1

Presenter

Md. Adil Ahammed

ID : 14307009
IUBAT—International University of Business Agriculture and Technology

2
 Presentation
on

A Study on Braking system of TATA

vehicle at Nitol Motors Ltd.

3
 Contents
Introduction
Objectives
Company Overview
Brake
Types of brake
Retarder brake system
Brake Pad
ABS system
Brake fluid
Problems finding, analysis and solution
Recommendation
Conclusion
4
 Introduction
The automobile technology has been advancing rapidly in the modern world. In my training
period at Nitol Motors Limited, I have gained lot of knowledge about braking system. It is a big
sector and so complicated combination of thousand of parts. In a short time it is not possible to
know about whole braking system. But I try to best my self to understand about the braking
system and I got good support from Nitol Motors Limited.

5
 Objectives
 To develop a career as a future roles of professional engineer.
 Reflect on work experience & articulate professional engineer.
 Innovative thinking and become a new business models in automobile sector.
 Creative solution of the problems.
 To study about braking system.
 To study about ABS system
 To study about retarder brake system of a vehicle.
 To study about general problems related lining and brake fluid.

6
 Company Overview
Nitol motors limited is a concern of Nitol-Niloy group, whose prime function is marketing TATA vehicles.
Nitol motors limited founded in 1983 very soon it has been growing ever since and 1988 became the
importer and sole distributor of Tata vehicle from TELCO, India. It provides a wide variety of commercial
transportation and passengers vehicle solution. The comprehensive product range has enhanced the
companies image as a market leader of light, medium and heavy commercial vehicle with 55 branches
throughout Bangladesh.

7
 Continue….
Mission Statement
Providing the quality products and proper after sales service through multi
distribution channels to make people lives easier.
Providing modern technology offering reasonable prices.
To create a bond with every customer in order to maximize profit through
perfect competition.

Vision Statement
Helping Bangladesh to develop as a real prosperous, self dependent proud
nation by over coming the dependency on imported foreign goods through
industrialization.

8
 Key People
Abdul Matlub Ahmad is a Bangladeshi Business
leader. This genius was born in 1952. Completed
BA. (Hons.) and M.A in Economics from world
most reputed Oxford University. He is the Chairman
of Nitol-Niloy Group and the past President of
Federation of Bangladesh Chambers of Commerce
and Industries (FBCCI), past President of
Bangladesh-Malaysia Chambers of Commerce and
Industries (BMCCI) and President of Bangladesh
Cement Manufacturer's Association, founder
President of India-Bangladesh Chambers of
Commerce and Industries, Bangladesh Automobiles
Assemblers' Association.
Matlub says: “Technology is advancing fast and
demanding rapid innovation, self-employment is on Abdul Matlub Ahmad
the rise and becoming an accepted norm. This is a
9
great time to be an entrepreneur”.
 Supporting Service Center Name (NML & ASC)

10
 Brake
A brake is a mechanical device that inhibits motion by absorbing energy from a moving
system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its
motion, most often accomplished by means of friction.

11
 Purpose of Brake in a Vehicle
• 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 vehicles in desired position after bringing in at rest.
• Cars have brake so the can go fast.

12
 Types of Brake
Types of brakes based on method of actuation:
1. Mechanical brakes
2. Full hydraulic brakes
3. Vacuum assisted hydraulic brakes
4. Air over hydraulic brakes
5. Full air brakes

13
 Vacuum Assisted Hydraulic Brake
Power brakes are a system of hydraulics used to slow down or stop most motor vehicles. It
uses a combination of mechanical components to multiply the force applied to the brake
pedal by the driver into enough force to actuate the brakes and stop a vehicle that can
weigh several tons.

14
 Vacuum Assisted Hydraulic Brake

15
 Vacuum Assisted Hydraulic Brake
The pressure difference
between negative pressure
developed by the vacuum
pump and atmosphere the
booster provides increased
force, resulting in more
effective braking.

Vacuum Assisted Hydraulic Brake system

16
 Master Cylinder
The master cylinder is located behind the driver’s side dashboard mounted on the vacuum
booster. The pressure inside of the master cylinder is created by a primary and secondary
piston.

17
 Vacuum Booster
A vacuum servo is a component used on motor vehicles in their braking system, to provide
assistance to the driver by decreasing the braking effort. In the US it is commonly called a
brake booster.

18
 Brake Calipers
Brake calipers are one of the most important parts of a vehicle and are essential for car's ability
to stop. Often used in disc brakes, the brake calipers consists of one to two hollow aluminum or
chrome-plated steel pistons (caliper pistons).

19
 Residual Pressure Valve
The residual pressure valve in the master cylinder
keeps the fluid under certain pressure in the brake
lines. Slightest increase in pressure in master cylinder
will immediately initiate effective braking. Residual
pressure valve is designed as a double valve to control
the volume and pressure compensation.

Residual Pressure Valve

20
 Hydraulic Wheel Cylinder
A wheel cylinder is a component of a hydraulic drum brake system. It is located in each
wheel and is usually positioned at the top of the wheel, above the shoes. Its function is to
exert force to the shoes so as to bring them into contact with the drum and stop the vehicle
with friction.

Hydraulic wheel cylinder

21
 Full Air S-Cam Brake System
Full Air Brake System means a system that uses air as a medium for transmitting
pressure or force from the driver control to the service brake, including an air-over-
hydraulic brake subsystem, but does not include a system that uses compressed air or
vacuum only to assist the driver in applying muscular force to hydraulic or mechanical
components.
The main parts of the full air brake system are,
1. Air compressor
2. Air dryer
3. Purge tank
4. Dual brake valve
5. Unloader valve
6. Quadruple system protection valve

22
 Brake Circuit ( ‘S’ Cam )
 When the driver releases the
brake pedal air from brake
chambers and exhaust brake
cylinder get released through
DBV and solenoid valve
respectively.

 To park the vehicle operate the

graduated hand brake valve to
‘OFF’ position, air get released
from the brake actuator
through graduated hand brake
valve. Thus brake shoes
expand and hold the brake
drums.
23
 Dual-circuit Air System
In Figure , air is pumped by the compressor to the supply reservoir, which is protected from
over-pressurization by a safety valve. Pressurized air moves from the supply reservoir to the
primary reservoir (green) and the secondary reservoir (red) through one-way check valves. At
this point, the dual circuits start. Air from the primary reservoir is directed to the foot valve.
Air is also directed from the secondary reservoir to the foot valve. The foot valve is divided
into two sections (two foot valves in one). One section of this dual foot valve controls the
primary circuit and the other section controls the secondary circuit.

24
 Dual-circuit Air System

Simple dual circuit with brakes released

25
 Dual-circuit Air System
If there is an air loss in either
circuit, the other circuit will
continue to operate
independently. Unless air is
lost in both circuits, the
vehicle will continue to have
braking ability. The primary
and secondary circuits are
equipped with low-pressure
warning devices and pressure
gauges.

26 Secondary circuit failure with brakes applied

 Air Compressor
The first requirement of an air brake system is a way
to compress air and store it in reservoirs. The source
of the compressed air is the compressor, which takes
in air from the atmosphere and compress it. The
compressed air is then pumped through an air line to
a supply reservoir.

Air compressor

27
 Air Dryer
A air dryer is used for removing water vapor or moister and
other contaminants from compressed air. The air dryer on all
vehicle is located between the compressor and then first air
tank. The air dryer is a essential parts for a braking system. We
have to change the air dryer when the dew point is highest and
the ambient temperature is cool.

AIR DRYER

28
 Purge Tank
The purge tank is connected to air
dryer, having capacity of three
liters. This tank stores the dry air
to the specified pressure.
Whenever unloader valve releases
the further pressure to atmosphere
the air from purge tank flows in
reverse direction to clean the air
dryer descant to make it ready for
regeneration cycle.
Purge tank

29
 Retarder Brake System
A retarder is a device used to augment or replace some of the functions of primary
friction-based braking systems, usually on heavy vehicles. Retarders serve to slow
vehicles, or maintain a steady speed while traveling down a hill, and help prevent the
vehicle from "running away" by accelerating down the hill.

30 Retarder
 Electromagnetic Retarders
The electric retarder is a generator whose load is itself. All power generated by the generator
is dissipated back into the generator as heat. The retarder has cooling turbines which remove
the heat as it is generated. The vehicle's motion energy is converted into heat by the
generator.

Electromagnetic retarders
31
 Engine Compression Retarders
The engine compression retarder uses up vehicle motion energy during the compression
stroke of each piston because the other cylinders are not producing power during their power
stroke time interval. No (or insignificant) engine power is generated, because the throttle
must be at the idle position for the retarder to operate.

Engine Compression Retarders

32
 The Hydraulic Retarder
Hydraulic retarders are auxiliary braking devices that reduce the velocity of a vehicle,
particularly when a vehicle is driven downhill.

33 The hydraulic retarder

 Working of the Hydraulic Retarder
When activated the manual switch and or the foot
brake pedal the retarder receives an electronic signal
from the retarder control unit. The oil sump is
supplied with compressed air. Oil to be used as
operating medium is moved to the inlet throttle via
the rise duct. From there into the retarder circuit
between the moving rotor and the fixed stator. The
rotor is connected to the vehicle propeller shaft.
Through its rotary motion it accelerates the oil
builds up braking torque and is pulled in the braking
position via a helical gear. The rigid stator redirects
the oil and moves it back to the rotor result the rotor
and therefore the propeller shaft are deaccelerated.

34
 Brake pads
Brake pads are a component of disc brakes used in automotive and other applications.
Brake pads are steel backing plates with friction material bound to the surface that faces
the disc brake rotor.

Brake Pads
35
 Semi Metallic Brake Pads
These types of brake pads are made from about 30%
to 65% metal, and are commonly made out of steel
wool, wire, copper or other metal materials. Semi
metallic brake pads have a high temperature fade
resistance and friction label and are designed to give
the best stopping power in all weather condition.

Semi Metallic Brake Pads

36
 Non-asbestos Organic
This type of brake pad, commonly referred to as
NAO, is made from organic materials such as fiber,
glass, rubber and even Kevlar. These types of t pads
are usually softer and don't create much noise, but
they tend to wear faster and create a lot of dust.

Non-Asbestos Organic

37
 Low-metallic brake pads
These brake pads typically have anywhere from 10
percent to 30 percent metal content versus and 30 to
65 percent in semi-metallic versions. This types of
brake pads are used in passenger car and in
commercial vehicle. This types of brake pads have
the same advantage and disadvantages like semi
metallic versions.

Low-Metallic brake pads

38
 Ceramic Brake Pads
Ceramic brake pads are composed primarily of
ceramic fibers and other filler materials. While
ceramic brake pads are usually more expensive
than other types of pads, they are cleaner and
produce much lower noise levels. Also, they
provide for excellent braking and don't cause a
lot of wear on the brake rotors.

Ceramic Brake Pads

39
 Anti-lock Braking System (ABS)
Anti-lock Braking System also known as anti-skid braking system (ABS) is an automobile safety
system which prevents the locking of wheels during braking and avoid uncontrolled skidding.

40
 Anti-Lock Brake Types
Anti-lock braking systems use different schemes depending on the type of brakes in use.
We will refer to them by the number of channels -- that is, how many valves that are
individually controlled -- and the number of speed sensors.
I. Four-channel, four-sensor ABS
II. Three-channel, three-sensor ABS
III. One-channel, one-sensor ABS

41
 Main Components of ABS System
It has four main components
1. speed sensors
2. Valves
3. Pump
4. Controller
5. Modulator valve
6. Controller
7. Sensor ring

42
 Speed Sensor
It is used to calculate the acceleration and
deceleration of the wheel. It consists of a toothed
wheel and an electromagnetic coil or a magnet
and a Hall Effect sensor to generate signal.

43
 Valve
Each brake line which is controlled by the ABS
has a valve. In some of the systems, the valve
works on three positions.
In position one, the valve remains open; and
pressure from the master cylinder passed through it
to the brake.
In position two, the valve blocks the line and
separates the brake from the master cylinder. Valve
operates in second position when the driver applies
the brake harder.
In position three, some of the pressure from the
brake is released by the valve.

44
 Controller
The controller used in the ABS system is of
ECU type. Its main function is to receives
information from each individual wheel speed
sensors and if a wheel loses its traction with
the ground, a signal is sent to the controller,
the controller than limit the brake force (EBD)
and activate the ABS modulator. The activated
ABS modulator actuates the braking valves on
and off and varies the pressure to the brakes.

Controller

45
 Modulator Valve
To modulate the brake actuator air pressure
in three states viz. Apply, Hold, Release and
operates according to the command from
ECU during ABS operation. It is normally
open type and acts as a pipe during normal
braking.

Modulator Valve
46
 Working of Anti-lock Braking System
 The controller (ECU-Electronic Control Unit) reads the signal from each of the speed
sensors of the wheel.
 As the brakes are suddenly applied by the driver, this makes the wheel to decelerate at faster
rate and may cause the wheel to lock.
 As the ECU reads the signal which indicates the rapid decrease in the speed of the wheel, it
sends signal to the valve which makes the valve close and the pressure to the brake pad
reduces and prevents the wheel from locking.
 The wheel again starts to accelerate, again the signal sends to the controller, this time it
opens the valve, increasing the pressure to the brake pad and brakes are applied, this again
reduces the speed of the wheel and tries to make it stop.
 This process of applying brakes and releasing it happens 15 times in a second when a driver
suddenly applies the brake harder. Due to this the locking of the wheel is prevented and the
skidding of the vehicle eliminated. During braking with ABS system, the driver can steer
the vehicle and reduces the risk of vehicle collision.
47
 Brake Fluid
Brake fluid is a type of hydraulic fluid
used in hydraulic brake and hydraulic
clutch applications in automobiles,
motorcycles, light trucks, and some
bicycles. It is used to transfer force into
pressure, and to amplify braking force. It
works because liquids are not appreciably
compressible.

Brake fluid
48
 Types of Brake Fluid
While brake fluid function is relatively easy to understand, there is a wide variety of
types to choose from, which may be confusing when it is time to replace the brake, or
hydraulic fluid.
Generally, there are two types of brake fluid, they are
• Petroleum based
• Non-petroleum

It is further classified into

• Silicon based
• Glycol based

49
 Essential Qualities of Brake Fluid
Brake fluid must:
 Be chemically stable (not coagulate).
 Maintain a proper viscosity and provide good lubricity.
 Have little viscosity variation under cyclic temperature conditions.
 Have a high boiling point and not be subjected to vapor locks.
 Be compatible with rubber or metal parts and not cause corrosion, weakening.
 Not freeze (stay free-flowing in freezing weather).

50
 Handling Safety of Brake Fluid
 Never mix different types of brake fluid.
 Never re-use brake fluid.
 Drain and refill the brake fluid from time to time. This is especially important with disk
brakes.
 Never mix water or oil with brake fluid.
 As brake fluid is moisture-absorbing, the container must be kept tightly closed during
storage.

51
 Service and Maintenance
Most automotive professionals agree that glycol-based brake fluid, (DOT 3, DOT 4, and
DOT 5.1) should be flushed, or changed, every 1–2 years under non-racing conditions.
Many manufacturers also require periodic fluid changes to ensure safety.

52
 Problems Finding and Solution
Problem 1:
Finding: Fluid dripping from the master
cylinder.
Analysis: Master cylinder is leaking
Solution: Rebuild a master cylinder, but it might
be more trouble than its price. For that reason,
replace a master cylinder if find it to be bad. One
of the main things to remember when replacing a
master cylinder is to bench-bleed it before you
install it.

Master cylinder
53
 Problems Finding and Solution
Problem 2:
Finding: Car pulls to one side when braking.
Analysis:
The most common cause of the car pulling to one side
under braking is a fault with the pad or calliper. It could be
that the brake on one side is ‘grabbing’ or is not properly
engaging. Both of these problems can be caused by
sticking callipers, wear, corrosion or misalignment.
Solution: The calliper will need to be freed and serviced.

54
 Problems Finding and Solution
Problem 3:
Finding: Brake pedal pulses up and down when
applying brakes.
Analysis: The problem is usually caused by the rotors
being warped or out of true. As rotors age, they go
through the heating and cooling process thousands of
times, so it's inevitable for them to lose their shape or
trueness.
Solution:
Resurfacing the rotors, if they are still thick enough,
or replacing them if they are not. If do either of these
processes, and the brake pads are more than half
worn, it’s worth it to just replace the pads at the same
time. Rotors being warped

55
 Problems Finding and Solution
Problem 4:
Finding: Brake squealing, screeching,
humming, etc.
Analysis: Dust in the caliper and retaining.
Solution: Clean the caliper and retaining
components of caked up dust and grim.
Lubricate and replace worn parts.

Dust in the caliper

56
 Recommendation
During the practicum period it seemed to me that some necessary steps can be taken to
develop the working procedures, customer’s satisfaction as well as reputation of the company.
• Mechanics and driver training should be more organized and developed.
• They need to improve the relationship between management and workers.
• Enough tools should be available to give best service.
• Free service can be provided to attract customer.
• They should increase the number of service center for customer satisfaction.
• They need a strong rules to use safety instrument and safety system.

57
 Conclusion
There are five types of brake system but, in TATA vehicles there are two types of brake system
used. They are the Vacuum Assisted Hydraulic brake system and full air S-Cam brake system.
For this reason, the service center works with this two types of brake system. That’s why, I
covered this two system but I gained the knowledge of all brake system.
Retarder usually used on heavy vehicles and maintain a steady speed while traveling down a
hill. That means it is not available for all vehicles and the retarder problems are rare problem for
this reason, I could not gain the proper practical knowledge about retarder.
Success comes from great dedication, pledge and dynamic leadership and Nitol Motors Limited
have a strong management to walk a long way. Hope fully they will serve the nation
successfully in future also. Good wishes for them to reach there vision.

58
 Thanks to all

59
 QUESTION PLEASE

60