Lesson 2

 Types of Brakes

Types of Brake System

1. Mechanical Brake System 5. Power Brake System
2. Drum Brake System 6. Split-Hydraulic System
3. Disc Brake System 7. Anti-lock Brake System
4. Hydraulic Brake System 8. Air Brake System

1. MECHANICAL BRAKE SYSTEM

It consists of mechanical linkages for braking effort transfer from pedal to brake
drum.
 2. DRUM BRAKE SYSTEM
Is a brake in which the friction is caused by a set of shoes or pads that press
against a rotating drum-shaped part called a brake drum. It is a brake in which brake
lining attached to them are
pushed by hydraulic
pistons against the inner
surface of a drum
rotating together with
the axle.

Working Principle

Drum Brake System

Brake drums are essential component of drum brakes. Together with a brake
shoe, a brake drum forms a friction pair, which decelerates the rotation of the wheel.

Components of Drum Brake System

 Backing Plate
The plate, attached to the axle assembly, holds
the components of the drum brake assembly.
  Brake Shoe
Brake shoe is the part of a braking system which carries the brake lining in the
drum brakes used on automobiles.

 Brake Drums
Are essential component of drum brakes.
Together with a brake shoe, a brake drum forms a
friction pair, which decelerates the rotation of the
wheel.

 Return Springs
The return springs pull the shoes back when
the brakes are released

 Hold-down Springs and Pins

These springs and pins hold the shoes
to the backing plate and keep the shoes in
position.

 Wheel Cylinder
 When the brakes are applied, hydraulic pressure pushes the two pistons in the
wheel cylinder outward against the shoes

 Self-Adjustment Mechanism
SELF ADJUSTOR - To maintain the correct
shoe-to-drum clearance.

 Parking Brake
The parking brake, also called the emergency or e-brake, is a mechanical brake
used primarily to lock the brakes when the vehicle is parked.

Types of Drum Brake Designs

 Nonservo Brake Design

Nonservo drum brakes, also called leading-trailing brakes, place the anchor at
the bottom of the backing plate, between the lower edges of the brake shoes, as shown
in the figure.
  Servo Brake Design
It is drum brake design that use leverage to increase brake application force
 Servo brakes are often used on larger vehicles, such as trucks, vans, SUVs,
and larger passenger cars

ADVANTAGES
 It can generate greater stopping force than disc.
 Cheaper than the disc brake

DISADVANTAGES
 drum brakes include mechanical brake fade
 Over heating
 3. DISC BRAKE SYSTEM

How Disc Brake works?

A disc brake is a type of brake that uses calipers to squeeze pairs of pads against
a disc or "rotor"to create friction. This action slows the rotation of a shaft, such as
a vehicle axle, either to reduce its rotational speed or to hold it stationary.

Working PRINCIPLE

The disc brake system works based on Pascal's law which states that " Pressure
exerted anywhere in a contained incompressible fluid is distributed equally in all
direction throughout the fluid".

Parts of Disc Brake System

 Wheel Hub

It holds the wheel and the disc

rotor and bearing inside it allows their
smooth rotation.

 Disc Rotor
It is the part to which the brakes pads
squeeze against which slow the rotation of
the wheel. It produces a lot of heat due to
friction and the drilled holes provides

ventilation to remove this heat.

  Calipers
Brake calipers are a vital part a vehicle's braking system. Brake calipers squeeze
the brake pads against the surface of the brake rotor to slow or stop the vehicle.

 Caliper Bracket
This bracket keeps the brake calipers in fixed position, making it possible to slow
the vehicle down.

 Anti-rattle Clips
Keeps brake pads stable.

 Slider Pins
Its slides along the caliper frame within the fixed extend.
  Banjo fitting
Comprises a hollow bolt and spherical union for
fluid transfer. They are commonly found in
automotive fuel, oil and hydraulic systems. The pipe
connected may be either rigid or a flexible hose.

 Bleeder screw
Is a device used to create a temporary opening
in an otherwise closed hydraulic system, which
facilitates the removal of air or another substance
from the system by way of pressure and density differences.

 Dust boots
To protect the piston and seal from road debris and water.

 Piston Seal
The one function of the piston seal is to stop
brake fluid from leaking out of the caliper. The
other function of the piston seal is to pull
the piston back and therefore release the brakes. The
brake fluid under pressure forces the piston to slide
out of the caliper.

 Piston
A single piston and the caliper body or mount to provide
clamping force to the pads and rotor.
  Brake Pads
The primary function of a brake pad is to
slow or stop the motion of a machine or vehicle.

Types of Disc Brakes

 Fixed Caliper
Rigidly mounted over the rotor and do not slide or move when the brakes are
applied. This type of design requires pistons on both sides of the rotor to apply pads.

It has one or more pistons mounted on each side of the rotor.

When the brakes are applied, only the caliper pistons move, pressing the brake
pads against the disc.

 Floating Caliper Type Disc Brake

Also called sliding calipers, is the most common type. It has one or two pistons.

These are mounted on slides that allow the caliper to move in and out sideways
when the brake are applied then released.
 Calipers are typically have a single piston located on the inboard side of the
caliper.

REAR CALIPER PARKING BRAKE

Advantages and Disadvantages of Disc Brake

ADVANTAGES
 Lighter than Drum brakes
 Better Cooling (braking surface is directly exposed to air)
 Better resistance to fade
 Replacement of brake pads are easy
  Self-adjusting brakes
DISADVANTAGES
 Expensive than drum brakes
 Higher pedal pressure is required (installed with vacuum booster)
 Difficult to attach a suitable parking attachment

Type of Vehicles using Floating Caliper type Disk Brake

 Hond Civic 1998 lxi

 Ford Ranger

 Kawasaki Dominar 2019

  Toyota Hiace ZL

Type of Vehicles using Fix Caliper type Disk Brake

4. HYDRAULIC BRAKE SYSTEM

A system of fluid-filled pipes that can multiply force and transmit it easily from
one place to another.
Who invented hydraulic brakes?
Malcolm Loughead of Detroit, Michigan invented "fluid-operated" (hydraulic)
brakes in 1919.
It uses the momentum (moving power) of the car to provide the force that
pushes the hydraulic piston into the cylinder, giving a kind of power-assisted braking.
Loughead and his brother Allan were airplane pioneers and the founders of the
Lockheed Corporation (originally known as the Loughead Aircraft Manufacturing
Company).

Hydraulic Brake System Principles

• Fluids cannot be compress
• Fluids can transmit movement
• Acts "like a steel rod" in a close container.
• Master cylinder transmits fluid to wheel cylinder or caliper piston bore.
• Fluids can transmit and increase force
PRESSURE=FORCE/AREA

Brake Fluid
 The fluid through which energy is passed in the hydraulic brake system

Properties of Brake Fluid

• Does not thicken or then with changing heat
• Must not boil.
• Must be compatible with brake parts material.
• Must lubricate internal parts.
• Must not evaporate easily.

Basis of Hydraulic Braking System

1. Frictional Contact
Mechanism
A. Drum Brake
Parts of Hydraulic Drum
Brake
• Brake pedal/brake
lever
• Master cylinder
• Brake fluid reservoir
• Brake lines
• Drum cylinder
• Brake drum

B. Disc Brake
Parts of Hydraulic Disc Brake
• Brake pedal/brake lever
• Master cylinder
• Brake fluid reservoir
 • Brake lines
• Disc rotor
• Disc caliper

Brake pedal or Brake lever

In hydraulic braking system same as
other braking brake pedal or brake lever is
required by the driver to apply braking,
this brake pedal or brake lever is attached
with the master cylinder through
mechanical rod or connecting rod.

Master Cylinder
It is the simple cylinder and piston
arrangement which converts the mechanical force from
the brake pedal into the hydraulic pressure.

Brake fluid reservoir

It is the simple reservoir tank containing
brake fluid which is connected to the master
cylinder with the help of brake hose.

Brake lines
 They are the hollow high pressure metal tube that connects the master cylinder
with the drum cylinder inside these brake lines high pressure brake fluid from the
master cylinder flows which is responsible for further brake actuation.

Brake Drum
It is housing of drum cylinder, brake shoes
and spring, the outer part of the drum rotates
with the wheel and inner part consisting the brake
shoe and cylinder remains stationary.

Drum Cylinder
It is the cylinder fitted inside the drum of the drum
brakes and is connected with the brake shoes, the
high pressure brake fluid from the brake lines comes to this cylinder

Brake booster
Is a brake safety component that is coupled at intermediate position between
brake pedal and brake master cylinder.

Constructional Details:
1. Shafts or Booster Shafts
a. Primary shaft
b. Secondary shaft
2. Valves
a. Atmospheric valve
b. Vacuum valve or one way valve
3. Springs
a. Primary spring
b. Secondary spring
4. Diaphragm
 5. Body

Proportioning valve
A vehicle's brake system provides a way to
control how much and when brake pressure is
applied to each axle set of the brake
system.

2. Brake Force Distribution

A. Single Acting Hydraulic Brakes
In single acting type of hydraulic brakes, simple single cylinder type of
master cylinder is used which provides limited hydraulic pressure which can only
be transferred in single direction.
B. Double Acting Hydraulic Brakes
In double acting type of hydraulic brakes, double or tandem master
cylinder is used which provides higher brake force which can be transferred in
double direction.

5. POWER BRAKES
What are power brakes?
Power-assisted brakes are also referred to, by some, as power brakes. Power-
assisted brakes are designed to use the power of the engine to increase braking power.
Power assisted brakes can use vacuum or hydraulic assistance to reduce the driver’s
pedal effort.
Vacuum Assist
In a vacuum-assisted brake
system, a vacuum booster is
used. A vacuum booster needs
a vacuum source to operate.
In gasoline-powered cars, the engine provides a vacuum suitable for the boosters. In
the case of diesel engines, vacuum is not produced, thus, a separate vacuum pump is
used.

Hydraulic Assist
Almost the same as the vacuum assist, except that it uses a hydro booster as
assistance in power braking.
 A hydro boost unit is located between the firewall and the master cylinder, just like
a vacuum booster. It has hydraulic lines leading from the power steering pump to the
power steering gear, much like the lines incorporated into the power steering system.

6. SPLIT-HYDRAULIC BRAKE SYSTEM

 - Is to visualize to the brakes are applied to the wheels on separate lines carrying
a special hydraulic fluid.
- This is safer than undivided brake systems because this is divided by two lines.

Types:

 Front and Rear Braking System

o Is another name to the H-split braking system
o Is less desirable when the vehicle is less expected to be hauling loads
because if the front system fails the remaining rear system may be
inadequate to safely stop the vehicle.
o This costs less than the Diagonal Split.

 Diagonal Braking System

o Is another name to the x-split braking system
o Preferred in most modern automobiles and light trucks.
o In this system, the master cylinder has two outlets which are connected to
two brake lines carrying brake fluid.
o As it connects wheels in diagonal position.
o Diagonal system is much better than Front and Rear Braking System
because if the rear brake fails, you still have the brake control on the
other rear wheels.

Advantages and Disadvantages of Split-Hydraulic System

ADVANTAGES
 A split system is safer in the event of partial failure.
 Fluid loss in one half of the systems still leaves the other half able to stop the
vehicle, although with an increase in the stopping distance.
 Equal braking effort to all the four wheels.

DISADVANTAGES
 Even slight leakage of air into the braking system makes it useless.
 The brake shoes are liable to get ruined if the brake fluid leaks out.

7. ANTI-LOCK BRAKING SYSTEMS

- Is used in advanced automobiles to prevent slip and locking of wheel after
brakes applied.
- It will help you to control the steering wheel during braking.

Four Major Components:

1. Speed Sensor
- This sensor monitors the speed of each wheel and determines the necessary
acceleration and deceleration of the wheels.
2. Valves
- The valves regulate the air pressure to the brakes during the ABS action.
- The brake valves controls the pressure that is being transferred to the brakes
from the master cylinder.

3. Electronic Control Unit

- Is an electronic control unit that receives, amplifies and filters the sensor signals
for calculating the wheel rotational speed and acceleration
- It receives a signal from the sensors in the circuit and controls the brake
pressure, according to the data that is analyzed by the unit.

4. Hydraulic Control Unit

- It receives signals from the ECU to apply or release the brakes under the anti-
lock conditions.
- It controls the brakes by increasing the hydraulic pressure or bypassing the pedal
force to reduce the braking power.
Types of Anti-lock Braking System

1. Four-channel, four-sensor ABS

- There is a speed sensor on all four wheels and a separate valves for all four
wheels.
- This is the best combination for an effective ABS system.

2. Three-channel, three-sensor ABS

- Commonly found on pickup trucks, has a speed sensor and a valve for each of
the front wheels, along with one valve and one sensor for both rear wheels.

Advantage and Disadvantage of Anti-lock Brake System

ADVANTAGES

 It prevents the locking of the wheel and thus eliminates the chance of skidding.
  The skidding of the vehicle is completely removed, which results in excellent
control during breaking.
 A better steering control is obtained with the ABS system.
 It reduces the chance of collision by 30%

DISADVANTAGE
- A vehicle equipped with ABS is costlier as compared with a vehicle without ABS.

Cars installed with Anti-lock Brake System

 TOYOTA HILUX 2016

 MAHINDRA xuv500

8. AIR BRAKE SYSTEM

An Air Brake is a type of friction brake for vehicles in which compressed air
pressing on a piston used to apply the pressure to the brake pad needed to stop the
vehicle.
Application of Air Brake System
Trucks Bus
How does Air Brake System works?

1. The working of Air Brakes starts with the air compressor. It is the main
component of the whole system. Air compressor directly powered by the engine.
It compresses the atmospheric air and then transfers it into the storage tank.

2. Air firstly passes through the air filter and dryer before entering into the storage
tank. Air filter removes the dust particles from the air, and dryer removes
moisture content from the air.

3. The main working of the braking system starts when the passenger sitting in the
vehicle presses the brake pedal, which is directly attached with the actuators
having a piston-cylinder arrangement.

4. After pressing the pedal, piston compresses the air due to this pressure in the
assembly increases. The outlet port of the triple valve is closed this time and
inlet port opens after that compressed air from the reservoir enters into the
braking lines.
Components of Air Brake System
1. Air Compressor

- Is the main part of any Air Brake System.

- Powered by the engine using belt drives.
- It comprises the atmospheric air up to the desired
pressure and transfers it to the storage tank.

2. Storage Tank
- It stores the compressed atmospheric air at high
pressure.
- Also a necessary part of the Air Brake System because
compressed air is responsible for the whole operation.
- Breaks can be applied several times during running of an
automobile, so compressor alone is not able to perform this tasks that’s why air
storage reservoir required.

3. Brake Pedal
- Is the input to the brake mechanism.
- Operated by the driver inside the automobile.
- The brake pedal itself, is a kind of mechanical linkage
which transfers input motion to the further mechanism
and initiate the brake application.

4. Safety Valve
- A safety component which is attached to the air storage tank.
- Air is released by the safety valve when the air pressure
reaches a certain value.
- It prevents the bursting of the tank due to excessive pressure
because air compressor works continuously and supplies
compressed air to the tank.

5. Air Filter and Dryer

- Are the two major components which are used before the air enters into the air
compressor.
- It is necessary that only dry air enters into the air compressor because moisture
content will lead to failure of braking system due to the condensation of the
water particles.
- As the name implies air filter is used to remove the dust particle from the
 atmospheric air whereas dryer removes the
moisture and humidity from the inlet air.

6. Dirt Collector
- Is a small device used before the triple valve.
- Used to collect the dirt particles separated by the air filter.

7. Brake Drums
- The part which execute the brakes.
- It is the last part of the assembly.
- It is mounted on the tires of the automobiles.

8. Breaking Lines
- Also known as the “Supply Lines”.
- The transfer of compressed air from the reservoir to brake drum is done by this
part only.

9. Triple Valve
- Is responsible for the whole operation in air brakes.
- To apply and release the brake, a continuous apply and releasing which is done
by Triple valve.

Advantages and Disadvantage of Air Brake System

ADVANTAGES
Since air brakes are used as an alternative to
Hydraulic Brakes, which are used in lighter vehicles such as
automobiles. Hydraulic breaks use liquid (hydraulic
fluid to be specific) to transfer pressure from the brake
pedal to the brake shoe to stop the vehicle. Air brakes are
used in heavy commercial vehicles due to their reliability. They have several advantages
for large multi-trailer vehicles:
• The brake system can never run out of its operating fluid

• It can serve to control the force applied.

• Air Brakes are effective even with considerable leakage.

DISADVANTAGES
• Air Brakes generally cost more

• Can contribute to higher maintenance and repair costs.

Problems and Troubleshooting of Brake System

 Low/Spongy Brake Pedal

Possible Cause/s
• Insufficient brake fluid in the master cylinder.

• The brake lines may have contaminants like air in

them.

• Not have been bled properly.

Prevention:
• Always ensure that a qualified brake fitter services your brakes.

• Make sure that you fill the master cylinder with approved brake fluid to the
appropriate level and bleed your brake lines before use.

 High Pedal Force

Possible Cause/s:
• Brakes when subjected to undue heat stress may glaze and become inefficient.

• Brake pads may simply be worn out.

• Calipers or wheel cylinders may have become clogged and need cleaning or
replacing.

• The brake booster could be faulty and need repairs or service.

Prevention:
• Use your brakes carefully, not overusing them or avoiding excessive braking to
preserve your brakes.

• Regular service and use of quality brake pads, brake fluid, brake cleaner and
lubricant will extend and preserve your brakes.

 Brake Drag
Possible Cause/s:
• Brakes may be adjusted too tightly.

• The master cylinder by-pass port may have

become clogged by contaminants.

• The pedal return springs may be worn and need replacing.

• Backing plates may have become distorted from excessive force and
overheating.

• Wheel cylinder may have become sticky and need repairing.

Prevention:
• Ensure that brakes are adjusted properly and are not too tight.

• Regular service and cleaning will prevent brakes from deteriorating, cleaning the
brakes with quality cleaner and a brake lubricant will also extend the life of
 brakes.

 Brake Pull
Possible Cause/s:
• Contaminated pads and linings, mismatched brake
materials such as pads or brake linings.

• A faulty caliper pad alignment or uneven adjusting of

pads or even a seized caliper may be at fault.

Prevention:
• Keep your brakes clean and serviced.

• Make sure that you are fitting the appropriate pad or lining.

• Check that your brake system is properly and evenly adjusted will ensure
smoother acting brakes.

 Brake Grab
Possible Cause/s:
• Contamination of brakes with brake dust, grease or fluids.

• Misalignment of brake calipers, loose brake mounting bolts

or seized caliper pistons and slides may cause the fault.

• Check brake lines and hoses are not collapsed, clogged, kinked or pinched.

Prevention:
• Correct fitting of brake parts and maintenance will ensure that your brakes
function as expected.

• Be sure to fit the right pads correctly and firmly to the calipers as well as linking
to their assemblies.
• Check that your brakes are not contaminated, lines and hoses are free of
obstruction.

• Always use high quality brake cleaner, lubricant, brake fluid.

 Brake Noise
Possible Cause/s:
• Damage to the brake pads or lining, damage to the
brake drum and damage to the springs can all produce
brake noise.

• Too much lateral run out and faulty caliper alignment

may also contribute to excessive brake noise.

Prevention:
• Take your vehicle to a brake specialist as soon as you hear any undue noise from
your brake system.

 Vibration
Possible Cause/s:
• Both rotor run out and parallelism can cause the
vibration under braking.

• Wheels out of balance and alignment.

• Wear and faults in steering components.

Prevention:
• Ensure that brake pads are fitted properly and that all components are fitted to
specification will keep the rotor from suffering undue and uneven wear.
 • Regular service will identify problems and often stop these problems before they
become apparent.

 Brake Wear
Possible Cause/s:
• Abnormal brake wear occurs when the wrong type of
pad or lining is fitted or the rotor surface is rough.

• Caliper pistons or pins seized up.

Prevention:
• Choose the right pad is as important for its durability as it is to safety.

• Regular maintenance of your vehicle`s braking system is essential for its integrity
and longevity.

Maintenance of the Brake System

1. Verify whenever possible the power of braking of each of the four wheels with a
brake meter/brake tester.

2. Keep the indicated level of brake fluid. Check it often, and replace every two
years or 50,000 miles.

3. Be sure to review each time the status of brake pads. Their average life is 25.000
km.

4. You must change the brake shoe (or a shoe or a brake block) for every four
changes of brake pads or so.

5. Check to see their headlights and brake lights are working.

6. Regular Maintenance.