AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD

A REPORT
ON
PNEUMATIC BRAKING SYSTEM

SUBMITTED BY: AYUSHI GUPTA

MECHANICAL ENGINEERING
IIIRD YEAR

WHAT IS PNEUMATICS?

Pneumatics is a branch of technology, which deals with the

study and application of use of pressurized gas to affect
mechanical motion.

Pneumatic systems are extensively used in industry, where

factories are commonly plumbed with compressed air or other
compressed inert gases. This is because a centrally-located
and electrically-powered compressor that powers cylinders and
other pneumatic devices through solenoid valves is often able
to provide motive power in a cheaper, safer, more flexible, and
more reliable way than a large number of electric motors and
actuators.

Pneumatics also has applications in dentistry, construction,

mining and other areas.

EXAMPLES OF PNEUMATIC SYSTEMS AND

COMPONENTS

Air brakes on buses and trucks

Air brakes, on trains

Air compressors

Air engines for pneumatically powered vehicles

Barostat systems used in Neurogastroenterology and for

researching electricity

Cable jetting, a way to install cables in ducts

Compressed-air engine and compressed-air vehicles

Gas-operated reloading

Holman Projector, a pneumatic anti-aircraft weapon

GASES USED IN PNEUMATIC SYSTEMS

Pneumatic systems in fixed installations such as factories use
compressed air because a sustainable supply can be made by
compressing atmospheric air. Smaller or stand-alone systems can
use other compressed gases which are an asphyxiation hazard, such
as nitrogen - often referred to as OFN (oxygen-free nitrogen), when
supplied in cylinders.
Pneumatic brakes are equipment drive assemblies that use airactuated components to slow or stop shafts. There are several basic
types of pneumatic brakes. Band brakes, the simplest pneumatic
brake configuration, feature a metal band lined with heat and wear
resistant friction material. Drum brakes, which are commonly used
on automobile rear wheels, actuate when shoes press against a
spinning surface called a drum. Disc breaks consist of a caliper that
squeezes brake pads against a rotor. Cone brakes include a cone
that is lined with heat and wear resistant material that presses
against a mating cup surface. Typically, pneumatic brakes are used
in large motorized vehicles such as buses because they provide
reduced braking distances

BRAKE MECHANISM IN WHEELS

Almost all wheeled vehicles have a brake of some sort. Even
baggage carts and shopping carts may have them for use on a
moving ramp. Most fixed-wing aircraft are fitted with wheel brakes
on the undercarriage. Some aircraft also feature air brakes designed
to reduce their speed in flight. Notable examples include gliders and
some World War II-era aircraft, primarily some fighter aircraft and
many dive bombers of the era. These allow the aircraft to maintain a
safe speed in a steep descent. The Saab B 17 dive bomber used the
deployed undercarriage as an air brake. , or airplanes with both
wheel brakes and drag flaps raised into the air during landing. Other
methods convert kinetic energy into potential energy in such stored
forms as pressurized air or pressurized oil. Still other braking
methods even transform kinetic energy into different forms, for
example by transferring the energy to a rotating flywheel.

Brakes are generally applied to rotating axles or wheels, but may

also take other forms such as the surface of a moving fluid (flaps
deployed into water or air). Some vehicles use a combination of
braking mechanisms, such as drag racing cars with both wheel
brakes and a parachute
A braking mechanism according to the present invention for braking
the wheels of a wheeled truck assembly includes a handle mounted
to one beam which, when braking force is applied, urges a rod
toward the other beam. The rod operates a lever mounted to the
other beam which engages the actuation rod of the vehicle's
pneumatic braking system, thereby operating the linkage included
in the pneumatic system to separate the beams, bringing the brake
pads into contact with the wheels to brake the wheels.

REACTION FORCE TRANSMISSION MECHANISM FOR A

PNEUMATIC BRAKE BOOSTER
The present invention relates to a reaction force transmission
mechanism for a pneumatic brake booster including a largely
incompressible reaction plate that is interposed between an input
member and an output member and encased at the peripheral side
and has lateral abutment surfaces for the input member and the
output member, wherein the abutment surface close to the input
member can be acted upon by a pressure member which is adapted
to be fixed to a control housing and, consequently, can be excepted
from the transmission of the reaction force to a vehicle driver. To
improve its service life, the reaction plate includes a recess in the
area of the abutment of a valve piston extension, in which recess a
substantially incompressible, elastic insert is placed.
We are involved in the manufacturing of high quality pneumatic
failsafe disc brakes that finds application in steel mills, wind
turbines, textile machinery and and any industrial application that
involves stopping or starting of machinery. These are manufactured
using superior quality material and are appreciated for durability,
reliability, high tensile strength and dimensional accuracy. Further,
our entire range of disc brakes can easily be customized as per the
definite needs of our clients.

RAILWAY AIR BRAKES

An air brake is a conveyance braking system actuated by
compressed air. Modern trains rely upon a fail-safe air brake system
that is based upon a design patented by George Westinghouse on
March 5, 1872. The Westinghouse Air Brake Company (WABCO) was
subsequently organized to manufacture and sell Westinghouse's
invention. In various forms, it has been nearly universally adopted.
In the air brake's simplest form, called the straight air system,
compressed air pushes on a piston in a cylinder. The piston is
connected through mechanical linkage to brake shoes that can rub
on the train wheels, using the resulting friction to slow the train. The
mechanical linkage can become quite elaborate, as it evenly
distributes force from one pressurized air cylinder to 8 or 12 wheels.
The pressurized air comes from an air compressor in the locomotive
and is sent from car to car by a train line made up of pipes
beneath each car and hoses between cars. The principal problem
with the straight air braking system is that any separation between
hoses and pipes causes loss of air pressure and hence the loss of
the force applying the brakes. This deficiency could easily cause a
runaway train. Straight air brakes are still used on locomotives,
although as a dual circuit system, usually with each bogie (truck)
having its own circuit.

RAILWAY AIR BRAKES

The job of a passenger train brakeman wasn't too difficult, as he
was not exposed to the weather and could conveniently move from
car to car through the vestibules, which is where the brake wheel
was (and still is, in many cases) located. Also, passenger trains were
not as heavy or lengthy as their freight counterparts, which eased
the task of operating the brakes.
A brakeman's job on a freight train was far more difficult, as he was
exposed to the elements and was responsible for many more cars

ADVANTAGES
The advantages of the brakes include: brake can be used in
dynamic applications; field serviceable; easy flange connection
according to IEC and NEMA standards; low maintenance because
very few parts are exposed to wear; compact design; easily
interchangeable because of independent brake module; cast-iron
housing and good thermal capacity for use in harsh environments;
long life; and certified according to the European Explosive Directive
Air brakes must have a safe level of pressure to disengage the
parking brake, so if your brake system is faulty you can't move the
vehicle. An air brake system is a little less complex than a typical
ABS setup. An airbrake system *WITH* ABS is a bit more complex.
Air brakes are a proven technology that will apply more pressure
that hydraulic brakes and will stop a heavy vehicle far quicker with a
foolproof system. One leak in hydraulics and it's game over. Air
brakes are almost foolproof.

SPECIFICATIONS OF PNEUMATIC BRAKES

Specifications for pneumatic brakes include torque rating, speed,
power, maximum pressure, linear force, and linear speed. Springreturn brakes require power to engage. Spring-actuated brakes
require power to disengage. Non-contact brakes use methods such
as magnetic fields and eddy currents. Friction brakes generate
friction between contact surfaces. Wrap spring brakes transmit
torque from the input to the output through a wrapped spring that
uncoils to disengage the brake. Pneumatic brakes with teeth engage
only during stops or at slow speeds. Oil shear brakes achieve
engagement through the viscous shear of transmission fluid
between the brake plates.

TYPES OF PNEUMATIC BRAKES

There are several basic types of pneumatic brakes. Band brakes, the
simplest pneumatic brake configuration, feature a metal band lined
with heat and wear resistant friction material. Drum brakes, which
are commonly used on automobile rear wheels, actuate when shoes

press against a spinning surface called a drum. Disc brakes consist

of a caliper that squeezes brake pads against a rotor. Cone brakes
include a cone that is lined with heat and wear resistant material
that presses against a mating cup surface. Typically, pneumatic
brakes are used in large motorized vehicles such as buses because
they provide reduced braking distances.
Selecting pneumatic brakes requires an analysis of measurements
and mounting configurations. Important measurements include
diameter, the cross-sectional width of the assembly; length, the
dimension along the axis of rotation; and weight. Shaft
configurations can be in-line along the axis of the load, parallel but
offset from the axis, or perpendicular (right angle) to the axis

DISC PNEUMATIC BRAKES-A TYPE

The brake shoe carries the brake lining, which is riveted or glued to
the shoe. When the brake is applied, the shoe moves and presses
the lining against the inside of the drum. The friction between lining
and drum provides the braking effort. Energy is dissipated as heat.
Modern cars have disc brakes all round, or discs at the front and
drums at the rear. An advantage of discs is that they can dissipate
heat more quickly than drums so there is less risk of overheating.
The reason for retaining drums at the rear is that a drum is more
effective than a disc.

LIMITATIONS

Brakes are too sensitive: pedal linkage binding or defective

hydroboost causes this.

Excessive noise originating in the hydroboost unit is an

indication of the following problems: low power steering fluid,
air in the power steering fluid, a loose power steering belt, or a
restriction in the hydraulic hoses.

Limited braking force can be applied.

SPECIAL FEATURES ADDED

Pneumatic brakes are available with a variety of special

features. Some devices use electrical or electronic signals to
monitor parameters such as position, speed, torque, lockup, or
slip status. Others prevent play or backlash during load
engagement and prevent direction reversal during load
disengagement. Adjustable torque, the torque at which the
brake disengages or can be manually adjusted, is used
primarily for torque limiters. Washdown-capable pneumatic
brakes use housing materials that are rated for washdown
cleaning. Bidirectional pneumatic brakes can be set up to
rotate in either direction.