Automotive Braking Systems

By Shane Dunlevy
 Overview
• Brakes convert kinetic energy into heat by
creating friction
• System must have very high reliability
• Types of brakes:
- Disk
- Drum
 System Basics
• Hydraulic actuation
allows multiplication
of pedal force.
• In this system, a 10lb
force on the pedal
produces 360 lbs of
force at the friction
surface.
 Braking Dynamics
• Dynamic weight transfer
caused by braking shifts
the weight balance
towards the front of the
car
• Dynamic weight for the
front and rear can be
found using Newton’s
Law W′=
f
mgd ma h
+ x
c+d c+d

mgc max h
W r′ = −
c+d c+d

€
 Braking Dynamics
• Because the maximum braking force is
equal to the coefficient of friction times the
normal force, the front wheels will have an
increased capacity to provide braking force
• Also, the system must be designed to
distribute the application of force between
front and rear
 Disk Brakes
• Caliper squeezes pads to
create force on the
surfaces of the rotor.
• Used in most automotive
applications.
• Benefits:
– Simple design
– Self adjusting
– Rotor venting allows faster
heat dissipation
 2 Types of disk brake calipers
• Floating caliper
– Piston pushes pad
against the inner rotor
surface, reaction force
causes the caliper to
slide and contact the
outer surface
 2 Types of disk brake calipers
• Fixed caliper has at
least one piston on
each side
• Each piston drives it’s
corresponding pad into
contact with the rotor
 Drum Brakes
• Expanding shoes create
force on the inner surface
of the drum
• Used on the rear of some
trucks and SUV’s
• Self-energizing design
requires less activation
force
• Require periodic
adjustment
Tandem Master Cylinder
 Master Cylinder
• Provides a reservoir for brake fluid and contains the
driving pistons in the hydraulic circuit
• 2 Types
Front - Rear split
-One piston for front brakes and one for rear
-If a leak occurs you could lose front brakes
Diagonally split
-One piston drives one front wheel and one rear wheel
-Diagonal layout allows you to maintain directional
control if a leak occurs
Diagonally Split System
 Power Assistance
• Power booster reduces pedal
force required to stop vehicle
• Engine vacuum is used to
actuate a large diaphragm
• When the pedal is depressed,
vacuum is applied to only one
side of the diaphragm and force
is appled to the master cylinder
push rod
• Booster stores sufficient
vacuum for several brake
applications if the engine fails.
Power Booster in closed position
 Anti-Lock Brakes
• A locked (sliding) wheel offers less braking
force than a decelerating rolling wheel
• The locked wheel also produces little lateral
force, preventing steering control
• Anti-Lock systems (ABS) monitor wheel
lock-up and modulate brake pressure to
provide controlled braking under most
circumstances
 Anti-Lock Brakes
• System can have 2, 3 or 4 channels
• Trucks typically use 3 channel with only one
sensor for the rear axle
• Most modern cars use 4 channel system
• Wheel speed sensors monitor each wheel speed
• ABS controller and high-pressure pump increase
or reduce pressure to wheels in order to maintain
consistent wheel speeds
Typical 3 channel system
 Valves and Switches
Pressure Differential Switch
-Senses a pressure differential between the two master
cylinder stages and warns the driver that the system has
a leak
Metering Valve
-Prevents the front brakes from engaging until the rear
drums have enough pressure to overcome the shoe
return springs (Front disk-Rear drum systems only)
Proportioning Valve
-Reduces the pressure to the rear wheels to balance the
effect of weight transfer to the front wheels.