BRAKING SYSTEM

INTRODUCTION Brakes are employed to stop or slow-dow t!e speed o" a #e!$%le depe d$ & 'po t!e dr$#$ & eeds( When braked, each wheel of the vehicle builds-up a certain braking force. For this reason, greater the number of wheels braked, greater will be the braking effort, and sooner will the vehicle come to halt. Modern vehicles are therefore equipped with brakes on all the wheels.

Brak$ & Re)'$reme ts* The following requirements are expected of an efficient braking s stem. !t must stop the vehicle with in a smallest possible distance. !t must act instantaneousl in case of an emergenc braking. !t must be strong enough to sustain braking force. !t must neither slip nor should cause an skid to the vehicle. The brake linings should have longer life b qualities. !t must operate with the least effort b the driver. possessing higher anti-fading

+RINCI+,E O- BRAKING The brake is a friction-creating device, which caused speed reduction of the vehicle at a faster rate than the speed reduction obtained b changing the gears "top to #rd, to $nd, to %st& and closing-down the accelerator. 'owever, this rate cannot be high enough to

stop the vehicle instantaneousl . !t is because a vehicle of weight w moving at a speed v possesses kinetic energ whose value is given b

% W (.). * --- --- +$ $ g TY+ES O- BRAKES ,ifferent t pes of brakes are used on various categories of vehicle. These can be classified according to following considerations. .( O T!e Bas$% o" A%t'at$ & Met!od Mechanical brakes ' draulic brakes -neumatic "or air& brakes /a0 .ompressed air brakes )lectric brakes 2( O T!e Bas$% o" Co str'%t$o ,rum brakes ,isc brakes /and brakes 3( O T!e Bas$% o" A%t$o o" Brake S!oes !nternal expanding brakes )xternal contracting brakes 4( O T!e Bas$% o" Com1$ at$o s ,rum and ,isc combination brakes /10 +acuum brakes

 Mechanical and ' dro combination brakes

5YDRAU,IC BRAKES The modern cars are mostl equipped with h draulic brakes on all the four wheels. The braking s stem of #-wheelers also use h draulic brakes but on rear wheels onl . Their front wheel is equipped with a mechanical brake. Wide popularit of h draulic breaking s stem can be attributed to its several advantages, which it has over the mechanicall operated /01()2. 2ome of these advantages are )qual braking on all the wheel. .omparativel lesser braking effort required b the driver. 'igher multiplication of brake pedal effort. 3uieter operation due to the absence of too man links, rods and shafts. 0educed loss of effort between brake pedal and brake shoes on account of fewer frictional parts. The h draulicall operated brakes are suitabl used on both the drum and the disc brakes. 'owever, there is a basic difference in these two s stems. !n h draulicall operated drum brakes, some h draulic pressure has to be alwa s maintained with in the s stem whereas in h draulicall operated disc brakes it is not so.

5YDRAU,IC DRUM BRAKES The assembl of a brake drum. !t consists of the following main components. /a0 /rake ,rum /rake lining /e0 )xpander 1d4uster The brake drum is mounted on the axle hub and the whole assembl is housed /"0 1nchor /&0 0etracting spring /!0 /10 /ack plate or torque plate /%0 /rake shoe /d0

concentricall with in the wheel. 1 back plate made of pressed steel sheet is mounted on the axle causing. !t is meant for supporting the brake shoes, expander and the anchor. !t also serves to protect the assembl from dust, dirt and mud. Two brake shoes age hinged or fulcrumed on the back plate b means of anchor pins towards heel end of the shoes. The toe-end of the shoes is connected to the expander. The brake linings made of friction materials are riveted on the brake shoes on their convex faces, which remain near to he brake drum. 1 retracting spring "ma also be two in number& is attached to the two brake shoes for the purpose of pulling-back the shoes, awa from the brake drum when the brakes are released. The expander attached to the toe end of the brake shoe, ma be a cam, toggle lever, or wedge in mechanical brake, or a wheel c linder in case of h draulic and pneumatic brakes. !t is operated b foot pedal or hand lever through mechanical, h draulic, or pneumatic linkage. The brake linings do wear in due course of their working and need to be ad4usted from time to time. Therefore an ad4uster is used for this purpose.

,ayo't a d Compo e ts* - 2implified la out of a t pical h draulic brake s stem. !n consists of the following mains parts. Master c linder, operated b foot pedal Wheel c linder /rake fluid "or brake oil& pipelines

Master Cyl$ der* - 1 Master c linder is the most important component of h draulic brake s stem. !t remains connected to the brake pedal on one end and to the wheel c linder through the pipings, houses and their unions on the other end "output side&. !n effect it is a plunger t pe pump, which delivers oil at about #56-566-k-a pressures during /raking. The Master c linder assembl alwa s remains full of brake oil so that instantaneous braking ma be done when desired. Co str'%t$o * - !t consists of the following main parts in its assembl . . linder bod integral with the brake oil reservoir having inlet and b -pass ports. 0eservoir cap having air vent. -lunger connected to a push rod, which is attached to the brake foot pedal. -lunger return spring attached with in the pressure chamber. .heck valve with a rubber cup and valve seat to prevent back flow of brake oil from wheel c linder to pressure chamber. -lunger seals7 primar and secondar . 0ubber boot for protection against the dust and dirt. -iston stopper.

The washers, circlips and rubber cups and also be prevent leakage. The plunger is of var ing having the least area in its middle portion. 6ork$ &* - When the brakes are applied the effort exerted on the brake pedal forces the plunger outward b the push rod. .onsequentl , the plunger compresses upon the brake oil stored in the pressure chamber against the pressure of return spring. This initiates pressure stroke, which opens the check valve to allow oil to flow into the brake lines. When the brakes are released the plunger return spring pushes back the plunger towards the boot end. The oil brake pipelines returns back and raises the check valve from its seat. When the oil pressure falls to a required minimum value, the return spring helps the valve to reseat. Types o" Master Cyl$ der* - 2everal designs of master c linder are emplo ed on auto vehicles of different makes and models. These are7 .( 2ingle Master c linder ,rum brakes ,isc brakes 2( ,ouble Master c linder 3( Tandem Master c linder

6!eel Cyl$ der* - !t consists of the following main parts. Two pistons, one each connecting to the left and right brake shoes. -iston return spring. Wheel c linder bod enclosing the pistons and the spring.

1 h draulic pipeline is connected to wheel c linder. When the fluid is forced into the c linder, piston move awa from the center and force a part shoes. The shoes pivot on pins and press against the internal surface of brake drums secured on the wheels, thus slowing down the rotation of the wheel. When the pressure in the h draulic s stem drops, the shoes are drawn to each other b spring and the pistons return to their initial position.

Brake -l'$d* - The s stem is filled with a fluid consisting of Caster O$l a d Al%o!ol "other combinations are also used&. This is known as Brake "l'$d or 1rake o$l. Its "' %t$o s $ !ydra'l$% 1rak$ & are s$m$lar to t!e "' %t$o o" 1lood $ !'ma 1ody(

DISC BRAKES 1s compared to the drum brakes, the disc brakes are the development of later ear. /asicall the are also friction brakes but with practicable differences. The had been used on aircraft in the past, have been successfull used on racing cars and are now used as standard equipment on various vehicles. 1dvances in disc brakes are seen as a sign of ousting of drum brakes.

Co str'%t$o * - 1 ,isc /rake resembles a flat clutch fitted on each wheel. The generall adopted t pe disc brake is referred as spot brake. !t consists of the following main parts.

/a0 .aliper or c linder casing * outer and inner /d0 Friction pad

/10 0otor disc

/%0 -iston

/e0 -ad supporting plate /"0 /leeder plug

/esides above, the disc brake assembl also enclose piston seal, dust boot, pad wear indicator, anti squeal shim etc. The c linder casing is made in two halves named outer and inner c linder and resembles a caliper. That is wh the disc brake is named caliper-t pe. The caliper is attached to the axle housing in a rear-wheel brake and to the steering knuckle in a frontwheel brake. The rotor disc is connected to the road wheels through axle shaft. The assembl houses two friction pads, one on each side of the disc. These pads are held in position b steel pad plates.

6ork$ &* - The ,isc brakes are operated h draulicall . When the vehicle is to be braked the brake fluid "or oil& pumped b the Master . linder-brake pedal s stem "see topics on h draulic brakes& enters into the caliper through inlet tube. !t then flows through the oil passages provided their in and experts pressure on the pistons. There are four pistons and each of them forces the friction pads against the rotating disc. The pressure of pads stops rotation of the disc and hence the axle shaft "i.e. the wheels mounted on them& stops. When the brakes are to be released, the compression springs force back the piston to release pressure from the friction pads.

COM+ARISON BET6EEN DRUM BRAKES AND DISC BRAKES

1lthough ,isc brakes are getting increasing applications on Modern 1uto vehicle, et the ,rum brakes are not out of favour. !n fact both t pes have their own merits and demerits and therefore suit well on one or the other vehicles. 1 comparison between them is made in the chart given below.

S(NO( .(

DESCRI+TION 8ife of friction material

DRUM BRAKE

DISC BRAKE "about

0easonable "about %566 0easonable km& $566 km&

2( 3( 4( 7( 8(

+isibilit outside

of wear from :ot possible !nferior friction Troublesome taking /ulk +er slow and

.an be seen at a glance /etter time )as and rapid 8ighter "b * $5<& )fficient exposure atmosphere due to to

'eat dissipation 0eplacement material Weight of

9( :( ;(

.ooling

Water and dirt collection /reaking effect

1ccumulates ;enerall inconsistent

2elf cleaning .onsistent

.<( ..( .2(

Temperature effect

,rum expands, tends to =naffected separate out from linings

2elf energi9ing action /rake pedal effort

)xists 'igher

1bsent -roportional pressure alwa s retardation to

.3(

/ehavior

of

h draulic 2ome

.4(

s stem in released stat. 0esistance to fading

exists

:o h draulic pressure on the piston )xcellent More, since brakes are not self-energi9ing

.7( .8(

Force needed to appl brake Fair .omparativel :ature of wear 2hape of friction lining :on uniform .urved

=niform 2traight

C,UTC5ES
INTRODUCTION
The clutch is an intermediate mechanism, which is placed in between the fl wheel and the gearbox for the purpose of allowing or discontinuing the power flow from engine to the transmission s stem. !n normal conditions, the clutch remains in engaged position and allows flow of power from engine to the gearbox. 'owever, when the flow of power is to be interrupted for an reason, it is disengaged and hence the power flow discontinues temporaril . The disengagement of the clutch is required when the gear position is to be changed, or when the vehicle needs to kept in neutral position "i.e. engine running but the vehicle stationar &. The control for disengaging the clutch is imparted b a foot-pedal in >-wheelers and b a hand-lever in $-wheeler through control linkages.

RE=UIREMENT O- A GOOD C,UTC5

While discharging its functions, the following requirements are desirable in a clutch. Grad'al E &a&eme t* - 1 clutch should take on the power drive smoothl without undesired 4erks whenever it is re-engaged. This helps in increased driving comfort, less effort on the driver, and prolonged life of the clutch. E""ortless Operat$o * - The operation of clutch disengagement should be easier so that the driver does not feel tired. 1 hard "uneas & clutch operation will cause erratic running. S$>e* - The si9e of a clutch should be such that it occupies minimum space. 1lthough the si9e is governed b the designed value of frictional surface area of the clutch facing,

even through this area can be accommodated efficientl b providing two or more clutch plates, such as in multiplate clutch.

SING,E +A,TE -RICTION C,UTC5 2uch clutches use a single -late having friction facing on both the sides. .ushioning effect in them is obtained b installing springs of different designs. ,epending upon the t pes off springs the use, the single plate clutches ma be classified into following two t pes7 'elical spring t pe single plate clutch ,iaphragm spring t pe single plate clutch.