AUTOMOTIVE BRAKE SYSTEM

Introduction
The braking system is the most important system in your car. If your brakes fail, the result can be
disastrous. Brakes are actually energy conversion devices, which convert the kinetic energy (momentum)
of your vehicle into thermal energy (heat). It is used for slowing or stopping a moving vehicle, wheel,
axle, or to prevent its motion, most often accomplished by means of friction.
TYPES OF BRAKE SYSTEM
MECHANICAL BRAKE
 The mechanical brake is used in small power automobiles like scooters, motorcycles, and
some modern vehicles.
 Mechanical brakes are assemblies consisting of mechanical elements for the slowing or
stopping of shafts in equipment drives. They use levers or linkages to transmit force from one
point to another.
Types of Mechanical Brake:

 DRUM BRAKE – is a brake that uses friction caused by a set of shoes or pads that press
outward against a rotating cylinder-shaped part called a brake drum. Drum brakes are
primarily used at the rear axle of small and compact class vehicles. The term drum brake
describes the design principle: namely, an enclosed cylindrical structure.

DRUM BRAKE COMPONENTS:

a) Backing plate: Provides a solid base for other components in the drum brake
attached to the axle sleeve.
b) Brake drum: Bolted to the wheel hub and spins with the wheel. Often made of cast
iron, and is resistant to heat and wear. This is what you see when you look at an
assembled drum brake and is the component upon which braking force is applied to
slow or stop the car.
c) Wheel cylinder: Contains two pistons, one at each end of the cylinder, to operate the
brake shoes. The cylinder applies pressure to the pistons, which pushes the brake
shoes towards the drum, slowing or stopping the car. One cylinder is needed per
wheel.
d) Brake shoe: Pushes into the drum to create the friction necessary to slow or stop the
car. Secured to the backing, but able to slide when pressure from the wheel cylinder is
applied. It has a lining attached to it, made up of organic or metallic compounds. The
lining is what actually comes in contact with the drum and wears away with use. Each
brake contains two shoes. The primary shoe is closer to the front of the vehicle, while
the secondary shoe is closer to the rear. Depending on the type and brand, the brake
shoes may be interchangeable.
e) Automatic adjuster: Keeps the brake shoes at a consistent distance away from the
drum, even as the lining wears away.
f) Return springs: Pulls the brake shoes back away from the drum when the driver lets
off the brake pedal.
  DISC BRAKE - 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 COMPONENTS:
a) Rotor: Circular disc bolted to the wheel hub that spins with the wheel.
Rotors are most commonly made of cast iron or steel, however some very
high-end cars use a carbon ceramic rotor. Rotors can be slotted or drilled
for better heat dissipation.
b) Brake pads: Component that pushes into the rotor, creating the friction
that slows and stops a car. They feature a metal portion called a shoe and a
lining that is attached to the shoe. The lining is what actually comes in
contact with the rotor and wears away with use.
c) Piston: The piston is what moves the brake pads into the rotor when the
driver presses the brake pedal. Some brake systems have a single piston
that moves both pads, while others have two pistons that push the brake
pads from each side of the rotor.
d) Caliper: Housing that fits over the rotor and holds the brake pads and
pistons, as well as contains ducting for brake fluid.
e) Sensors: Some vehicles have brakes that contain sensors embedded in the
brake pads which work to tell the driver when the pads are worn out.

HYDRAULIC BRAKE
 Brake system in which a brake pedal moves a piston in the master cylinder; brake fluid
then applies great force to the brake pads or shoes.
 The pressure on a liquid is called HYDRAULIC PRESSURE.
 It works based on PASCAL’S LAW.
 Pascal’s law is that 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.
Main Components of Hydraulic Brake:
 Master Cylinder - is a hydraulic device in which cylinder and one or two pistons
are arranged in such a manner that the mechanical force applied by the driver of a
vehicle either by brake pedal (in cars) or by brake lever (in bikes) is converted
into hydraulic pressure which in turn transferred to the brake caliper for braking.
- is the heart of the hydraulic brake system.
Types of Master Cylinder:
1. Single Circuit Master Cylinder
 It is the simple type of master cylinder just like a medical syringe, in
this type of master cylinder single piston inside a cylinder is used to
cause braking.
 Single circuit master cylinder distributes equal force in all the wheels
due to the use of single cylinder single piston or circuit.
 commonly used in many 2 wheelers and some light weight 4 wheelers
 Construction:
 Reservoir. It is the storage tank used for storing the brake
fluid in hydraulic type of braking system, usually it is made
up of plastic.
 Cylinder. It is the air tight housing inside which the piston
moves with the moment of brake pedal which in turn
causes conversion and multiplication of force. Cylinder is
usually made up of cast iron or aluminum. It is connected
with the reservoir through inlet valve and also with brake
lines through outlet valve. There is only 1 compression
chamber.
 Piston. It is the reciprocating part of the master cylinder
that reciprocates inside the cylinder due to the movement of
brake pedal, the piston causes compression of brake fluid
inside the cylinder which in turn generates high hydraulic
pressure.
 Returning spring. It is the simple coil type of spring used
inside the cylinder which helps the piston and brake pedal
to retain its original position after brake pedal is released.
 Valve. In single circuit master cylinder, it is the outlet
valve through which the brake line is attached. The
compressed brake fluid is further transferred to the caliper
through this valve.
2. Tandem Master Cylinder or Dual Circuit Master Cylinder
 It is the modified type of master cylinder in which dual cylinder-dual
piston or single cylinder dual piston along with dual circuit is used for
independent braking between front and rear wheels.
 This type of master cylinder is used in almost all cars as it is more
efficient than single circuit master cylinder.
 It provides the independency between front and rear wheels braking or
diagonal type of braking which is the important safety feature for a
vehicle.
 Construction:
 Reservoir. Instead of single reservoir, 2 or dual chamber
reservoir is used as a storage tank for brake fluid.
 Cylinder. Same cylinder as in single circuit type is used with
the little modification i.e. it is the housing of 2 pistons and also
there are 2 outlet and 2 inlet valves. 2 compression chambers
inside the cylinder.
 Piston. Instead of one piston, 2 pistons that are primary piston
and secondary piston are used. The actuation of secondary
piston occurs after completion of the primary piston
movement. Primary piston is connected to the brake pedal and
secondary piston is placed just behind the returning spring of
primary piston.
 Return spring. 2 returning springs are used, one with the
primary piston and second with the secondary piston.
  Valve. 2 inlet and 2 outlet valves are used.
 It is widely used in almost all the cars equipped with hydraulic braking
system.
 Using tandem master cylinder in vehicle equipped with hydraulic
braking system is made compulsory by governments of many
countries because of its safety to brake failure.

POWER BRAKE
 Power-assisted brakes are also referred to, by some, as power brakes.
 Power-assisted brakes are designed to use the power of the engine and/or battery to increase
braking power. Power assisted brakes can use hydraulic, vacuum, air pressure or gearbox-
drive assistance to reduce the driver’s pedal effort.

 AIR BRAKE - are applied by the pressure of compressed air. Air pressure
applies forces on brake shoes through suitable linkage to operate brakes. An air
compressor is used to compress air. This compressor is run by engine power.
 AIR-HYDRAULIC BRAKE - Is an arrangement of braking mechanism which
uses brake fluid, typically containing glycol ethers or diethylene glycol, to
transfer pressure from the controlling mechanism to the braking mechanism.
 VACUUM BRAKE. The vacuum brake system derives its brake force from the
atmospheric pressure acting on lower side of piston while a vacuum is maintained
above the piston. The vacuum is created in the system by exhauster provided in
the locomotive. Vacuum Brake application takes place when vacuum is destroyed
by allowing air to enter to the system.
 ELECTRIC BRAKE. In Electric brakes an electromagnet is used to actuate a
cam to expand the brake shoes. The electromagnet is energized by the current
flowing from the battery. When the current flow is stopped the cam and brake
shoes return to their original position and Brakes are disengaged. “Electric Brakes
are not used in automobiles as service brakes”.

COMBINED BRAKE SYSTEM

 A combined braking system (CBS), also called linked braking system (LBS), is a system for
linking front and rear brakes on a motorcycle or scooter.
 In this system, the rider's action of depressing one of the brake levers applies both front and rear
brakes. The amount of each brake applied may be determined by a proportional control valve.
 This is distinct from integrated brakes, where applying pressure to the rear brake pedal only
applies some braking force to the front brake.
 One front brake caliper was connected to a secondary master cylinder, and the caliper was
allowed to rotate slightly to apply pressure to the piston in that secondary master.
 Combi-Brake system helps in achieving easier operation while braking. When the rider presses
the rear brake lever, it activates both front and rear brakes simultaneously. This helps in safer
braking and better control of the bike.

ADVANTAGES:
  Safety: It is relatively good and safe than the regular bike braking system. It helps to
maintain the balance of the bike during brake.
 Availability: The price of this braking systems price is comparatively low and easy to use
for regular bikes.
 Braking Distance: It reduces bike braking distances compared to regular brakes and its help
to prevent accident in sudden braking.
 Slippery Surface: CBS gives better performance in slippery and rough road conditions and
provides safe braking.

DISADVANTAGES:

 CBS braking does not cause any inconvenience for motorbike. If the riders follow the
following rules for bad road surfaces, then it is possible to avoid the accident.
 Whenever there is need a sudden or necessary brake, then press both the front and rear brakes
together.
 Avoid abrupt/ excessive brake in slippery and rough road.

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 lose their brakes and the car will
still be able to stop when we press the brake pedal.

EMERGENCY BRAKE

 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 brake failure.
 Most cars use a cable to actuate the emergency brake.
 Some cars with four wheel disc brakes have a separate drum brake integrated into the hub of the
rear wheels.
 This drum brake is only for emergency brake system, and is actuated only by the cable. It has no
hydraulics.

BRAKE FLUID

 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 brake fluid boils (becomes a gas), it will lose most of its ability to transmit force.
 This may partially or completely disable the brakes.
 Use the one recommended by the manufacturer.
 • DOT3 and DOT4 – glycol based (absorb water)

• DOT5 – silicon based (does not 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.

The DOT part refers to the U.S. Department of Transportation, which issues detailed standards
for all motor vehicle brake fluids in the country.

References:

https://www.yourmechanic.com/article/how-disc-brakes-work
https://www.mechanicalbooster.com/2018/05/what-is-master-cylinder.html
https://learnmechanical.com/brake-system/
https://www.privatefleet.com.au/glossary/what-is-powerassisted-braking/
https://www.britannica.com/technology/air-brake