Transilvania University of Brașov

Mechanical Engineer

PROJECT
Braking System

Student: Vrânceanu Vlad Ionuţ;

Group: AE 1731
 1 THE CASE OFSUSPENSION SYSTEM WITH RIGID 3 ARMS

1.1 ROLE OF SUSPENSION, CONDITIONS IMPOSED

When driving the vehicle, road irregularities oscillation of wheels which produce bridges are
transmitted. The suspension vehicle connects elastic damping between its axles and frame or
bodywork miscorand cushioning dynamic loads and vibrations resulting from the action of vertical
components of the interaction forces between the wheels and the road.
Speed of the vehicle on uneven road surface is limited primarily of suspension qualities and
secondly engine power. Convenience vehicle is driven mainly by suspension.
By printing the desired character of the oscillations, the suspension mechanism with guiding
the deck influences manageability, handling and driving stability, elements that together define
roadholding of the vehicle.
Kinematics wheels passing over bumps running track, and the sprung mass of the unsprung
front, the vertical variation of tasks are determined by the type of mechanism guiding the deck. The
character of these movements is determined by the suspension of the vehicle by its elastic and
damping elements. To ensure an adequate comfort, suspension settings must be chosen so as to take
into account the specific circumstances set theory suspension, namely:
- The magnitude of the sprung mass is reduced even more as the ratio of the mass
suspended / unsprung mass is higher, highlighting the advantage to those articulated rigid bridges
and first generalization from cars with comfort.
- Pulsing system harmonics is even less with how the elastic stiffness is smaller, that is more
elastic bow. Reducing spring stiffness is limited by increasing the nominal static deflection. Suspension
stiffness is chosen tolerance limits of the human body when it undergoes a vertical periodic motion.
- The rigidity of the front axle suspension is smaller than the rear axle. During walking, the car
approaches obstacles through the front wheels first, and after a while the rear axle. In this case with
all the attack delayed the rear axle, the rear wheels catch up vertically moving the front wheels
because their oscillation period is shorter and the oscillations cancel gallop.
- Keep unchanged suspension characteristics change when hanging mass (mass distribution
remains unchanged), should alter the stiffness of the springs in the same proportion to the mass
suspended. This condition explains the interest in suspension stiffness proportional to the load
. - To ensure convienece, damping oscillations should vary in the first period between 92% and
98% of energy transmitted partially suspended, according to values of the amplitudes of the first two
3.7 ... 22.4. Higher depreciation, increase dynamic loads transmitted through the muffler hanging
slopes and lower depreciation can lead to balance body and wheels to travel on horses with repeated
irregularities.The comfort can be achieved combining maximum rigidity springs with dampers
proportional burden nonlinear characteristics.
By type the elastic suspensions may be: with metallic elements (leaf springs, coil springs,
torsion bars) with elements still non-metallic (rubber springs, air springs and hydro) and mixed.
By the elements characteristic type elastic suspensions may be linear characteristic,
characteristic nonlinear, characteristic feature progressive and stepwise.

Elastic elements, regardless of the type of characteristic, can form depending on which type of
mechanism guiding the wheels, suspensions dependent or independent. The option for a bridge or
another is made depending on the destination of the vehicle by considering the requirements of
comfort, maneuverability, stability and cost-wheel and road.
 1.2 DESCRIPTION OF THE SUSPENSION RIGID WITH 3 ARMS

The suspension is stiffer with 3 arms in its components:

- Axle bridge
- The 3 arms of support
- Springs (coil or sheet)
- 3 arms rigid suspension allows a single movement of the wheels, namely a circular sector with
a radius equal to the length of time the resultant suspension arms.
The mechanism of rigid axle guide member must cancel translatilepe X and Y and must cancel 2
rotations after X and Z.Cancellation is by taking forces during movement.
In this type of suspension does not change the track during passage over bumps or potholes, are
canceled because some movements of the wheel.
Classification guiding mechanisms is:
-The easiest way is realized using leaf springs or helical springs. They have two roles:
-Role of spring
-The role of the guide mechanism

X means the forces of compression or traction forces arc. Particularly lateral forces lead to a
request for bending. When Y may be caused by traction or braking forces and a twisting moment of
the deck.
If this action on the wheel axle with a moment of braking or traction on the wheel then (coefficient
corresponding action and reaction) actioneza wheel on the deck with a time equal but opposite.

1.2.1 Exemples of rigid suspensions with 3 arms

FIG. 1.2.1.b,c,d. Rigid suspension with 3 arms

 FIG. 1.2.2. Indirect and no engines deck
(designedas a beam with thin walls, made from sheet of prese and welded)

a.

FIG. 1.2.3. Deck and suspension from backside from Dacia 1300 (section)

a- sectionby the rear wheel;

b- the view generate;
c- the view bottom of the drive rod collector pressure to the rear brakes;
d- the deck;
1- rear spring;
2- the shock;
3- extensible side arm;
4- central –side arm;

5- may metallic tray sitting spring;

6 bar stabilization from back;
7- Rear brake cable;
8- tire;
9- wheel rim;
10- Rear axle steering knuckle;
11- drum brake;
12- rear axle;
13- corrector rear brake pressure;
14- rod drive of correction pressure;

1.3 STEERING GEOMETRY AND POSSIBLY OF CONTROL

1.3.1 The angles of wheel

a)Camber

The camber wheel angle in degrees as a median between the track and wheel
perpendicular to the ground when viewed from the front of the vehicle (fig. A1).

Fig.a1

If the top of the wheel is leaning towards the inside of the vehicle, camber is positive (Fig. A2).
 Fig. a2

If the top of the wheel is leaning towards the inside of the vehicle, camber is negative (Fig.
A3).

Fig. a3
 b The angle of convergence

Convergence is the angle formed by the wheels of the vehicle center line (smooth
passing longitudinally through its center) and wheel center line of the vehicle when viewed
from above .(fig. b1).

When extension of the centerline of the wheel tend to meet in front of the vehicle, then we
say we have positive convergence (fig b2); if they tend to unite behind the vehicle, then we say that
we have convergent negative (fig. b3)

Fig. b2 fig. b3
 1.4 TYPES OF MECHANISMS OF GUIDANCE

Guiding devices transmit vertical components of forces between the wheels and the road, and
the moments of these forces in the body, and character movement determining wheel in relation to
the car body and in relation to the road.

Z and moments Mx vertical forces are transmitted to the body through the elastic suspension.
Damping elements are designed to dampen oscillations arising avoid the resonance
phenomenon.

a) Dependent mechanisms guiding wheels

Fig. a1

Guiding scheme a bridge rigid mechanism position control three branches: two longitudinal
arms and a cross arm (arm Panhard)

Fig a2
 Guiding scheme a brige rigid mechanism position control of 3 arms: 2 arms lower longitudinal
arms and one longitudinal bifurcated (triangular) higher.

Fig. a3

Scheme guiding a bridge rigid mechanism position control four arms: two arms and two arms
lower longitudinal upper diagonal

Fig. a4

Scheme guiding a rigid axle Five-arm mechanism position control: two lower longitudinal
arms, two arms and a top longitudinal cross arm (arm Panhard

b) Mechanisms guiding wheels semidependent

 Fig. b1

Guiding mechanism with torsion beam (semi-rigid axle, wheels semidependente- Mazda)

Guiding mechanism with torsion beam and Panhard bar

c) Mechanisms guide wheel independent

Scheme transverse arm mechanism

 Fig. c1

McPherson suspension with transverse oscillation and oscillating slide

Scheme guiding mechanism with cross arms balancing uneven parallel axes.
 Fig. c2

Suspension with unequal arms superimposed tranversal axes parallel balncing

 Fig. c3

Suspension Multi-link

1.4.1 Advantages and disadvantages of rigid suspension system with 3 arms

Advantajes:
- High payload capacity at a reduced size
- Good performances in off-road
- Simplicity construction
- Reliability

Disadvantajes:
- Redus comfort
- Can not adjust the angle of the wheel

1.4.2 The use stiffer suspension system with 3 arms

The suspension system is rigid with 3 arms in used terrain vehicles, personal cars older
building personal vehicles or low cost nowadays. (Dacia 1300 Chevrolet Spark).
 1.5 A KINEMATIC ANALYSIS OF THE GUIDING MECHANISM CHOISE

FIG. 1. The behaivor of the suspension over the bumps

1.5.1 Reaction to the kick on

 Of the 6 degrees of freedom possible, the deck is allowed only 2 degrees of freedom,
namely
 • X-axis turning – roll
translation of the axis Z – bouncing

At bouncing, the track never shrink deck, which is good because it maintains stability car, but
camber changes, leading to loss of grip and unequal wheel loading.

1.5.2 Behaivor roll

On this deck with rigid axle crane, the bumps, the body leans autorismului after bridge and
overturning există possibility.

1.6 THE POSSIBILITY OF ADJUSTING THE STEERING GEOMETRY (WHEEL AND PIVOT)

Convergence angle is adjusted by changing the length bieletelor direction. Loosen the screws
of the end of steering rods, left and right, then screw rotates dereglaj to bring convergence angle. This
adjustment lengths bieletelelor left and right must be equal.
Rear toe angle is not adjustable on some models. If rear toe angle deviates from the specified
value, the whole rear axle and wheel axle should be checked for damage. Repair or replace the faulty
part.
 2 LEVEL STUDY OF THE DISC BRAKES

Brake disc models used to project

Fig.2.1

Brake disc and caliper ventilated and airy

 Fig.2.2

Brake disc and calliper and schemes work

Fig 2.3
 Fig.2.4

Ventilated disc and caliper brake with a little piston

2.1 DESTINATION OF THE SYSTEM BRAKE

To reduce vehicle speed to be created forces which oppose the motion.

As some effects reduced drag and resistance to acceleration in the event
braking becomes active force, resulting need for the vehicle to be equipped with devices
to achieve strong opposite movement. These forces are called braking forces; they
They must be sufficiently large values that can be adjusted by the driver depending
needed. Braking forces are created by braking mechanisms included in system
the vehicle's brakes.
The braking system of the vehicle is intended:
- reduce by a certain amount or cancellation progressive speed vehicle;
-imobilization stationary vehicle on a level road and on slopes that he can ascend and descend;
- stabilizing the vehicle speed when descending long hills.
 2.2 COMPONENTS PARTS AND CLASSIFICATION OF BRAKING SYSTEM

The braking system consists of device braking and slowing device.

Braking device serves to reduce vehicle speed to a value, desired including until it stops with a a
deceleration larger and without deviation away from dangerous trajectory, and immobilizing the
vehicle stationary on a level road and slopes that you can climb and descend.
Retarder device serves to stabilize the vehicle speed down long gradients without braking devices of
service, security and parking to be used or contribute to this stabilization.
Braking device consists of:
- brake mechanism;
- transmission and control element.
Brake mechanism serves to produce braking force opposing the motion or
tendency to move the vehicle.
Transmision on the brake divice it is composed of all elements contained
and brake control element between the actual and are functionally linked.
Comand element is the part directly operated by the driver or by the trailer concerned to provide the
necessary energy transmission brake or a control.
By constructive peculiarities of the brake mechanism braking devices are classified according to the
geometry of rotating and fixed brake parts themselves.
By the shape of the part that rotates differ:
- drum brakes;
- disc brakes;
- combined brakes.
By the form fixed parts, brakes can be:
- with brake blocks;
- withpads;
- with belt;
- with disk;
- combinates.
By the site of the braking mechanism differ:
- wheels brakes;
- transmission brakes.
In the first case braking when acting directly on the wheel hub, and the
latter acts on a transmission shaft of the vehicle.
By the type of transmission are different:
- Brakes with mechanical transmission;
- Brakes with hydraulic transmission;
- Brakes with pneumatic transmission;
- Brakes with electric transmission;
- Brakes combined transmission;
- Drive servo brakes..
2.3 OPERATING CONDTIONS

Braking devices of motor vehicles must meet the following

conditions:
- Be capable of some deceleration imposed;
- To ensure vehicle stability during braking;
- Braking to be progressive, without shocks;
- Correct distribution of braking effort to bridge;
- The driver does not require too much effort to drive;
- Preserving qualities vehicle braking in all working conditions
encountered in exploitation;
- To ensure the evacuation of heat that arises during braking;
- Have high reliability;
- To provide safe operation in all working conditions;
- Adjustment to make games more often and comfortable or automatically;
- To quickly enter into operation;
- Braking is not influenced by the unevenness of the road and steering wheels
direction;
- Allow vehicle immobilization slope, in the case of a stationary long
duration;
- Do not allow oil and impurities to enter the friction surfaces;
- Braking force to act in both directions of motion of the vehicle;
- Not to make braking intervention than the driver;
- Be designed, constructed and installed to withstand the corrosion
and aging to which it is exposed;
- Concomitant not be possible to operate the brake pedal and pedal
acceleration;
- Have quiet operation;
- Have a simple, inexpensive construction.
 3 MATERIALS USED IN CONSTRUCTION OF BRAKE

3.1 TYPES OF RESISTANT AND ALLOWED

The table 5.1 presents the main and most common materials used in industry construtoare braking
equipment, material used for brake discs and drums as well as plates and brake pads.

The table 3.1

3.2 HOW TO MODIFY

Brake discs and drums are obtained by casting iron, steel or aluminum alloy and are processed
cold for defining the shape and roughness required.

Cast iron has optimal thermal properties - low plasticity and good thermal conductivity, but
also has production-related advantages, such as turnabilitatea or machinability. It also has practical
advantages: good damping properties.

Aluminium is a very light material has lower density than iron, hence the disk co-molded can
be made, depending on the application, 15% -20% lighter than a piece made entirely of cast iron.

This is an important result since car manufacturers consider reducing the total weight of 1 kg
car a success, even more so when reduced unsprung mass, ensuring comfort and precision driving.
 Pads and brake pads are made of softer material than the wear of discs and drums for their
controlled.

3.3 TECHNOLOGY USED IN CONSTRUCTION BRAKING MECHANISM

3.3.1 Disk brake

Part of wheel discs stand the pressure plates, one acting on the inner surface of the disc, and
the other on the outer surface, resulting in a very high friction, which reduce speed to stop the
vehicle.

Every brake discs are required and their state depends on the optimal efficiency of brake pads.
In fact, if a disc worn pads not exert enough pressure on it and necessary for braking at full capacity.

From a historical perspective, brake discs used in most of the braking systems are
made of cast iron, while today, the cars competitive and better performing are equipped
with disc design compound of the following construction: material ceramic composite
carbon fiber only for the braking surface and a mounting surface of cast aluminum or steel.

Fig. 3.1
Disc brake caliper Brembo co-molded and 6-piston

In Figure 3.1 shows the rotor co-molding compound made from two materials: cast iron and
aluminum.

This disc has many advantages: low weight by 15-20%, driving comfort, less corrosion, less wear
and better braking performance.
 Disc brake compound is co-molded cast iron braking surface and an aluminum mounting base,
combining high temperature resistance and low weight aluminum iron.

The innovation consists in the way in which the two materials are joined in a single piece in
the behavior of the disc in use, operating at low temperatures as a drive unit, while at high
temperatures, there is a need for high performance and there is the possibility of deflection behaves
like a disc made.

Fig. 3.2

Brembo ventilated disc brakes

 Fig.3.3

Disc brake caliper Brembo and ceramic

Innovative technology - the basic material used is carbon fiber technology used is that of
composite materials. The elements that make this material extremely abrasion resistant silicone and
carbon. Carbon fibers are structured so effectively absorb the tensions arising from braking. These are
capacity so as to ensure a high coefficient of friction resistance in varying temperature conditions.

Ceramic brakes - superior parameters

- High braking power - impeccable behavior in situations where braking at the limit

-,High - very resistant to corrosive elements: salt, salt water, rust resistance due to extreme
surface hardness materials.

- Long life - debug to 4 times higher than conventional models, providing optimal braking
performance up to 300,000 km.

- Empowers a sporty driving style - providing significantly reduce braking distances by up to

50%.

- Easy to use - prompt braking, quicker response to the throttle.

- Exclusive design - perforated surface and super sporty character design highlight.
 3.3.2 The brake pads

The brake pads are essential components of the braking system. Quality wafers is critical
because they are in contact with the disc and put pressure on them so that the vehicle can brake.

They consist of two different surfaces stuck together:

-Surface interior, made from abrasion-resistant material that is in contact with discs

-Surface pool, which consists of a metal support

Fig.3.4

Pads of semi-metallic compounds

Range of materials used in the manufacture of brake pads ranging from asbestos to organic
and semi-metallic formulations. Each such material has its advantages and disadvantages linked to the
use in various environmental conditions related to wear, noise and the ability to brake.

The most effective brake pad turn out to be those made of semi-metallic compounds which
offers, besides superior braking power and lift capacity to disperse heat. The major disadvantage of
this type of plates is that they generate a significantly higher noise.

Ceramic brake pads performs better at high temperatures, cutting the fading effect. Also, this
type of brake pad wear heavier and produce less dust and noise, noise emitting ceramic friction that
is not in the range of frequencies that the human ear can receive. However ceramic brake pads are
only suitable in applications and are not suitable light motor vehicles (trucks), heavy, even the media.

In the past, asbestos was a favorite material in the manufacture of brake pads because it
shows a good ability to disperse heat. But because this material is damaging human health, today
most brake pads are made from mineral fibers, cellulose, aramid, poliacrilonitrile, fiberglass, steel and
copper fibers.

Depending on the properties of these materials vary and the wear of disks breaks .Aceste
properties are basically an average between braking performance and longevity.

Fig.3.5

3.3.3 Ceramic brake pads

3.3.4 The caliper
The caliper brake and is part of the fixed and support acts of brake pads.
From the construction point of view it can be made of multiple parts or can be poured monobloc
Materialels it is made of steel and cast iron caliper are.Calliper actuation system is the liaison between
the brake pads and frana.It is composed actuators consist of piston cylinders acting on brake pads.
In various forms constructive calipers can have from one to six piston, the higher the number
is higher so they are more efficient brakes and the downforce is constantly respective disc pad surface
waters.
Fig 3.6 Caliper monobloc with 4 pistions

Fig.3.7

Caliper monobloc with 6 pistions

 4 WAYS BRAKING SYSTEM DAMAGE

Fig 4.1
As a constructive solution we chose the in brake disc and calliper brake, fig 4.1, because it is a
widespread constructive solution in the automotive world.

Figure 4.1 shows the big picture disc brake system and brake pad consists of: -disc
de frana ventilat
- caliper;
- brake pads;
- gripping the wheel studs;
- wheel hub;
- hole to check the thickness plates;
- vent.
 4.1 ADVANTAGES AND DISADVANTAGES OF DISC BRAKES COMPARED TO DRUM
BRAKES

Advatages:
-reduce sensibility friction coefficient of variation of the servo brakes without effect;
-even distribution of pressure on the friction surfaces and, as a consequence, uniform wear of
the seals and rare need to adjust the brake;
-large surface cooling and good conditions for evacuation of heat allows them to dissipate as
heat high energies;
-stability in operation at high and low temperatures;
-balancing forces axial and radial forces lack;
-the possibility functionariicu small games friction between surfaces, which allows to reduce
the time of entry into service;
-braking effectiveness independent of the wear of the friction linings;
- simplicity same time ensuring braking regardless of the direction of travel;
reduced-weight brake for braking the same time;
- the more favorable deflection brake parts;
- easy replacement of friction;
- achieve automatic adjustment of clearance between the friction surfaces through a simple
construction.
Disadvatages:
- reduced efficacy
- higher thermal stresses for friction and brake fluid;
- the difficulty of achieving a parking brake or safety with sufficient effectiveness.

4.2 WAYS OF DAMAGE SYSTEM , DAMAGE WAYS OF BRAKE DISC AND DRUM AND
DRUM BRAKE DISC

France "not it" is "weak" or not act. Failure is the effect of causesmultiple refers to incorrect
brake adjustment, damage or wear of organsas well as loss of liquid or air, when braking hydraulic
pneumatic respectively.
Incorrect brake adjustment can mean:
- Free race pedal too high;
- Increased game between shoes and drum;
- Loosening the adjustment nuts or springs on the brakes with automatic adjustment;
- Incorrect fastening and adjusting pivot clogs buttons. The defect is removed
by regulating the free lift pedal and play between shoes and drum.
Frecarese wear liners to ascertain the fact that the pedal, though
it functions normally but the braking effect is reduced because friction coefficient
of the drum and rivets fastening seals is low. The defect is removed by removing
friction linings station maintenance.
Worn brake drum aiming to ascertain whether, at the press sudden
repeated brake pedal while the wheel is held in place by hand, feel displacements of
drum plate shields against sabotage. The defect is removed by replacing the drum
brake maintenance statio
Wear central gasket and pistons pump piston cylinders receptoriface
that the pedal, brake fluid, instead of being sent to the receivers or cylinders
push their pistons, gaskets escape besides, such as brake no longer performs
suitable. In this case the cylinder explodes receptors or central pump, clean
asperities are replacing seals, rinse and introduce new liquid plant.Aer sau vapori in conducte ori
pierderi de lichid din instalatie.
 These flaws are due:
- Lack of fluid in the system;
- Overuse and prolonged brakes, so due to warming, alcohol or methyl evaporated and the formed
plugs;
- Dissolution, cracking or deteriorating joints, gaskets or cylinders metal pipes.
Some faults are removed in the process by filling liquid and the evacuation air or vapor in
pipelines. Pipes or fittings cracked or damaged replacing station maintenance.

Brake pedal rub though is not actionata.Acest defect is due to:

- Incorrect adjustment of clogs;

- Recoil springs weak or broken;
- The pistons of the cylinders receptor-coated gum, such as by activating the sabots remain in a lock
situation;
- Clearing the hole from central pump clogged, not allowing fluid to back in the tank so that the pads
will continue to sit on the drum apply;
- Pedal incorrectly installed or adjusted. Some faults can be removed partially route (Adjusting the
distance between shoes and drum, checking and adjusting the pedal). If the return spring is broken or
weakened the shoe is interrupted. Brake function at roatarespectiva, tying the pads with cable, not
touching drum. Maintenance station mounts a new arc.

During braking the car pull into a part .Acest defect occurs in general,brakes due to damage
and malfunctions of the brake system, such as
- The existence of eccentric drums;
- Improper fitting of gaskets;
- Use of the recoil springs sabotaged too strong;
- Clogging, deformation or cracking of the flexible connection;
- Penetration friction grease seals;
- Breakage or damage the membrane lining of a wheel brake cylinder;
- Tire pressure different.

Wheel lock. This defect can occur in one or all wheel during removal or after the braking,
even after the driver has released the foot brake. The causes that lead to blocking wheels are:
- Stiffness or cylinder piston scuffing one or more wheels;
- Camber brake drums;
- Clogging flexible connection;
- Arch camber damage or clogs

Stiffness or cilindruluiuneia piston scuffing or more wheels occurs. After releasing, when the
recoil spring to sabotage it can not remove the drum.The defect is found easily because strong drum
brake heat, or lifting each wheel, jack, it is observed that is braked. In this case, the pipeline is
suspended brake wheel in question and continue driving slowly and carefully to station
maintenance.
Roundness drums. This camber defect manifests itself as follows:
- At the press moderate brake pedal while driving the car, it is moves up and down and pressing
stronger brake pedal, the wheel locks roundness drums is due to:
- Uptime without adjusting the game between shoes and drum manufacturing such a material
inappropriate or incorrect processing them. The repair station maintenance is performed, the
rectificandu or replacing it oval drums.
 Brake is interrupted (car wobbling) This flaw is due to:
- Improper fixing seals Braking shoes;
- Deregulation clogs the pivot joints (big games) or camber drums;
- The existence of big games in wheel bearings or planetary shafts;
- Excessive game suspension springs;
- Deflection shafts;
- Hitting or deflection drums;
- Brake linings oiled, too long or too hard.
All malfunctions is removed from the station maintenance.
Braking is accompanied by noises. Failure is manifested in the form of
"Screeching" sharp and strong, sometimes accompanied by vibration. This noise can have the
following causes
- Excessive wear of brake linings;
- Penetration of grease mixed with dust, drying and polishing its surface gaskets;
- Using drums with different wall thicknesses;
- Weakening the plate anchor bolts or rivets;
- The use of disc brakes too elastic or insufficiently tightened bolts fasteners;
- Negresarea joints;
- Brake disc crack or deteriorate.
4.3 WAYS OF MAINTENANCE SYSTEM BRAKE

Maintenance hydraulically operated braking system contains the following:

- Control the tightness of the hydraulic system;
- Checking and completion fluid level in the pump reservoir central;
- Checking and adjustment of the power of the rod and piston pump;
- Venting the plant;
- Checking brake lining wear;
- Checking and adjusting the play between shoes and drum.
4.3.1 HYDRAULIC CONTROL OF INTESITY SYSTEM

Consists in tracing the pump reservoir fluid level in central and tracking pressure in the system
Tracking central cylinder reservoir fluid level in the brake repeated immediately, enable to
find any leaks of the plant. If the level drops it pursuing ducts, piping, boiler pump, cylinder receptors
in order spot detection which produces losses. Pressing the brake pedal, the fluid level decreases in
proportion to the central cylinder reservoir clearance between shoe and drum respectively plaques
and disc. When releasing the pedal still drops by 2-6 mm due compensation volume piston pump
central retired after returning continuously in 2-3 seconds at the initially, as the recovery in the
position of brake shoes.
Tracking pressure in the system give more choice over how sealing central pump piston seal.
Instead of a vent at a cylinder receiver mounts a high pressure gauge control (0 ... 160) x 105 N / m2
or low pressure (0 ... 16) x 105 N / m2. If verification at high pressure, pressing the pedal
progressively, and continually grow indications unit. If by holding the pedal pressure drops, garnish no
central pump piston seals and fluid returns in the reservoir. If verification of low pressure acting pedal
lightly by hand, if gasket central pump is faulty, failing pedal to the floor and indications gauge
decreases. If you press on the pedal until the pressure manometer is (2.5 ...... .3) x 105 N / m2 to
release finds:
- Drum brake with a residual pressure of (0.5 ...... .1,5) x 105 N / m2, provided by: double
pump valve to prevent aspiration central air after braking at cylinder seals receptors;
- Disc brakes, void residual pressure due to automatic adjustment solution
game.
If residual pressure is exaggerated reasons may be:
- Bow pump piston central broken;
- Hole clearing blocked;
- Play between the rod and piston void.

4.3.2 Checking fluid level the pump reservoir central

The liquid level in the tank is necessary is between landmarks maximum and minimum of this.
Due to brake pad wear during fluid level exploitation decreases. If the seals have advanced wear, it is
recommended to fill up liquidthe maximum level.
Brake successive lowering is caused by leak in the circuit. In general, brake fluid is replaced at
intervals of two years. The brown color gray or black indicate overheating or degradation over time
and, in this case, the liquid
It must be replaced. The liquid should be clear, yellow-green, sometimes blue.

4.3.3 The air descharge from the system

In case of replacement brake fluid, air enters the facility, which should be removed. For
venting the plant, originally the liquid in the tank is filled up to a level 10-15 mm below the filler
opening. Pressing on the brake, with the liquid and the air is discharged, whose presence is
established by releasing bubbles in the vessel with brake fluid coming out through the hose.
Continue pressing the pedal a few times, until the pot bubbles stop appearing.

4.3.4 Cheching brake linear wear

On drum brakes, gasket thickness is measured by visitation and adjustment windows, or,
failing that, by removing the drums.
Disc brakes, linings wear is assessed by measuring the thickness of the wafer with a terminal
strip.
4.4 UNIQUE FACT

Checking the brakes in time can have serious consequences.

With a wear on brake discs which exceeds the limit allowed by the manufacturer to a
sudden braking can break them, the consequences are unpredictable because the wheels can
lock and vehicle direction can not be controlled.
 5 JUSTIFICATION FOR SOLUTION CHOSEN DESIGN AND CALCULATION

5.1 JUSTIFICATION FOR CONSTRUCTIVE SOLUTION

For maximum effectiveness of brake discs and callipers with brake use on all wheels.

5.2 CALCULUS OF BRAKE SYSTEM

Choosing overall dimensions of the vehicle.

*lenght L= 7345 mm

*width w= 1993 mm

*height Ha= 2790 mm 2.79 m

*wheelbase w= 4325 mm 4.325 m

Choosing the size of the automobile weight

*own mass 5000 kg

*no. of passangers NI= 17

*medium mass of a passager mp= 85 kg

*medium mass of a baggage mb= 10 kg

*total mass of vehicle

mt= 6615 kg

*total weight of vehicle

Ga= 64870 N

g= 9.81 m/s^2

Distribution of weight on
decks

a= 1946 mm 1.946 m

b= 2379 mm 2.379 m
*front deck

m1= 3638 kg

*pe puntea spate

m2= 2977 kg

Dynamic radius of
the wheel

* coefficient of deformation of the tire λ= 0.935

* width balloon B= 195 mm

* the exterior diameter of the

rim d= 16 in 406.4 mm

* balloon tire height0.6 H= 100 mm

* Static radius of the

wheel

rs= 303.2 mm

*dynamic radius of th
wheel

rd= 283.3948 mm 0.283 m

The braking system is calculated by setting a maximum acceleration that you need to
have your car after an emergency braking.
.
Maximum
deceleration:

afmax= 6.5 m/s^2

Braking
power
braking
systems

*The total braking power braking system

Ff= 43000 N

* the ratio of the braking forces conducted at two decks

= 1.882

hg= 0.672 m

= 14920 N

= 28080 N

It chose the following brake:

Front deck:

*vent discs D1= 296 mm

Rear deck:

*discs D2= 240 mm

Choose the ratio of inner radius and inner radius of the disk
 = 0.6

Front deck

* exterior radius disc

= 148 mm

*inner radius disc

= 103.6 mm

*medium radius disc

= 125.8 mm

Rear desk

*exterior radius desk

= 120 mm

*inner radus desk

= 84 mm

*medium radius desk

= 166 mm

Peripheral force to be obtained on the front axle wheels

= 34310 N

Peripheral force to be obtained at the rear axle disks

 = 18230 N

Choose to feature brake servo brakes without effect (0.5 ...... 0.65).

* front axle brake feature

C1= 0.52

* rear axle brake feature

C2= 0.63

= 17840 N *front

= 11490 N *rear

Constructive dimensions are chosen plates and check later.

,Considering the pressure distribution on the surface friction,

y0 distance from the center of the circle line drive tangential force of friction
resulting, in the case of a circle of radius r sector will be given by:

r – radius of disc
ri - inner radius
re – exterior radius

r= 148

ri= 84

re= 120

θ= 15

α= 50

= -74.956

= -0.261
If a portion of the circular distance f is calculated using the equation:

= 102000 mm

= -0.54

Braking time developed a disc brake open is calculated using the equation:

Mf=N1*f*nf
N1 - is the normal reaction of the friction disc:
nf - the number of pairs of friction surfaces

0.075

= 126.941 N

= -5141 Nmm

The coefficient of efficiency

E=Mf/Su*re

β= 40
 = 128.773

E= -33270

5.3 IDENTIFICATION OF WAY TO INCREAS QUALITY SUBASSEMBLY OF BRAKE

One of the main ways to increase the quality braking system is to using unconventional
material in producing subassemblies.

Innovative technology - the base material utilizateste carbon fiber technology used is
that of composite materials. The elements that make this material extremely abrasion resistant
silicone and carbon. Carbon fibers are structured so effectively absorb the tensions arising from
braking. These are asafel capacity in order to ensure a high coefficient of friction resistance in varying
temperature conditions.
The cooling system is piped ensure in continuuun internal air flow capable of ensuring a prompt and
fast optimization of interior temperature.
Ceramic brakes - far superior parametric

- High braking power - fell impeccable behavior in situations of braking at the limit
- High - very resistant to corrosive elements: salt, pressing, rust resistance due to extreme
surface hardness materials.
-Life in delungata - up to 4 ORIM higher than for conventional models, providing optimal
braking performance up to 300,000 km.
- Empowers a sporty driving style - providing significantly reduce braking distances by up to
50%.
- Easy to use - prompt braking, quicker response to the throttle.

Also to increase the quality, monobloc calipers can cast aluminum, making them lighter while
providing performance iridicate me.
An important element to increase the quality and efficiency of the brakes, is the number of
pistons per caliper. The higher the number is higher so it is better controlled brake pressure on each
pad is much better distributed.
If the brake system is conventional for a better performance for the entire duration aims
cooling and brake disc up to a level where they are working optimally. This controlled cooling is
performed using piping that takes air from the front with the current vehicle and transports in the
area near the braking system.
For for this cause airy and ventilated discs are used, which retain their princonstructia an optimum
operating setpoints.

5.4 IDENTIFICATION OF WAYS TO REDUCE COSTS FOR BRAKE

Reducing the cost of production is limited by the quality assurance necesare.Deci cost can not
be reduced only to the level requirements to ensure the product is subjected to.
Areas where cost savings can be made is that the production and manufacturing materials.
Also reduce operating costs can consider being an important element in piata.Cu economy as a
product requires less maintenance cost by more will be sought.
In conclusion must be a compromise between cost of production and quality of materials.
Bibliography:

1.Untaru M.,Calcululsiconstructiaautomobilelor,E.D.P., Bucuresti

2.Fratila G.,Sisteme de franare ale autovehiculelor,E.T.B., Bucuresti

3. http://www.autoshop101.com/forms/brake04.pdf

4.http://www.brembo.com

5.http://auto-tehnica.ro/blog/