Professional Documents
Culture Documents
VEHICLES
RQF Level: 8
Course no: AUTHC801
Credit: 10
Module leaders:
Patrick BANDA
Michael SHAMU
The brakes on a truck are probably its most vital
safety component
The brakes on a truck are probably its most vital safety component
Objectives
Conduct heavy vehicle brake systems repair
• Diagnose heavy vehicle pneumatic brake
system
• Conduct heavy vehicle pneumatic brake
system repair
• Perform post repair activities of heavy vehicle
pneumatic brake system
Brakes and Braking
Introduction
• To stop a vehicle, brake shoe linings are forced
against the surfaces of the brake drums, creating
friction
• This friction generates heat while reducing the
energy of revolving brake drums and wheels
• This heat is absorbed by the brake drums, which
dissipate the heat into the atmosphere
• When enough friction is created between the brake
lining and the drums, the wheels stop turning
Brakes and Braking
Example:
• If a 200-horsepower engine accelerates a vehicle to
100 km/h in one minute
• What power is needed to stop in 6 seconds (i.e. in
1/10 the time it took to reach 100 km/h)
• It requires a stopping force of 10 times the
acceleration force i.e. the equivalent of 2,000 HP
• If the vehicle had 6 wheels, each wheel would have
to provide 1/6 the braking force
• If one or two of the wheels have ineffective brakes,
the other wheels will compensate for the braking
Brakes and Braking
Example:
• Excessive braking result in heat generation which
the brake drums cannot absorb and dissipate
• This result in brake fade, brake damage and/or
brake failure
NB: Brake fade is when brakes stop operating
properly because they have become overheated
• The heat generated can cause fire
• Brake linings operate best at around 250°C and
should not exceed 425°C
Brakes and Braking
Brakes and Braking
Summary
• Distance to stop a vehicle depends on its speed and
weight, in addition to energy, heat and friction
• So;
If weight is doubled, braking force must be doubled
If speed is doubled, braking force must be increased
4 times
If weight and speed are doubled, braking force
must be increased 8 times
Brakes and Braking
Use of Air Pressure
• Force can multiplied by the use of air to gain
mechanical advantage
• Air can be compressed (squeezed) into a smaller
space than it will normally occupy eg in tires
• The smaller the space into which air is squeezed,
the greater the air’s resistance to being squeezed
• This resistance creates pressure which is used to
gain mechanical advantage
Brakes and Braking
Stopping Distance
• Stopping distance consists of three factors
Driver’s reaction time
Brake lag
Braking distance
• Braking distance depends on
the ability of the brake lining to produce friction
the brake drums to dissipate heat
the tires to grip the road
Braking distance depends on
Brakes and Braking
Stopping Distance
• Heavy vehicles require powerful braking systems
• These are obtained by use of mechanical leverage
and air pressure
• Brakes must be used keeping in mind the heat
generated by friction
• Excessive heat reduces braking effectiveness
• The heavier the load and the faster the speed, the
greater the force needed to stop the vehicle
NB: An air brake equipped vehicle, does not always
stop immediately
Air Brake Systems
Fundamentals
• Air brakes are used in heavy vehicles due to their
reliability
• They have several advantages for large multi-trailer
vehicles
• The supply of air is unlimited, so the brake system
can never run out of its operating fluid, as hydraulic
brakes can
• Minor leaks do not result in brake failures
Advantages
• Have an air tank to store sufficient pressure to stop
the vehicle if the compressor dies
• Effective than other brakes even with a leakage
• Uses air to operate the brakes, which is easily
available
• Horns and seat adjusters can be operated better
with compressed air than hydraulics
• Air couplings are easy and accessible to connect
and disconnect than hydraulic lines
• Higher braking effect and control over the system
• Less wear and tear of parts
Disadvantages
• Generally more expensive than hydraulic brakes
• Compressed air has moisture that requires an air
dryer to remove making the system expensive
• High maintenance and repair costs
• A faulty dryer causes ice to build up in the air-brake
system in winter.
• Noise in operation which can impair hearing
• A simple leakage can cause entire system failure
• Difficult to seal
• Not applicable underwater and in extreme
temperatures
Application of Air Brake System
• Suitable where there are many trailers, high speed
heavy loaded long haul vehicles
• Applicable in locomotives
• Not suitable for small vehicles due to limited space
Components of Air Brake System
A basic air brake system that can stop a vehicle has 5
main components
• Compressor - pumps air (a governor controls it)
• Reservoir/tank - store the compressed air
• Foot valve - regulates the flow of compressed air
from reservoir when it is needed for braking
• Brake chambers and slack adjusters - transfer the
force exerted by the compressed air to mechanical
linkages
• Brake linings and drums - create the friction
required to stop the wheels
Components of Air Brake System
They are divided into 3 categories
a. Supply System Components
b. Control System Components
c. Actuation components
Assignment 1
In groups, discuss each of these categories
Components of Air Brake System
Supply System Components
• Air compressor
• Air Governor
• Air Dryer
• Reservoirs
• Single Check Valves
• Low Pressure Warning System
• Safety Valve
• Drain Valve
• Pressure Protection Valve
• Regulator Valve
• Pipes
Components of Air Brake System
Components of Air Brake System
Control System Components
• Application Valve
• Relay Valves
• Quick Release Valves
• Push Pull valves
• Double Check Valves
• Electric-Pneumatic Valves
Components of Airbrake System
Actuation components
• Foot valve
• Brake chambers
• Slack adjusters
• Brake shoes
• Brake drums
Basic Air Brake Circuit
Basic Air Brake Circuit
• The compressor pumps air to the supply reservoir
• Over pressurization of the tank is protected by a safety
valve
• The governor controls the pressure in the reservoir to the
bottom of the foot valve
• When the driver depresses the foot valve, air pressure
moves to the brake chambers
• The brake chamber push rods move the slack adjusters
which rotate the S-cams resulting in the outward
movement of brake shoes causing friction that stops the
wheels
• When the driver releases the foot valve, air in the brake
chambers is vented out via the foot valve
Basic Air Brake System
Compressor and governor valve
• The compressor is in constant drive with the engine
• When pressure in the system has reached a
predetermined level, (80 - 135 psi), it is not
necessary for the compressor to pump air
• The governor places the compressor in the
unloading stage
• Thus it controls the min and max air pressure
Basic Air Brake System
Basic Air Brake System
Basic Air Brake System
The function of the air governor is to monitor system
air pressure and manage the loaded and unloaded
cycles of the compressor.