➢ Electric brake

Types of braking system

➢ Mechanical brake ➢ Hydraulic brake ➢ Vacuum brake

➢ Air brake
Hydraulic system components
• Human
• Pedal
• Booster
• Master cylinder
• Braking lines/hoses
• Calipers/Shoes
• Pads/Brake lining
• Discs/Drums
Hydraulic braking system gain
Braking
Human Braking force
• From the “conservation of energy” point of view, this sys
requires the conversion of the vehicle kinetic energy that
can be dissipated or stored.

• In Conventional braking, the vehicle kinetic energy is

converted to heat by friction, this heat is then dissipated.

• Where in the Regenerative type the vehicle kinetic energy

is converted into a form which can be either used
immediately or stored until needed.
Types of brakes
➢ Drum brake ➢Disk brake
Drum brake
➢ Brake shoe ➢ Wheel cylinder

➢ Backing plate ➢ Return spring

How drum brake works?
Disk brake
➢ Brake pads ➢ Calipers

➢ Rotor ➢ Piston housing

How disk brake works?
Components & Equations
➢ Human
➢ Pedal
➢ Booster
➢ Master cylinder
➢ Lines/Hoses & Fittings
➢ Calipers /Shoes
➢ Pads
➢ Discs
➢ Pedal & Leverage ratio
Leverage ratio (Lr) = X/Y
Human: Inputs human force (20→30 Kg average human foot)
Pedal: Boosts the human force by a pedal ratio (4-6 times)

Fm = Fh* Lr Fmaster f = Fhuman Lr Kbf

Fmaster r = Fhuman Lr Kbr

Average Pedal Ratio Lr from 3 → 5 ul

Lr can be adjusted to control the output braking force from the system, taking
into consideration the dimension limitations and driver ergonomics.

Ex: For a pedal with pivot-master distance 8 cm, if you choose Lr 5 ul, you will
get a long pedal of total length 40 cm.
➢ Master cylinder
Function: Splits pressure and distributes forces (Diagonal or
F/R). As Pressure is constant across Hydraulic system, Pascal's Law.

Pressure = Force / Area

To calculate master cylinder area:

𝜋 2
𝐴 𝑚𝑎𝑠𝑡𝑒𝑟 = × 𝑑𝑏𝑜𝑟𝑒
4
➢ Master cylinder
Fm = Fh* Lr
Force to front Master cylinder
𝐵1
𝐹𝑓 = 𝐹𝑚 ×
𝐵1 + 𝐵2
Force to rear Master cylinder
𝐵2
𝐹𝑟 = 𝐹𝑚 ×
𝐵1 + 𝐵2

𝐹𝑚 = 𝐹𝑓 + 𝐹𝑟
➢ Caliper
Function: Transforms pressure to normal forces on
discs/drums.
As Pressure is constant across Hydraulic system, Pascal's Law.

𝐅 𝐦𝐚𝐬𝐭𝐞𝐫 𝐅 𝐜𝐚𝐥𝐢𝐩𝐞𝐫
➢ =
𝐀 𝐦𝐚𝐬𝐭𝐞𝐫 𝐀 𝐜𝐚𝐥𝐢𝐩𝐞𝐫

➢ 𝐅 𝐜𝐚𝐥𝐢𝐩𝐞𝐫 𝐍 = 𝐏 ∗ 𝐀𝐜𝐚𝐥𝐢𝐩𝐞𝐫

➢ 𝐅 𝐜𝐚𝐥𝐢𝐩𝐞𝐫 𝐟𝐫𝐢𝐜 = 𝐅 𝐜𝐚𝐥𝐢𝐩𝐞𝐫𝐍 ∗ µ f pad

➢ 𝐀𝐜𝐚𝐥𝐢𝐩𝐞𝐫 = 𝛑 ∗ 𝐝𝟐 𝐛𝐨𝐫𝐞
In case of multi-piston calipers
𝟒 𝛑
𝐀𝐜𝐚𝐥𝐢𝐩𝐞𝐫 = (𝐝 𝟏𝟐 𝐜 𝐛𝐨𝐫𝐞 + 𝐝𝟐𝟐 𝐜 𝐛𝐨𝐫𝐞+ 𝐝𝟑𝟐 𝐜 𝐛𝐨𝐫𝐞……..+ 𝐝𝒏𝟐𝐜 𝐛𝐨𝐫𝐞 )
𝟒
 ➢ Rotor & Tires
Function: Transforms forces from pads to ground through
wheel hub.
➢ 𝐓𝐨𝐫𝐪𝐮𝐞 = 𝐟𝐨𝐫𝐜𝐞 ∗ 𝐝𝐢𝐬𝐭𝐚𝐧𝐜𝐞

Note: 𝐓𝐁 𝐑𝐨𝐭𝐨𝐫 = 𝐓𝐁 𝐭𝐢𝐫𝐞 = 𝐓𝐁𝐫𝐚𝐤ing

𝐑𝐨+𝐑𝐢
➢ R disc 𝐦𝐞𝐚𝐧 = 𝟐
𝑻
𝐓𝐁𝐫𝐚𝐤𝐢𝐧𝐠 𝐝𝐢𝐬𝐜 = 𝟐 ∗ 𝐅 𝐜𝐚𝐥𝐢𝐩𝐞𝐫 𝐟𝐫𝐢𝐜 * R disc 𝐅 𝐁 𝐖𝐡𝐞𝐞𝐥 = 𝑩𝒓𝒂𝒌𝒊𝒏𝒈
𝑹 𝒕𝒊𝒓𝒆

➢ 𝐅 𝐁 𝐭𝐨𝐭𝐚𝐥 = 𝛴 𝐅 𝐁 𝐖𝐡𝐞𝐞𝐥 = Total braking forces for each wheel

➢ 𝐅 𝐁 𝐖𝐡𝐞𝐞𝐥 expresses generated braking force from hydraulic system on a single wheel
Resistances
▪ Braking Resistance 𝛴𝑭𝒐𝒓𝒄𝒆𝒔 = 𝒎𝒂

FBT= Fbf + Fbr F B T + Fr + 𝑭 𝒂

𝒂=
▪ Rolling Resistance 𝒎

Fr = f r * W 𝑾 𝒉
𝑾𝑻 = 𝒂
▪ Air Resistance 𝒈 𝑳

𝟏
𝑭𝒂 = 𝝆 𝑪𝒅 𝑨𝒇 𝑽𝟐 𝑳𝟐
𝟐 𝑾𝒇𝒔 = 𝑾
𝑳 𝑾𝒇𝒅 = 𝑾𝒇𝒔 + 𝐖 𝐓
▪ Total Resistance
𝑳1
FRt = F B T + Fr + 𝑭𝒂 𝑾𝒓𝒔 = 𝑾 𝑾𝒓𝒅 = 𝑾𝒓𝒔 − 𝐖 𝐓
𝑳
Systems ID

▪ Front/rear split found on rear-wheel-drive

vehicles

▪ Diagonal split found on FWD and high

front-to-rear brake ratio

▪ Vehicles with ABS each wheel can have its

own circuit
Locking
Function: Transforms forces from pads to ground
through wheel hub.

After a certain limit tires start to skid & Coefficient of

adhesion drops.

𝐅 𝐛 𝐌 = 𝛍𝐩 ∗ 𝐖 𝐝

𝑾 𝒉
𝑾𝑻 = 𝒂
𝒈 𝑳
Wheel lock (Front/Rear)
Front: Loss of steering.
Rear: Loss of directional stability.

Note:

1. Component sizes determine the maximum

system attainable forces.
2. The tire contact and vehicle weight determine
the absolute maximum attainable braking forces
rear and front.
Front
3. The vehicle dynamic weight distribution
determine the maximum possible braking forces
for all circumstances
Rear
Bleeding
Task
Design Braking system for the car shown assuming
the following:
Diameter for tire: 𝑑𝑡𝑖𝑟𝑒 = 500𝑚𝑚
Diameter for disk: 𝑑𝑑𝑖𝑠𝑘 = 220𝑚𝑚
Rolling resistance: 𝐹𝑟 = 150 𝑁 380
.cg
Air resistance: 𝐹𝑎 = 200 𝑁 700

Mass: m = 400 𝐾𝑔 1800

Road fraction coefficient: 𝜇𝑃 = 1.2 Determine :

Leverage ratio 𝐿𝑟 = 5.5 Deceleration a=?

Assuming any missing data Front dynamic load transfer: 𝑊𝑓𝑑 = ?

Deadline Friday 8 July 2022 – 5pm Rear dynamic load transfer: 𝑊𝑟𝑑 = ?