Unit 2 Suspension & Brakes System

Prof. Praveen P. Rathod

[email protected]
Department of Mechanical Engineering

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
Teaching Scheme: Credits:
TH: -- 03 hrs/week
TH:--03

PR.: - 02 hr/week OR:-- 01

Examination Scheme:
Insem-30
Endsem-30
CE-20
Competency Skill: -20
3/29/23
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 Suspension System
Introduction:
• The automobile frame and body are mounted on the front
and rear axle not directly but through the springs and shock
absorbers.
• The assembly of parts, which perform the isolation of parts
from the road shocks, may be in the forms of bounce, pitch
and roll is called suspension system.
Note:
• suspension system consists of a spring and damper.
• The energy of road shock causes the spring to oscillate.
• These oscillations are restricted to a reasonable level by the
damper, which is more commonly called as shock
absorbers.

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 Vehicle Axis system

Rotations:
– A roll rotation about x-axis
– A pitch rotation about y-axis.
– A yaw rotation about z-axis.

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• Basic suspension movements:
1.Bouncing: The vertical movement of the complete
body.
2.Pitching: The rotating movement of all the parts
between the spring and road and the portion of spring
weight itself.
3.Rolling: The movement about longitudinal axis
produced by the centrifugal force during cornering.

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 Functions of suspension system
1.It prevents the vehicle body and frame from road
shocks.
2. It gives stability of the vehicle.
3.It safeguards the passengers and goods from road
shocks.
4.It gives the good road holding while driving,
cornering and braking.
5. It gives cushioning effect.
6. It provides comfort.

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SUSPENSION SYSTEM – LAY OUT

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 Requirements of suspension system

1. There should be minimum deflection.

2. It should be of low initial cost.
3. It should be of minimum weight.
4.It should have low maintenance and low
operating cost.
5. It should have minimum tyre wear.

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 VEHICLE MASS
• SPRUNG MASS
• UNSPRUNG MASS

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SPRUNG MASS AND UNSPRUNG MASS

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 SPRUNG MASS
• In a vehicle with a suspension, such as an automobile,
motorcycle or a tank, sprung mass (or sprung weight) is the
portion of the vehicle's total mass that is supported above
the suspension.
• The sprung weight typically includes the body, frame, the
internal components, passengers, and cargo.
• It does not include the mass of the components suspended
below the suspension components (including the wheels,
wheel bearings, brake rotors, callipers)

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 UNSPRUNG MASS
• In a ground vehicle with a suspension, the unsprung
weight (or the unsprung mass) is the mass of the
suspension, wheels or tracks (as applicable), and
other components directly connected to them, rather
than supported by the suspension.
• Unsprung weight includes the mass of components
such as the wheel axles, wheel bearings, wheel hubs,
tires, and a portion of the weight of driveshafts,
springs, shock absorbers, and suspension links.

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Department of Mechanical Engineering, VIIT , Pune-48
 LEAF SPRINGS

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• Leaf springs are formed by bending.
• They are made of long strips of steel.
• Each strip is named as Leaf.
• The long leaf is called Master Leaf, and it consists of eyes at
its both ends.
• One end is fixed to the chassis frame, the other end is fixed
to the shackle spring.
• The spring will get elongated during expansion and
shortened
during compression.
• This change in length of spring is compensated by the
shackle.
• The U-bolt and clamps are located at the intermediate
position of the spring.
• The bronze or rubber bushes are provided on both eyes on
the master leaf. of Mechanical Engineering, VIIT , Pune-48
Department
MATERIAL FOR LEAF SPRING

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 Types of Leaf Springs
There are six types of leaf springs
• Full – elliptic type
• Semi – elliptic type
• Quarter – elliptic type
• Three Quarter – elliptic type
• Transverse Spring type
• Helper Spring type

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Department of Mechanical Engineering, VIIT , Pune-48
 Semi-elliptical Springs

• Semi-elliptical springs are usually used in all the vehicle. Particularly in trucks, semi-
elliptical springs are fitted in front and rear axles.

• Semi-elliptical springs are cheaper and require less repairing. They increase the
range of spring action and last for a long time.

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 Quarter-elliptical Spring

Quarter-elliptical springs were used in old small cars, like Chrysler cars.
This type of spring consists only a quarter portion of the full elliptical
spring and fitted with the frame by the bolt.

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 Three quarter elliptical Spring

Three quarter elliptical spring is the combination of semi-elliptical

and quarter elliptical springs. This types of springs was used in old
cars.

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 Transverse Spring

Transverse spring in just like the semi-elliptical spring but inverted in

shape. One end of the spring in joined with chassis frame by shackle,
and the other end with the axle. It is also fixed with frame by the bolts
at the center.

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 Full-elliptical Spring

• Full elliptical springs are consists of two semi-elliptical springs

joined together oppositely.

• This type of spring was used in old cars. They do not maintain
correct axle alignment.

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 Helper Spring

• Helper spring is just like a semi-elliptical spring but without eyes at the
ends.

• It is fitted with the main springs particularly on the rear axle of the truck to
carry the heavy load.

• The ends of the helper spring touch the brackets fitted on the frame when
the truck is heavily loaded.

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 COIL SPRING

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Department of Mechanical Engineering, VIIT , Pune-48
• The coil springs are mainly used in independent
suspension, though they have been also used in
conventional rigid axle suspension.
• They can be accommodated in restricted spaces.
• The energy stored per unit volume is almost double in coil
spring than the leaf spring.
• Coil spring do not have noise problem nor do they have
static friction.
• Spring takes shear as well as bending stresses.
• A helper coil spring also sometimes used to provide
progressive stiffness against increasing load.
• It can not take side thrust and torsional load so that
alternative arrangement is used there.

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 Suspension System
Basic Parts:
Control Arm:- movable lever
that fastens the steering knuckle
to the vehicle’s body or frame.

Steering Knuckle:– provides a

spindle or bearing support for the
wheel hub, bearings and wheel
assembly.

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 Suspension System
Basic Parts:
Ball Joints:– joints that
allow control arm and
steering knuckle to move up
and down and side to side. It
is spherical bearing.
Springs:– supports the weight
of the vehicle; permits the
control arm and Wheel to move
up and down.

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 Suspension System
Basic Parts: Shock
absorbers or
dampeners:- keeps the
suspension from continuing
to bounce after spring
compression and extension.

Control arm bushing :–

sleeves that allows the control
arm to swing up and down on the
frame.
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RUBBER SPRINGS

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Department of Mechanical Engineering, VIIT , Pune-48
 TORSION BAR

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• Torsion bar suspension is used in independent suspension
system.
• It is a rod acting in torsion and taking shear stresses only.
• It is made up of heat treated alloy spring steel.
• This bar stores amount of energy nearly as same as coil
spring.
• The bar is fixed at one end to the frame, while the other end
is fixed to the end of the wheel arm and supported in the
bearing.
• The other end of the wheel arm connected to the wheel hub.
• When the wheel strikes a bump, it starts vibrating up and
down, thus exerting torque on the torsion bar which acts as
a spring.

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 SHOCK ABSORBERS

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• Shock absorbers - controls unwanted
spring motion through dampening
– compression cycle
– extension cycle
• Without shock absorbers, the vehicle would continue
to bounce up and down long after striking dip or hump
in the road.
• Hydraulic Shock absorber
• Gas pressurized shock absorber- Nitrogen gas

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 Shock absorbers
•A shock absorber is a mechanical device designed to smooth
out or damp shock impulse, and dissipate kinetic energy.

•Limits spring compression-

extension movements to
smooth the vehicle’s ride.

•Without shock absorbers,

the vehicle would continue to
bounce up and down long
after striking dip or hump in
the road.
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 Sway Bar (Stabilizer Bar)

• Used to keep the body from leaning excessively in

sharp turns.
•Fastened to lower control arms.
•During cornering, centrifugal force makes the outside of
body drop and inside raise.
• Their purpose in life is to try to keep the car's body
from "rolling" in a sharp turn.
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 Air Suspension
Air suspension:- Air
Suspension is a type of
vehicle suspension powered by
an electric or engine driven air Pneumatic Spring On Semitrailer
pump or compressor. This
compressor pumps the air into
a flexible bellows, usually made
from textile-reinforced rubber.
This in turn inflates the bellows,
and raises the chassis from the
axle.

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 Advantages:-
•These maintain a constant frequency of vibration whether
the vehicle is laden or unladen.
•Constant frame height is maintained.
•It helps to reduce the load while the vehicle in motion i.e.
the dynamic loading as the spring rate variation between
laden and unladen weight is much less.
•It gives smooth and comfort ride of the vehicle.
•The stiffness of the system increases with the increase of the
deflection.

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Common Air Suspension Problems:-
• Air bag or air strut failure
-due to old age, or moisture within the air system that
damages them from the inside.
• Compressor failure
- Primarily due to leaking air springs or air struts
-Compressor burnout may also be caused by
moisture from within the air system coming into contact
with its electronic parts.
• Dryer failure
-which functions to remove moisture from the air
system eventually becomes saturated and unable to
perform that function
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 HYDRO-ELASTIC SUSPENSION
Hydrolastic is a type of space-efficient automotive suspension system used in many cars
produced by British Motor Corporation (BMC) and its successor companies.

• Cars using the Hydrolastic suspension system

• BMC 1100
• Mini (from 1964 to 1971)
• Austin America (from 1968 to 1971)
• Austin 1800
• Austin Maxi (until March 1978)
• Austin 3-Litre
• MG 1100 (from 1962 to 1968)
• Morris 1500
• Morris 2200

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 HYDRO-ELASTIC SUSPENSION

Hydraulic or Hydro-elastic suspension:

• The main component of the hydraulic suspension is the displacer unit, which is attached to
the individual wheels of the vehicle.

The displacer unit consists of two chambers.

• Chamber A is just above the flexible diaphragm and the other B
is above the separating member and connected by the other displacers
by a hose pipe.
• The stem is usually connected to
the lower link of the double wishbone.
• The diaphragm is connected with the piston and bears the wheel load.

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• The fluid in chamber A can all the time pass into the chamber B through the bleed holes
provided in the separating member.

• When the pressure of liquid in B rises sufficiently above that in A, then the rubber flap
valve which is loaded by the spring will open downwards thus allowing the fluid to pass from
B to A through the holes.

• Similarly to pass the fluid from A to B the damper valve functions accordingly.

• The fluid in B acts on the under side of the rubber element and through the hose pipe is
transmitted to the other wheel unit.

• The Canister Displacer unit in Hydraulic suspension is provided at the outside of the
rubber element, while the pot member at inside.

• The canister is fixed to the body structure of the vehicle.

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Non-independent suspension:- It has both right and
left wheel attached to the same solid axle. When one
wheel hits a bump in the road, its upward movement
causes a slight tilt of the other wheel.
Independent suspension:- Independent suspension is a
broad term for any automobile suspension system that allows
each wheel on the same axle to move vertically
independently of each other

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 Non-
Independent
suspension

Independent
Suspension

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Double Wishbone Suspension
With Unequal Length Upper and Lower Arms

Found On:
-Stock Cars (Front)
-Corvettes (C5 &C6) (Front
and Rear)
-Honda Civics (‘88-’00)
(Front)
-Most Modern Sports Cars

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 Advantages

Arguably the best handling suspension design

• Wheel gains negative camber in bump
• Low Unsprung Weight
Packaging does not compromise styling
• Low Height
Many different geometry characteristics possible
• Designer can design suspension with minimal
compromises
• Infinite adjustability, with the most ease
• Vehicles roll centers can be placed almost
anywhere

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 Disadvantages
More expensive
• More components to make and assemble
• Alignment and fitment are critical to vehicle performance, large area of
adjustment
• Tolerance of parts must be smaller
• Requires constant alignment checks for optimum performance
More complex
• Design often becomes more complex because all suspension parameters
are variable
• Frame has to be able to pick up a-arm inboard points
Tire scrub occurs with vertical wheel displacement
• However this can be minimized during design

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Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Suspension Types: MacPherson Strut

Invented by Earl S.
MacPherson
First used on the 1951 Ford
Consul
Ford held the patent for the
Macpherson strut system
by many rival companies
invented similar systems to
avoid Ford royalties

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Suspension Types: MacPherson Strut

Advantages
Low production costs
Stamped construction
Preassembled
Strut body carries spring assembly
Compact
Simple mounting and no need for an
upper control arm
Simplicity
Reduction in fasteners and alignment of
vehicle suspension components.

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 Suspension Types: McPherson Strut

Disadvantages
Large camber variation
Body roll and wheel movement
contribute to camber attitude
Vertically tall mounting position
This compromises vehicle styling
Rough ride
Some ride comfort may be lost, as it
is hard to move smoothly because of
bending input force
Dangerous replacement
The spring must be compressed and
assembled on the strut body, this
causes the handling of a charged
spring.

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 Independent suspension
front and rear
Advantages:
• Better Handling and Cornering
• Better Stability and Steering
• More Ride Comfort
• Lower Weight

Disadvantages
• Complex Design
• More Maintenance Cost
• More Wear and Tear
• Less Overall Strength

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 Brakes
• Brake is a device used for slowing ,stopping & controlling
the vehicle.

• Braking operation based on kinetic energy of vehicle is

to converting into heat, which dissipated into
atmosphere.

• While driving the vehicle, torque of the engine produces

The
tractive effort due to periphery of driving vehicle.

• When the brakes are applied it produces negative

tractive effort on wheel.

• While, this help to slow down an vehicle

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 Main functions of braking system
• To stop the vehicle
safely in shortest
possible distance
in case of
emergency.
• To control the vehicle
when it is
descending along the
hills.
• To keep the vehicle in
desired position after
bringing in at rest.

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 HYDRAULIC BRAKING
SYSYTEM

construction
hydraulic braking system is mainly confined with “brake fluid” this fluid consist
of Alcohol,castor oil & glycerin.hydraulic braking system has following
components.
master cylinder,brake pedal,wheel cylinder,brake drum,retracting spring,brake
shoe etc.
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 Working System
The brake pedal is connected to the master cylinder
by means of piston for application of brake driver
presses the brake pedal, which moves the master
cylinder.
In master cylinder pressure is instantly transferred to
all four wheels. The brakes shoe moves against the
brake drum to apply brakes.
When driver releases the brake pedal, the master
cylinder piston returns to its original position due to
return springs, dropping fluid pressure. Brake shoe
retracting spring pulls the brake shoe from drum to
their original position & brakes are released.
ROLE OF MASTER CYLINDER:

TO BUILD THE hydraulic pressure required to

operate the system.
To bleed or force air out of brake line & wheel
cylinder.
A to act reservoir to maintain a constant
volume of
fluid in system
ADVANTAGES OF HYDRAULIC BRAKE

simple in construction :Mechanical joints, linkages &

cam are eliminated.
Equal braking system: the brake fluid must exists
equal pressure.
Disadvantages of Hydraulic Brake

Fails whole system at one time: if there is leakages in

system, all four brakes are fail at one time due to loss
of fluid pressure. This difficulty can be eliminated
with use of tendum master cylinder
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Pneumatic Braking System

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 CONSTRUCTON
Pneumatic BRAKES ARE OPERATED BY MEAns of Air pressure engine to air
and stores in air reservoir.the compressed air enters in wheel cylinder to
push diaphragm
The pneumatic braking system consists as :
Air compressor, unloader valve, resevoir, brake valve, brake chamber
,quick release valve, Relay valve etc.

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 Working of Pneumatic
Braking System
Air Compresor
Its composes of generally Build the
air pressureby driven of engine.

UNLOADER VALVE:
ITS IS DEVICE MAINTAIN CONSTANT
PRESSURE IN RESERVOIR.the excess of
pressure is safely removed.

Reservoir:
it’s a tank in which high
pressure air is stored

Brake Valve:
its is located between air
reservoir and brake cylinder
RELAY VALVE:
IT IS VALVE KEPT IN BETWEEN
BRAKE CHAMBER & AIR CHAMBER FOR
CONTROLLING THE AIR CHAMBER

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 Mechanical Braking
System

Classification
Mechanical Braking System, brakes are available in following construction
1.Drum type 2.Disc type
Drum type Brake
There are generally of two types Internal
expanding drum brake.
External expanding drum brake.

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 Internal Expanding Brake Drum

Construction.
In Internal Expanding Drum
Brake consist of leading shoe,
anchor, adjustor, Heel of shoe,
trailing shoe, brake retracting
spring brake shoe, brake
shoe,toe shoe etc.
In internal expansion b raking
system brake liners are expands
internally
Its consist of stationary
plate,two shoes hinged at
anchor pins, and cam system to
expand the shoe and a retracting
spring.

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 Working system of internal braking system

Internal expanding braking

system consist of brake linings
are fixed at outsides when brakes
are applied the cam is turned, the
shoe with brake lining are forced
against the Drum.
This Causes brake lining creates
friction between the rotating drum
and expanding shoes.
This force of friction opposes
the rotating drum, thereby will
leads to slowing down the
vehicle.
When brake is released
Retracting springs brings the
shoe back towards its original
position.
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External contracting brake
drum

Construction
IN external contracting brake drum has brake drum is used for only parking
purpose .this system consist of Drum, brake & lining, operating lever with
adjusting lever and push rod with returning spring.
External braking system is model braking system used to operate in floor mills,
various types of electrical components.

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 Disc Type
Brake

CONSTRUCTION
DISC Brake consist of cat iron disc bolted to the wheel hub and an
stationary housing called “caliper”. The caliper is connected with
some stationary part of position of vehicle, like stub or axle on of
wheel of connecting rod .
The piston rod is connected in between which has friction pad is being
held by an piston pins, springs etc.

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 Working of Disc
brake
The brakes are operated when friction is being
created on friction pads by forced applying on
it against the disc .the forces created on its is
hydraulic pressure from master cylinder,
thereby an engaging the braking system.
When the hydraulic braking pressure is applied
on piston will engaged an released bar due
to pressure.
When pressure is released piston will regain
its
original position. Here friction pad works on
main fundamental working process.
“CALIPER “ is added on system to
balanced
two calipers by diagrammatically opposite
to
each to other. In this way braking torque is
reduced.
Advantages of Disc Brake
Better heat dissipation as braking torque on surface of exposed
air.
Adjustment of pads is automatic
Renewal of pad is quick and easy.
Disadvantages of
Disc Brake.
In comparison of brake drum of
similar capacity, rate pad wear is
more.
The HAND BRAKE MECHANISM
IS NOT SO CONVINENT.

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Department of Mechanical Engineering, VIIT , Pune-48
 Antilock Braking System
SOURCE: Internet

Anti-lock braking system (ABS) is an automobile safety system that allows the
wheels on a motor vehicle to maintain tractive contact with the road surface according to
driver inputs while braking, preventing the wheels from locking up (ceasing rotation) and
avoiding uncontrolled skidding. It is an automated system that uses the principles of threshold
braking and cadence braking which were practiced by skillful drivers with previous
generation braking systems. It does this at a much faster rate and with better control than a
driver could manage

ABS generally offers improved vehicle control and decreases stopping distances on dry
and slippery surfaces for many drivers; however, on loose surfaces like gravel or snow-
covered pavement, ABS can significantly increase braking distance, although still improving
vehicle control.
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 Construction of Anti Braking System
There are four main components of ABS: speed
sensors, valves, a pump, and a 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
– When the ABS system operates the brake lines lose
pressure. The pump re-pressurizes the system.
Controller
– The controller is an ECU type unit in the car which
receives information from each individual wheel speed
sensor, in turn if a wheel loses traction the signal is sent
to the controller, the controller will then limit the
brakeforce (EBD) and activate the ABS modulator which
actuates the braking valves on and off.
 Working of Anti Braking System
The anti-lock brake controller is also known as
the CAB (Controller Anti-lock Brake).

Typically ABS includes a central electronic control unit

(ECU), four wheel speed sensors, and at least two
hydraulic valves within the brake hydraulics. The ECU
constantly monitors the rotational speed of each wheel;
if it detects a wheel rotating significantly slower than
the others, a condition indicative of impending wheel
lock, it actuates the valves to reduce hydraulic pressure
to the brake at the affected wheel, thus reducing the
braking force on that wheel; the wheel then turns faster.
Conversely, if the ECU detects a wheel turning
significantly faster than the others, brake hydraulic
pressure to the wheel is increased so the braking force
is reapplied, slowing down the wheel. This process is
repeated continuously and can be detected by the driver
via brake pedal pulsation. Some anti-lock systems can
apply or release braking pressure 15 times per second.
Because of this, the wheels of cars equipped with
ABS are practically impossible to lock even during
panic braking in extreme conditions

Modern ABS applies individual brake pressure to all four wheels

through a control system of hub-mounted sensors and a dedicated
micro-controller. ABS is offered or comes standard on most road
vehicles produced today and is the foundation for electronic
stability control systems, which are rapidly increasing in
popularity due to the vast reduction in price of vehicle electronics
over the years
 Hand Brake/ Parking Brake
• In road vehicles, the parking brake, also called hand brake,
emergency brake, or e-brake, is used to keep the vehicle
stationary and in many cases also perform an emergency stop.
• Parking brakes on older vehicles often consist of a cable
connected to two wheel brakes at one end and the other end
to a pulling mechanism which is operated with the driver's
hand or foot.
• In the more-traditional "cable-pulling" type, an electric motor
simply pulls the emergency brake cable on the push or pull
of a button rather than a mechanical pedal or handle in the
cabin.