46

Brake Systems

Martin Restoule Algonquin College

Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

Prepared by

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Objectives
Explain the basic principles of braking, including kinetic and static friction, friction materials, application pressure, and heat dissipation. Describe the components of a hydraulic brake system and their operation.

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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Objectives
Perform both manual and pressure bleeding of the hydraulic system. Briefly describe the operation of drum and disc brakes. Inspect and service hydraulic system components.

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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Objectives
Describe the operation and components of both vacuum-assist and hydraulicassist braking units.

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Friction
Kinetic friction
Kinetic or moving friction is created by brake pads or shoes rubbing against rotating brake rotors or drums. Changes kinetic energy into thermal energy (heat).

Static friction
Static or stationary friction holds the car in place when stopped and should be present between the tire and road at all times.
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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Friction

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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Factors Governing Braking

Pressure
The amount of friction generated between moving surfaces contacting one another depends in part on the pressure exerted on the surfaces.

Coefficient of friction
The amount of friction between 2 surfaces (pads and rotors or shoes and drums) Determined by dividing the force required to pull an object across a surface by the weight of the object continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Factors Governing Braking

Frictional Contact Surface
The amount of surface, or area, that is in contact. Simply put, bigger brakes stop a car more quickly than smaller brakes used on the same car.

Heat Dissipation
The tremendous heat created by the rubbing brake surfaces must be conducted away from the pad and rotor (or shoe and drum) and be absorbed by the air.
continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Friction Material Classifications

Fully metallic
Lining is made of sintered iron and has been used for years in heavy-duty and racing applications because they have great fade resistance. They require very high pedal pressure and tend to quickly wear out drums and rotors.

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Friction Material Classifications

Semi-metallic
Made of iron fibres moulded with an adhesive matrix. Offers excellent fade resistance with good frictional characteristics so only a moderate amount of application pressure is needed. Semimetallic pads and shoes do not cause excessive wear on rotor or drum surfaces.
continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Friction Material Classifications

Organic (non-metallic)
For many decades, asbestos was the standard brake lining material. It offers good friction qualities, long wear, and low noise. New materials, such as composite/organic, ceramics, and carbon fibres, are being used because of the health hazards of breathing asbestos dust.
continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Friction Material Classifications

Synthetic
Non-asbestos lining materials made of synthetic substances are now available. The major brake lining manufacturers are constantly experimenting with new materials that meet all established criteria for long life, friction characteristics, drum and rotor wear, and heat dissipation.
continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Brake System Components

Chapter 46

Brake fluid Master cylinder Power booster Control valves Wheel brake assemblies Parking brake ABS system
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Hydraulic Principles
An example of how hydraulics can increase output force

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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Dual Hydraulic Brake Circuits

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Dual Hydraulic Brake Circuits

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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How the Master Cylinder Works

A pushrod connects the brake pedal to the master cylinder piston. When the pedal is pressed, the piston is pushed forward and the fluid in front of the piston is displaced into the brake system moving the pads and shoes into contact with the drums and rotors. As more force is placed on the brake pedal, the fluid transmits force throughout the system. continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Master Cylinder Operation

At rest
Fluid in the reservoir can flow into the area ahead of the piston through the compensating port. This keeps the system full and prevents pressure build-up during temperature changes.
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

continued
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Master Cylinder Operation

Applied
The piston is moved forward blocking the compensating port forming a sealed pump chamber.

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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Master Cylinder Operation

Brake release
When the pedal is released the piston return springs force the piston back. The piston cup seal collapses and fluid flows past to allow speedy piston return and pressure decrease.
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

continued
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Master Cylinder Components

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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Lines and Hoses

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Brake System Valves

Metering valve
Delays application of front disc brakes until pressure builds to rear drum brakes.

Proportioning valve
Reduces the hydraulic pressure to the rear drum brakes to balance braking.

Pressure differential valve

Used to operate a warning light switch.

Combination valve
Combines several functions in one valve.
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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A Proportioning Valve

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Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Pressure Differential Valve

Chapter 46

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

continued

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Drum Brakes
A drum brake assembly consists of a cast-iron drum, which is bolted to and rotates with the vehicles wheel, and a fixed backing plate to which the shoes, wheel cylinders, automatic adjusters, and linkages are attached.
The shoes are surfaced with frictional linings, which contact the inside of the drum when the brakes are applied. The shoes are forced outward by pistons located inside the wheel cylinder.
continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Drum Brakes

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Disc Brakes
Disc brakes use a cast iron rotor, inboard of the vehicle wheel. Both sides of the rotor are machined smooth for the brake pads to rub against. Usually the 2 surfaces are separated by a finned centre section for better cooling (ventilated rotors). The pads are attached to metal shoes, which are actuated by pistons housed in the brake caliper. continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Disc Brakes

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Brake Fluid Inspection

Remove the cover and check the gasket. Check the fluid in the reservoir.
Do not overfill.

Check the fluid for contamination. Check the master cylinder for signs of leaks.
continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Vacuum Brake Boosters

All modern vacuum-assist units are vacuum suspended systems. The diaphragm inside the unit is balanced using engine vacuum until the brake pedal is depressed. Applying the brake allows atmospheric pressure to unbalance the diaphragm and allows it to move generating application pressure. continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Vacuum Brake Boosters

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Vacuum Booster Checks

Chapter 46

Pressure check Pedal travel Vacuum reading Release problems Hard pedal Grabbing brakes Internal binding
continued
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Hydraulic Brake Boosters

Decreases in engine size, increased use of diesel engines, plus the continued use of engine vacuum to operate other engine systems, such as emission control devices, led to the development of hydraulic-assist power brakes. These systems use fluid pressure, not vacuum pressure, to help apply the brakes. continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Hydraulic Brake Boosters

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Summary
The four factors that determine a vehicles braking power are pressure, coefficient of friction, frictional contact surface, and heat dissipation. Three types of brake lining materials are used: metallic, semi-metallic, and nonasbestos substances.
continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Summary
Two common brake system control valves are the metering valve and the proportioning valve. The brake lines transmit brake fluid pressure from the master cylinder to the wheel cylinders and calipers.

continued
Chapter 46
Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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Summary
Common brake problems include hard pedal, low pedal, leaks, grabbing, and longer than normal stopping distance. Brake system service includes checking the fluid, brake lines, and brake pedal movement.

Chapter 46

Copyright 2007 by Nelson, a division of Thomson Canada Limited.

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