 Shoes press against a rotating surface.

 In this system that surface is called a drum.

 Drum brake also has an adjuster mechanism, an

emergency brake mechanism and lots of springs.

 The shoes are pulled away from the drum by the

springs when the brakes are released.
 DRUM BRAKE ADJUSTER

 For the drum brakes to function correctly, the

brake shoes must remain close to drum without
touching it.

 If they get too far away from the drum (as the
shoes wear down), the piston will require more
fluid to travel that distance and the brake
pedal will sink closer to the floor when we apply
brakes.

 That is why most drum brakes have an

automatic adjuster.
DISK BRAKE AND DRUM BRAKE
 SOME MORE POINTS

 Most modern cars have disc brakes on front wheels and drum brakes on
rear wheels and some wheels have disc brakes on all four wheels.

 To increase safety, most modern car brake systems are broken into two
circuits, with two wheels on each circuit.

 If a fluid leak occurs in one circuit, only two of the wheels will loose their
brakes and the car will still be able to stop when we press the break pedal.
 EMERGENCY BRAKES

 In cars with disc brakes on all four wheels, an

emergency brake has to be actuated by a
separate mechanism than the primary brakes in
case of a total primary break failure.

 Most cars use a cable to actuate the emergency

brake.

 Some cars with four wheel disc breaks have a

separate drum brake integrated into the hub of
the rear wheels.

 This drum brake is only for emergency break

system, an is actuated only by the cable. It has no
hydraulics.
 BRAKE FLUIDS

 One of the important characteristics of brake

fluid is its BOILING POINT. Hydraulic systems rely
on incompressible fluid to transmit force.

 Liquids are generally incompressible while

gases are compressible.

 If the break fluid boils (becomes a gas), it will

loose most of its ability to transmit force.

 This may partially or completely disable he

brakes.
TYPES OF BRAKE FLUIDS

DOT 3
GLYCOL BASED
(ABSORB
WATER)
DOT 4
FLUIDS

SILICON BASED
(DOESN’T DOT 5
ABSORB WATER)
 PRECAUTIONS

 As a DOT 3 or DOT 4 brake fluid absorbs water, its boiling point decreases. It
can absorb water from air, that is why we should avoid opening the car’s
brake fluid reservoir and the container of the brake fluid should be tightly
sealed.

 Also DOT 3 and DOT 4 brake fluids eat paint.

 None of the different types of brake fluids should be mixed. They can react
badly with each other and corrode the brake system.
Anti-lock Braking System

Prepared
by:
Mr. Martin
Kamande
Anti-lock Braking System

Anti-lock braking system (ABS) is

an automobile safety system
prevent the wheels of a vehicle
locking as brake pedal pressure is
applied - often suddenly in an
emergency or short stopping
distance. This enables the driver to
have steering control, preventing
skidding and loss of traction.
Anti-lock Braking System

• 1929 :- ABS was first developed for aircraft by the

French automobile and aircraft pioneer Gabriel
Voisin, as threshold braking on airplanes is nearly
impossible.
• 1936: German company Bosch is awarded a patent
an “Apparatus for preventing lock-braking of
wheels in a motor vehicle”.
• 1936-: Bosch and Mercedes-Benz partner - R&D
into ABS.
• 1972: WABCO partners with Mercedes-Benz
developing first ABS for trucks.
• 1978: First production-line installation of ABS into
Mercedes and BMW vehicles.
• 1981: 100,000 Bosch ABS installed.
• 1985: First ABS installed on US vehicles.
Anti-lock Braking System

• 1986: 1M Bosch ABS installed.

• 1987: Traction control - in conjunction with
ABS – used on passenger vehicles.
• 1989: ABS hydraulic unit combined with
standard hydraulic brake unit
• 1992: 10M Bosch ABS installed.
• 1995: Electronic Stability - in conjunction with
ABS and TCS - for passenger cars.
• 1999: 50M Bosch ABS installed.
• 2000: 6 of 10 new cars on the road are ABS
equipped.
• 2003: 100M Bosch ABS installed.
• Nowadays:- Almost all new cars have ABS.
Anti-lock Braking System

When the brake pedal is depressed during driving, the

wheel speed decreases and the vehicle speed does as
well. The decrease in the vehicle speed, however, is not
always proportional to the decrease in the wheel speed.
The non-correspondence between the wheel speed and
vehicle speed is called “slip” and the magnitude of the
slip is expressed by the “slip ratio” which is defined as
follows:
Slip ratio = (Vehicle speed – Wheel speed)/Vehicle speed × 100%
When the slip ratio is 0%, the vehicle speed corresponds
exactly to the wheel speed. When it is 100%, the wheels
are completely locking (rotating at a zero speed) while
the vehicle is moving.
See Fig 2.
Anti-lock Braking System

• Figure 2 shows the relationship between

braking co-efficient and wheel slip. It is
shown that the slide values for
stopping/traction force are proportionately
higher than the slide values for
cornering/steering force. A locked-up wheel
provides low road handling force and minimal
steering force.
Anti-lock Braking System

The main benefit from ABS operation

is to maintain directional control of
the vehicle during heavy braking in
rare circumstances
Anti-lock Braking System

Hydraulic unit. Interconnecting wiring

 Electronic brake control The ABS indicator
module (EBCM). The rear drum brake.
Two system fuses.
Four wheel speed sensors.
(1) ABS control module and
hydraulic control unit (ABSCM &
H/U).
(2) Two-way connector.
(3) Diagnosis connector.
(4) ABS warning light.
(5) Data link connector (for
SUBARU select monitor).
(6) Transmission control module
(AT models only).
(7) Tone wheels.
(8) ABS wheel speed sensor.
(9) Wheel cylinder.
(10) G sensor.
(11) Stop light switch.
(12) Master cylinder.
(13) Brake & EBD warning light.
(14) Lateral G sensor (STi).
Anti-lock Braking System

• ABS brake system are

– Integrated
• An integrated system has the master
cylinder and control valve assembly
made together.

– Nonintegrated
• A nonintegrated has the master
cylinder and control valve assembly
made separate.
Anti-lock Braking System

• ABS systems consist of 4 primary

components:
1- ABS Controller; the brains of the
system. ABS Controllers are a computer
that reads the inputs and then controls the
system to keep the wheels from locking up
and skidding.

2- ABS Speed Sensors; there are

generally one on each wheel (sometimes
they are located on the differential).
It detects a change in acceleration in the
longitudinal direction of the vehicle and
outputs it to the ABSCM as a voltage signal.
Anti-lock Braking System

3- ABS Modulator/Valves; some system

have separate valves for each wheel with a
modulator to control them. Other systems
they are combined. In either case they
work with the controller and the pump to
add or release pressure from the individual
wheels brakes to control the braking.

4- ABS Pumps; since the ABS

modulator/valves can release pressure from
the individual wheels brakes there needs to
be a way to restore the pressure when
required. That is what the ABS pumps job
is. When the pump is cycling, the driver
may experience a slight pedal
vibration. This cycling is happening many
times per second and this slight vibration is
natural.
(1) ABS control module and
hydraulic control unit
(2) ABS control module section
(3) Valve relay
(4) Motor relay
(5) Motor
(6) Front left inlet solenoid valve
(7) Front left outlet solenoid valve
(8) Front right inlet solenoid valve
(9) Front right outlet solenoid valve
(10)Rear left inlet solenoid valve
(11)Rear left outlet solenoid valve
(12)Rear right inlet solenoid valve
(13)Rear right outlet solenoid valve
(14)Automatic transmission control
Module
(15) Diagnosis connector
(16) Data link connector
(17) ABS warning light
(18) Stop light switch
(19) Stop light
(20) G sensor
(21) Front left ABS wheel speed sensor
(22) Front right ABS wheel speed sensor
(23) Rear left ABS wheel speed sensor
(24) Rear right ABS wheel speed sensor
(25) IGN
(26) Battery
(27) Brake warning light
(28) Parking brake warning light
(29) Brake fluid level switch
(30) Lateral G sensor (STi)
(31) Driver-controllable center differential
control unit
Anti-lock Braking System

Figure 3. ABS Operating Diagram

We will discuss how one of the simpler system works.

 Sensors at each of the four wheels  sense the rotation of the wheel.
 Too much brake application  wheel stop rotating
 Sensors  ECU  releases brake line pressure  wheel turns
again.
 then ECU applies pressure again  stops the rotation of the wheel
releases it again and so on
NB:
 This releasing and re-application or pulsing of brake pressure
happens 20-30 times per second or more.
 This keeps the wheel just at the limit before locking up and
skidding no matter
 ABS system can maintain extremely high static pressure and must be
disabled before attempting repairs.
Anti-lock Braking System

• Solenoid Valve Assembly:

Is a pair of valves that can:

A. Increase pressure

B. Hold pressure steady

C. Decrease pressure
A. Increase pressure During pressure increase
mode of operation fluid is
allowed to flow through
Solenoid 1 both solenoids to the brake
caliper
Pressure increase

Solenoid 2
Pressure decrease/Vent
solenoid

Brake line under pressure

Brake fluid line not under pressure

B. Hold pressure steady During Pressure Hold
mode of operation both
solenoids are closed and
Solenoid 1 no additional fluid is
Pressure increase allowed to flow to brake
calipers.

Solenoid 2
Pressure decrease/Vent
C. Decrease pressure During Pressure Vent mode
the pressure increase solenoid
is closed. The Vent solenoid
Solenoid 1 opens allowing fluid to vent
Pressure increase into an accumulator chamber

Solenoid 2
Pressure decrease/Vent
Anti-lock Braking System

• Figure 4. ABS Block Diagram

Anti-lock Braking System

• ABS brakes are either

 1 Channel
 3 Channel
 4 Channel
Anti-lock Braking System

One-channel, one-sensor ABS

This system is commonly found on
pickup trucks with rear-wheel ABS. It
has one valve, which controls both
rear wheels, and one speed sensor,
located in the rear axle.
Anti-lock Braking System

 Three-channel, three-sensor ABS

This scheme, commonly found on pickup
trucks with four-wheel ABS, has a speed
sensor and a valve for each of the front
wheels, with one valve and one sensor for
both rear wheels. The speed sensor for
the rear wheels is located in the rear axle.
Anti-lock Braking System

 Four-channel, four-sensor ABS

This is the best scheme. There is a speed
sensor on all four wheels and a separate
valve for all four wheels. With this setup,
the controller monitors each wheel
individually to make sure it is achieving
maximum braking force.
Anti-lock Braking System

Configurations of ABS Types

Anti-lock Braking System

Figure 5.
Depending on the ABS application, there are
several typical layouts.
Anti-lock Braking System

• Advantages:

1. It allows the driver to maintain directional stability

and control over steering during braking

2. Safe and effective

3. Automatically changes the brake fluid pressure at

each wheel to maintain optimum brake performance.

4. ABS absorbs the unwanted turbulence shock waves

and modulates the pulses thus permitting the wheel
to continue turning under maximum braking pressure
 • Disadvantages
Anti-lock Braking System

1. Stop Times - Anti-lock brakes are made

to provide for surer braking in slippery
conditions. However, some drivers
report that they find the stopping
distances for regular conditions are
lengthened by their ABS system, either
because there may be errors in the
system, or because noise of the ABS
may contribute to the driver not braking
at the same rate.

1. Delicate Systems - It's easy to cause a

problem in an ABS system by messing
around with the brakes. Problems
include disorientation of the ABS
system, where a compensating brake
sensor causes the vehicle to shudder,
make loud noise or generally brake
worse.
Anti-lock Braking System

3. Cost - An ABS can be expensive

to maintain. Expensive sensors on
each wheel can cost hundreds of
dollars to fix if they get out of
calibration or develop other
problems. For some, this is a big
reason to decline an ABS in a
vehicle.

4. System damage - A variety of

factors can cause the system to
be less effective, and can present
with everything from shuddering of
the vehicle to loud noises while
trying to stop
Anti-lock Braking System

Problems with ABS

The sensors on the wheels might get
contaminated by metallic dust. When this
condition occurs the sensors become less
efficient in picking up problems. In modern
ABS systems, two more sensors are added
to help:
 wheel angle sensor,
 gyroscopic sensor
Anti-lock Braking System

The idea behind this is that when the

gyroscopic sensor detects that the car’s
direction is not the same as what the wheel
sensor reports, the ABS software will cut in to
brake the necessary wheel in order to help
the car go the direction the driver intends.
Anti-lock Braking System

The antilock braking system controls

braking force by controlling the hydraulic
pressure of the braking system, so that the
wheels do not lock during braking.

The antilock braking system prevents

wheels locking or skidding, no matter how
hard brakes are applied, or how slippery the
road surface. Steering stays under control
and stopping distances are generally
reduced.
 oWhat is ABS?
Anti-lock Braking System

oWhy is that important?

oHow do I know whether my vehicle has ABS?

oWill I notice anything when the ABS is working or not?

oDoes ABS change the way I should use the brakes?

oHow does ABS work?

oDo cars with ABS stop more quickly than cars without?

oAre all antilock systems the same?

oHow can I familiarize myself with ABS?