Professional Documents
Culture Documents
Fundamental of Braking
• Wheel braking torque requirements (related to car weight, tyre type, etc.): Adjust
braking capacity using pedal and hydraulic mechanical advantage, pad material,
rotor size, etc.
• Wheel torque = braking torque at the point where the wheel locks
Mechanical Brakes
•Drum Brakes
Hydraulic Brakes
•Drum Brakes
•Disc Brakes
Power Brakes
•Pneumatic Brakes
•Vaccum Brakes
•Electric Brakes
Typical Layout of System
Motorsport ChassisDrum Brakes
Design and Dynamics
• Leading-trailing brake
• Non-servo brake with anchor at bottom end of each shoe
WORKING OF DRUM BRAKES
• The shoes are pulled away from the drum by the springs
when the brakes are released.
Drum Brake Adjustment
• Brakes wear: clearance increases between lining and drum
• Typical drum brake adjust has threaded shaft attached to integral
starwheel
• Dual-servo self-adjusters operate when brakes are applied during a
stop when backing up
• Brake fade: results with excessive brake heat
• Drum brakes do not dissipate heat as well as disc brakes
• Increased heat causes drum to expand
• More effort required to stop the car
DISC BRAKE
• Disc brakes create braking power by forcing flat friction pads against
sides of rotating disc
Continued…
• Higher applied forces can be used in disc brakes than in drum brakes,
because the design of the rotor is stronger than the design of the
drum.
• Rotor
• Caliper
• Brake pads
Disc Brake System
• Pushrods transfer force through brake booster.
• Advantages
• Self-adjusting
• Easier to service
Disc Brake System
• Disadvantages
• Not self-energizing
O-rings. A. Square cut O-ring and O-ring cut to show square section.
B. Square cut O-ring groove in caliper.
Disc Brake Calipers
• Sliding calipers slide in the caliper mount and are held in place
by a spring steel clip.
Disc Brake Pads and Friction
Materials
• Coefficient of friction
• NAO materials
• Semimetallic materials
• Ceramic materials
Disc Brake Pads and Friction
Materials
• Combination of weighted qualities:
• Stopping power
• Heat absorption and dispersion
• Resistance to fade
• Recovery speed from fade
• Wear rate
• Performance when wet
• Operating noise
• Price
Disc Brake Pads and Friction
Materials
• Coefficients of friction:
• C: ≤0.15
• D: 0.15–0.25
• E: 0.25–0.35
• F: 0.35–0.45
• G: 0.45–0.55
• H: >0.55
• Z: Unclassified
Disc Brake Pads and Friction
Materials
• Disc brakes more prone to squealing
• Due to vibrations between brake pad and rotor
• Shims and spring-loaded clips help reduce squealing.
Disc Brake Pads and Friction
Materials
• Anti-noise measures:
• Softer linings
• Wear Indicators
• Warning lamps
• Messages on dash
Disc Brake Rotors
• Two-part rotor
• Composite rotor
Disc Brake Rotors
• Parallelism
• Lateral runout
• Dust shields help to shield the rotor from dust, water, and
debris.
Disc Brake Rotors
• Types of rotors
• Solid
• Ventilated
Disc Brake Rotors
• Integrated
• Pascal’s Law:
• Pressure in an enclosed system is equal and undiminished in all
directions
• Force = Pressure x Area
• Force applied to brake linings increases with larger diameter wheel
cylinder
Hydraulic Brake Fluid
• Glycol-based fluids are hygroscopic
• Absorb water
• Brake fluid
• Higher boiling point than water
• DOT specifications
• List both dry and wet boiling points
Properties of Brake Fluid
• Low pedal
• Brake pedal moves closer to floor before brakes applied
• Tandem master cylinder
• Cylinder bore with two pistons and chambers
• Master cylinder reservoirs
• Prevented from vacuum locking
• Rubber diaphragm in cover or plastic float
• Master cylinders
• Mounted on bulkhead
Split Hydraulic System
• Some disc brake calipers are designed to have less drag when
brakes are not applied
• More fluid needed to take up clearance
75
Wheel Cylinder
• The wheel cylinder consists of a number of components.
• One wheel cylinder is used for each wheel.
• A pair of pistons operates the shoes, one at each end of the wheel
cylinder.
• When hydraulic pressure from the master cylinder acts upon the
piston cup, the pistons are pushed toward the shoes, forcing them
against the drum and the piston is returned to its position by the
force of the brake shoe return springs when the brakes are not being
applied
Hydraulic System Valves and
Switches
• Tandem systems have a hydraulic safety switch
• Alerts drivers when half the system fails
• Metering valve
• Used on front disc brakes when car has rear drum brakes
• Prevents front brakes applying until rear shoes overcome spring
pressure and contact drums
• Unnecessary with four-wheel disc brakes
• Proportioning valves
• Prevent rear wheels from locking during hard stop
• Newer cars
• Equipped with antilock brakes
Pressure Control Valves and
Switches
• All modern brake hydraulic systems contain pressure
• control valves.
• Pressure control valves affect the hydraulic pressure delivered to the wheel
units, which
• Some valves and switches work together to sense problems and warn the driver
Metering Valve
• The front brake pads are very close to the rotor and are not held in
a retracted position.
• When the brakes are first applied, hydraulic pressure moves the
front disc pads into contact with the rotor almost immediately .
• However , the rear brake shoes are held in the retracted position by
return springs and must over come spring pressure to move the
shoes into contact with the drum.
• This means the front pads would apply much more quickly than the
rear shoes.
• A metering valve is used to keep this from happening.
Proportioning Valve
• when the brakes are applied, much of the vehicle’ s weight is transferred to the
front wheels.
• If the brakes are applied hard during an emergency stop, so much vehicle
weight is transferred to the front wheels that the rear wheels can easily lose
traction and lock up.
• Rear wheel lockup can cause wear on the rear tires and can cause the vehicle
to spin out of control, especially on wet or icy roads.
• However, rear wheel lockup is a problem on many vehicles with four -wheel
disc brakes, especially those with front-wheel drive.
• Inside the proportioning valve assembly, a calibrated spring holds the valve
away from the opening to the rear brakes.
Brake Lines and Hoses
• This tubing consists of rigid steel lines and flexible rubber hoses.
Steel Brake Lines
• Whenever Possible, The Hydraulic System Uses Rigid Steel Brake Lines,
Sometimes Called Tubing, to Transmit Hydraulic Pressure.
• Steel Lines Are Resistant To Collision Damage And Vibration, Can Stand Up
To High Brake System Pressures, And Are Relatively Inexpensive.
• For Added Safety , The Steel Used In The Lines Is Double-wall (Double
Thickness) Elded Steel Made From Copper -Coated Sheet Steel.
• Common Steel Line Sizes Range From 1/8-3/8” (3.25-9.5 Mm).
• Steel Lines Are Often Coated With Tin, Zinc, Lead, Or Teflon To Reduce
Damage From Corrosion.
• The Lines Are Clamped To The Vehicle Unibody Or Frame At Close Intervals
• Be rigid.
• Flexible hoses, are used at the wheels to allow for movement. As the
wheels rise, fall, and turn, the flexible hose will transmit high pressure
without breaking.
• Most flexible hose lines are made from natural rubber and synthetic
fabric.
• There are usually two-plies of rubber and two piles of braided fabric
material for added pressure.
Anti Lock Braking System
The theory behind anti-lock brakes is simple. A skidding wheel (where the tire
contact patch is sliding relative to the road) has less traction than a non-
skidding wheel.
If you have been stuck on ice, you know that if your wheels are spinning you
have no traction. This is because the contact patch is sliding relative to the ice.
There are four main components to an ABS system:
Speed sensors
Pump
Valves
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
Since the valve is able to release pressure from the brakes, there has to be
some way to put that pressure back.
That is what the pump does; when a valve reduces the pressure in a line, the
pump is there to get the pressure back up.
Controller
The controller is a computer in the car. It watches the speed sensors and
controls the valves.
ABS At
Work
The controller monitors the speed sensors at all times. It is looking for
decelerations in the wheel that are out of the ordinary.
Right before a wheel locks up, it will experience a rapid deceleration. If left
unchecked, the wheel would stop much more quickly than any car could.
It might take a car five seconds to stop from 60 mph (96.6 kph) under ideal
conditions, but a wheel that locks up could stop spinning in less than a second.
The ABS controller knows that such a rapid deceleration is impossible, so it
reduces the pressure to that brake until it sees an acceleration, then it increases
the pressure until it sees the deceleration again.
It can do this very quickly, before the tire can actually significantly change speed.
The result is that the tire slows down at the same rate as the car, with the
brakes keeping the tires very near the point at which they will start to lock up.
This gives the system maximum braking power.
When the ABS system is in operation you will feel a pulsing in the brake pedal;
this comes from the rapid opening and closing of the valves. Some ABS systems
can cycle up to 15 times per second.
Wheel speed sensors and computer
Monitor wheel speed
Wheel speed sensors measure rotational speed of the wheel
• Wheel locks: antilock brake controller pulsates the pressure
to that wheel
ABS is disabled below a certain speed
ABS senses failure: system reverts to conventional-only braking
Pedal feel: bump followed by rapid pulsing
Types of Antilock Brake Systems
• Integral ABS
• Combine master cylinder, power brake booster, ABS hydraulic circuitry in
single assembly
• Early systems used pump for pressure
• Reservoir is usually much larger
• Some systems have pressure sensitive switch
• Nonintegral ABS
• ABS unit is separate from master cylinder and is in series with brake lines
• Two or four wheel
• One, three, or four-channel
ABS Systems Schematic
Motorsport Chassis Design and Dynamics
A three-channel ABS
system
Longitudinal Slip
From week 2 - Slip ratio
•A vehicles tyres are not always moving at the same speed as the
vehicle – they can travel both faster and slower than the ground speed
•Distance traveled by the external surface of the tyre Xst
•Distance traveled by the wheel centre Xwc
•Could be due to
•Wheel spin / lock up
•Movement of the contact patch vs. the rim
•Longitudinal deformation of the contact patch
•
Motorsport Chassis Design andslip
Longitudinal Dynamics
Motorsport Chassis Design
Braking and Dynamics
force
4 Fr
P=
Where πd 2
F = force input,
r = pedal ratio,
d = master cylinder bore diameter
Motorsport Chassis Design and Dynamics
Braking force
Caliper forces
Fc = PA
Where
Fc = Clamping force,
A = total piston area per caliper
Motorsport Chassis Design and Dynamics
Braking force
At the discs
Braking torque:
Td = Fc µR
Where
Fc = clamping force,
μ = coefficient of friction at pad/disc interface
R = mean radius of disc
Motorsport ChassisBraking
Design and
forceDynamics
At the wheels
294 kg 299 kg
Fc = PA 14366.15N / 0.003117 m 2 =
= 4608605 N/m2 or Pa
(46.1 bar)
Motorsport Worked
Chassis Design
throughand Dynamics
example
4 Fr
P=
πd 2
P (πd )2
4 Fr
=F d =
4r π.P
Motorsport Chassis Design and Dynamics