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Hydraulic
System
Fundamentals
o Explain how cylinder size chan ges hydrau lic forc e and distance traveled.
Important Terms
Hydrauli cs
Master cy l i nder
Ca lipers
Cylind ers
Control va Ives
Pistons
Wh eel cylinders
H yd rauli c actuator
H yg roscopi c
Pascal's law
61
Auto Brakes
62
You learned in Chapter 1 that the earliest brake sys
tems were mechanical devices. You also learned that mod
ern brake systems are operated by hydraulic pressure.
Using hydraulics to apply the brakes is more efficient and
convenient than mechanical linkages. The hydraulic sys
tem is designed to allow brake pedal pressure to be
increased many times for greater braking power and to dis
tribute braking force equally. This chapter will explain in
detail the use of hydraulic pl'essure in braking systems.
Changes in Force
There are times when it is desirable to change the
amount of movement of the input and output pistons. In a
simple hydraulic system, changing the cylinder size
changes both the distance traveled and the amount of
force applied. In Figure 4-3, note that the input cylinder
has an area of one square inch and the output cylinder is
10 in2. If we apply a force of 1 lb. to the input cylinder, this
produces a pressure of 1 pound per square inch, or 1 psi
in the system. This pressure travels to the output pi ston. At
the output piston, the 1 psi acting on the 10 square inch
piston produces an output force of 10 pounds. Note that by
varying the size of the input and output pistons, we have
increased the input force 10 times.
501bs.
Incompressibility of Liquids
Gases such as air can be compressed, that is, made to
take up less space. Compressed air is used in the shop to
power air tools and other equipment. However, liquids
such as water, oil , and brake fluid cannot be compressed.
The inability of liquids to compress is the basis of brake
hydrau Iic system operation, as well as the operation of
power steeri ng and automatic transm iss ions.
Figure 4-1 compares the compressibi Iity of gases and
liquids. A weight is placed on the lids of closed containers
of gas and liquid . When weight is applied to a container of
gas, its volume is reduced. In other words, a gas under
pressure takes up less space than it does when not under
pressure. Placing the weight on the liquid increases its
pressure, but does not reduce its volume.
Transfer of M ovement
Since liquids are not compressible, they can be used
to transfer movement. Figure 4-2 shows a simple hydraulic
system consisting of two cylinders and two pistons, con
nected by tubing called a hydraulic line. Both the right and
left cylinders and pistons are the same size. The entire sys
tem is filled with liqUid. If the piston on the left side is
pushed, it pressurizes the liquid. This pressure on the liq
uid is transmitted through the hydraulic line to the other
piston, causing it to move.
It is important to note that moving the first piston
caused the second piston to move exactly the same amount.
This is because the force was transmitted through the liquid
unchanged. As long as the input and output piston areas are
the same, input force is transmitted unaltered. The cylinder
and piston assembly shown in Figure 4-2 is the basis of all
hydraulic brake system design and operation.
No pressure
50 Ibs. pressure
Liquid
HYdrauliC
line
,----.,""""--""7\
'
CYlinder
Chapter 4
63
Pascal's law
The simple brake system shown in Figure 4-4 illus
trates a basic law of hydraulics, called Pascal 's law.
Pascal's law states the pressure in a closed hydraulic sys
tem is the same everywhere in the system. This principle of
hydraulics was discovered in 1653 by Blaise Pascal.
When the master cylinder at the top of Figure 4-4 is
pressurized by pushing on the piston, the pressure created
is the same throughout the system. This principle allows
you to check pressure at one point in the system with con
fidence that the pressure is the same elsewhere in the sys
tem. It also allows you to check variations in pressure and
determine whethel' they are normal or caused by system
defects.
Cylinder \
~----",~---:"
x1 distance
x10 force
Master Cylinder
However, this increase in hydraulic force has a
price. The input piston moved one inch while the output
piston moved 1/10 of an inch. Therefore, the force was
increased ten times, but the amount of movement was
decreased to 1/10. Therefore, to increase force we must
accept a decrease in movement. How this principle is put
to work in the modern brake system wi II be covered later.
Master "",
cylinder ' " -- ~l ,~:q:;:;;:::X\
I; epedal
Force
pressure
Brake lines
(tubing)
Front
Rotor ~
L-'~:J '
Wheel cylinders ~ . _
pistons and
links
v -,-.----, '
iZ2L7
_LZ
64
Auto Brakes
Dual piston ~
master cylinder
Pistons
Caliper
Hydraulic
lines
Proportioning Valve
cylinder
Figure 4-5. The master cylinder generates the pressure needed
to operate the calipers, wheel cylinders, valves, etc.
Control Valves
The modern brake system contains several flow and
pressure control valves. These valves are:
D Metering valve.
D Proportioning valve.
D Residual pressure valve.
D Pressure differential valve.
The job of these valves is to make the brake system
more efficient, and to warn the driver when a failure
occurs. They perform these jobs by using spring pressure to
oppose hydraulic pressure. A brief explanation of these
valves is given in the sections that follow. Note that two or
more of these valves are sometimes installed into a single
assembly called a combination valve.
Metering
valve
Metering Valve
The metering valve is used to keep the front brakes
from applying before the rear brakes. The front brake
pads are not held in the retracted position by springs as
Chapter 4
65
pressure
valve assembly
r--r.:".,--------r.''7rl
Proportioning
valve
1'-' / 0 .1
~ Jlb
Figure 4-7. The proportioning valve helps to limit brake
pressure to the rear brake system, reducing the chance of
wheel lockup.
valve assembly
,....,...,-r--
----r.o-r-.
66
Auto Brakes
Brake Fluid
Figure 4-10. A-Actuator assembly during normal braking operation. 1-Applied master cylinder pressure. 2-Bypass brake fluid.
3-Normally open solenoid valve. 4-EMB braking action. 5-oc motor pack. 6-ESB braking action. 7-Gea r assembly 8-8al/
screw 9-Check valve unseated. B-Actuator position during the anti-lock brake phase. 1-Trapped bypass brake fluid. 2-Solenoid
valve activated. 3-EMB action released. 4-oc motor pack. 5-ES8 braking action released. 6-Gear assembly 7-Ball screw
8-Check valve seated. 9-Applied master cylinder pressure. (Delco Moraine)
Chapter 4
67
Reservoir
---------"'Q
cap
Brake fluid
reservoir
Reservoir
retainer
Valve bl ock
assembly
Pushrod \
rear
<
Spring
Pushrod
assembly
Push rod
(front)
Reservoir
grommet
High-pressure
hose
Pressure
switch
Return
hose
Pump
insulator
Resistance to Boiling
Th e most important req uirement of b,"ake fluid is its
res istance to boiling. If th e brake fluid boils, it beco mes a
gas. As w e learned ea rli er in thi s c hapter, gases are co m
pressib le. Therefore, if the brake f luid boils, pressin g on th e
brake pedal w ill simp ly co m press gas instead of appl yin g
the brakes. Since fri cti onal heat is tran smitted to the
hydraulic system during braking, fluid resi stance to boiling
is ve ry important.
Water Absorption
Another important qu ality of brake fluid is its ability to
abso rb w ater. Brake fluids are intentionally desi gned to be
hygroscopic, or abl e to absorb water. This woul d see m to
be a bad qu ali ty, sin ce water will lower th e fluid 's resist
ance to boilin g. Should water get into th e brake system,
how ever, it w oul d tend to collect at low spots in the sys
tem. Water col lecti ng at o ne spot in th e brake syste m could
ca use corros io n at that spot. Pure water would also freeze
in co ld weather, bl ock in g off brake lines o r sti ck ing pi s
to ns. Des igning brake flui d to abso rb wate r helps to mini
mize these probl ems.
You mu st take preca utions to lim it the exposure of
brake fluid to w ater. Brake fluid th at has a bo ilin g point of
446F (230 C) when completely w ater free has a boiling
point of 311 F (155 C) when it has abso rb ed th e maximum
amount of w ater it ca n hold, Figure 4-12A. Always keep
containers ti ght ly ca pped, and do not lea ve hydraulic sys
tem parts di sconnected for long peri ods of time.
68
Auto Brakes
536
240
()
0
220
C
'0 200
0..
OJ
'0
CD
500
464
428 0III
392 ~
"0
356 Q.
.~
320 "T10
180
160
~ot4
140
284
DO~--
120
248
100
212
2
% H2 0, wt.\wt.
A
)3:,11
f5//
Chapter 4
69
Summary
The brake hydraulic system has evolved over many
years and relies on the basic principles of liquids. The
study of liquids and how they work is called hydraulics.
liquids cannot be compressed . This property of liquids
is used to cause liquids to transfer movement and pressure,
as well as increase force. The operation of the brake
hydraulic system is based on Pascal's law which states that
pressure is transmitted unchanged through a closed
hydraulic system. The basic components of a brake system
are the master cylinder, wheel cylinders and calipers, con
necting lines and hoses, and various control valves.
The anti-lock brake system is operated by the same
hydraulic principles as the standard brake system . ABS
hydraulic control valves are operated by electric solenoids
controlled by an on-board computer. Pressure is often sup
plied by a motor driven hydraulic pump.
Some of the most important properties of brake fluid
are its ability to resist boiling, its ability to absorb water,
and its resistance to corrosion. Brake fluid must also lubri
cate moving parts and stay liquid at very low temperatures.
Brake fluid is classified and rated by the u.s.
Department of Transportation (DOT) and the Society of
Automotive Engineers (SAE). The two major classes of brake
fluid are glycol based and sili cone based. The two types
should not be mixed. Brake fluid containers should be kept
closed to reduce the amount of water absorption.
Review Questions-Chapter 4
(B) B only.
(C) Both A & B.
(D) Neither A nor B.
3. According to Pascal's law, the pressure in a closed
hydraulic system is the same ___.
(A) only at the input piston
(B) on Iy at the output pistons
(C) only at the input and output pistons
70
Auto Brakes
5.
wheel cylinders
10.
the
the pressure
(8) output
(8)
fluid transfer
Illuminate a
friction
(D)
travel.
To decrease
B& C
To decrease brake
gear
force.
(C) vane
force.
(D) piston
12. ABS
8. During hard
va
pump.
(A) rotor
pedal travel.
To increase brake
(B) if the
are
boil
(B) freezing
valve
corrosion
14.
(A) A only.
(8) B only.
Both A & B.
4.
(C)
5.
is its