Car Brakes: Function, Components & Types

Brakes Automotive brakes are vital components in vehicles, responsible for converting kinetic energy into heat through friction to slow down or halt the vehicle. Understanding the function, components, and types of automotive brakes is crucial for engineers, mechanics, and enthusiasts alike to ensu...

Brakes Automotive brakes are vital components in vehicles, responsible for converting kinetic energy into heat through friction to slow down or halt the vehicle. Understanding the function, components, and types of automotive brakes is crucial for engineers, mechanics, and enthusiasts alike to ensure vehicle safety, performance, and maintenance efficiency. is a mechanical device that inhibits motion by absorbing energy from a moving system. It is used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its motion, most often accomplished by means of friction. Brakes Brake Function Functions of the brake system in vehicles:  To slow down or to stop the vehicle as and when required.  To control the vehicle when the vehicle is rolling down on a slope road downward.  To travel smoothly and safely even in heavy flow of traffic by controlling the movement of the vehicle Brakes Brake System The braking system is a balanced set of mechanical and hydraulic device used to retard the motion of the vehicle. Whereas transmission is connected to accelerating and moving the vehicle, and suspension relates to smooth driving, the braking system serves to halt the motion of the vehicle. The braking system works by applying a static surface to the moving surface of the vehicle, thus causing friction and converting kinetic energy into heat energy. When the brakes are applied, rough surface brake pads or brake shoes are pressed against the rotating parts of the vehicle, be it disc or drum. The momentum of the vehicle is converted into heat resulting in the slowing of the motion of the wheels. Subsequently, friction between the tyres and the road surface slows the speed of the vehicle. The amount of the resistance or friction to the movement depends upon the type of the material in contact, the texture of the rubbing surfaces, and the pressure holding them together. Finally, when a vehicle comes to stop, it is held in place by static friction. Upon release of brakes, the static friction is overcome by the engine power converted into kinetic energy by transmission and drive train, and the vehicle starts moving. Brakes Principles of Braking Braking is the process of converting the kinetic energy (movement energy) of the vehicle in motion into heat energy. The motion energy of the vehicle turns into heat energy generated by the friction of the pads against the disc and the vehicle slows down or stops. When the driver presses the brake pedal, this pushing movement is transmitted to the brake servo by a push rod, the brake pedal connection works like a lever and the thrust force is increased and transmitted to the brake servo. The brake booster is transmitted to the piston rod in the brake main center just in front of it, increasing this thrust of the driver even more. There is hydraulic brake oil in the brake main center. The pistons in the brake center pressurize the hydraulic fluid (with greater force) and transmit it to the brake cylinders in the wheels and the pistons in the calipers, via hydraulic pipes and hoses, with the pushing movement of the driver by pushing the pedal and further strengthened by the servo. Brakes Disc brakes have brake caliper. Pressurized hydraulic fluid pushes the piston in the cylinder in the caliper towards the disc, there is a brake pad in front of the piston, by the brake pad rubbing against the disc, the disc fixed to the wheel center slows down, the wheel slows down or stops. Drum brakes have a wheel brake cylinder inside the drum. Brakes Brake Systems Parts and Their Functions: ► Disc Brake Mechanism: This is the part where braking occurs. Pressurized brake fluid coming from the brake main center acts on the piston in the caliper, the piston moves forward with pressure and presses the brake pad in front of the brake disc, and the disc-wheel slows down or stops as a result of friction. In new generation passenger cars, disc brakes are used on both the front and rear wheels, however, disc brakes at the front and drum brakes at the rear are very common in passenger cars and light commercial vehicles. For more information (See: Disc Brake System) ► Drum Brake Mechanism: The drum brake mechanism is generally used on the rear wheels of commercial vehicles (trucks), passenger cars and light commercial vehicles. With the effect of the hydraulic oil sent from the brake main center to the brake cylinder located on the brake plate, the pistons in the cylinder open to both sides and press the brake shoes with brake pads against the drum, thus braking is realized. The brake pad also contains the handbrake mechanism. Brakes Brake Fluid: A specially formulated hydraulic fluid that transfers the pressure from the master cylinder to the calipers or wheel cylinders. It must withstand high temperatures and provide consistent performance under varying conditions. Brakes Brakes Brakes Brakes Brakes Brakes Brakes Brakes How Car Brake Works – YouTube Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: STEP 6: Top off the brake fluid level strictly to the “Maximum” mark on the reservoir and clean up all brake fluid spills. Note that since brake fluid is water soluble, brake fluid spills on the hubs and calipers can easily be removed by spraying the hubs with a garden hose or pouring clean water over the hubs with a bucket or similar implement. Next, fit the wheels, and lower the vehicle to the ground. Test the brakes by test-driving the vehicle in a safe environment to verify that the brakes work as expected. Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: During the brake bleeding process, several issues can arise that may hinder effective bleeding or compromise brake system integrity. Here are some potential issues and how to troubleshoot them: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Step-by-Step of Bleeding A Car: Bleeding Brake System https://www.youtube.com/watch?v=n1NvtUwfRJc Process of Changing Wheel Cylinders INTRODUCTION The brakes are an essential safety feature on a car. When a problem occurs with the brake wheel cylinder, it should therefore be replaced by an experienced mechanic and handled immediately. The brake system on today's modern vehicles is comprised of highly evolved and efficient anti-lock braking systems, often applied through disk brake components. However, for most of the vehicles on the roads today, the traditional drum brake system is still used on rear wheels. The drum brake system includes multiple parts that must work harmoniously in order to efficiently apply pressure to the wheel hubs and slow a vehicle down. The brake wheel cylinder is the primary part that helps the brake shoes apply pressure to the inside of the drum, thereby slowing the vehicle down. Process of Changing Wheel Cylinders Unlike brake shoes or pads or the brake drum itself, the brake wheel cylinder is not designed to wear out. In fact, it's very rare that this component breaks or fails at all. However, there are times when the brake wheel cylinder can wear out sooner than expected. When you press the brake pedal, the master cylinder fills the wheel cylinders with fluid. Pressure created by this fluid is what activates the brake wheel cylinder to the brake shoes. Since the brake wheel cylinder is made from steel (on the outer cover) but rubber seals and components on the inside, it is possible for these internal components to wear out due to excessive heat and extensive use. When this occurs, they need to be replaced while servicing the brake drums; you should replace the old brake shoes and ensure all components inside the rear brake drum are also replaced at the same time. Process of Changing Wheel Cylinders Process of Changing Wheel Cylinders Wheel Cylinders Function Your vehicle’s wheel cylinders are filled with brake fluid and connected to the brake master cylinder using high-pressure brake lines. For your brakes to work properly, the brake fluid needs to be clean, and the cylinders need to hold brake fluid regardless of the pressure in the lines. Pushing on the brake pedal actuates the master cylinder. The master cylinder increases pressure inside your vehicle’s brake lines. The pressure inside the wheel cylinder increases as well, which pushes its pistons outward into the brake shoes. Brake shoes create friction against brake drums, which brings the vehicle to a stop. Process of Changing Wheel Cylinders Symptoms of a Faulty Wheel Cylinder A bad wheel cylinder is often hard to spot because it’s inside the drum brake. However, here are some signs that something’s wrong with it:  Your car has poor brake response — you’ll find that braking takes longer  Your brake pedal feels mushy, soft, or the pedal sinks to the vehicle floor  There’s a brake fluid leak in your rear brake drum that pools near a rear wheel  The rear drum brakes drag or lock up  If you run into any of these problems, don’t drive your car. Process of Changing Wheel Cylinders Importance of Replacing Wheel Cylinders Replacing wheel cylinders is crucial for several reasons, all of which contribute directly to the safety and performance of a vehicle's braking system: 1. Braking Effectiveness: Wheel cylinders play a pivotal role in drum brake systems by applying hydraulic pressure to the brake shoes, causing them to press against the brake drum. A failing wheel cylinder can lead to reduced braking force, which compromises the ability of the vehicle to stop effectively and quickly. 2. Safety: Reliable braking is paramount to vehicle safety. A worn-out or leaking wheel cylinder can result in inconsistent braking performance, longer stopping distances, or even brake failure in extreme cases. This poses significant risks to the driver, passengers, and others on the road. Process of Changing Wheel Cylinders 3. Prevention of Fluid Leaks: Wheel cylinders are sealed components that contain brake fluid under pressure. Over time, seals can deteriorate due to wear and exposure to heat and chemicals. A leaking wheel cylinder not only reduces braking efficiency but can also lead to loss of brake fluid, further impairing the braking system and potentially causing total brake failure. 4. Cost-effectiveness: Timely replacement of wheel cylinders can prevent more extensive damage and costly repairs. Ignoring issues with wheel cylinders may lead to damage to other brake components, such as brake shoes, drums, or even the brake lines, which would require more extensive repairs or replacements 5. Compliance and Vehicle Inspection: In many jurisdictions, vehicles must pass safety inspections that include brake system checks. A malfunctioning wheel cylinder can cause a vehicle to fail such inspections, leading to legal consequences and the inability to operate the vehicle legally on public roads. Smooth and Consistent Brake Operation: A new wheel cylinder ensures that the braking force is evenly distributed to both sides of the brake drum, promoting smooth and consistent braking. This improves driver confidence and control over the vehicle. Process of Changing Wheel Cylinders Why Does the Wheel Cylinder Fail? Since a wheel cylinder contains so many moving parts, this hard-working component can fail for many reasons. Here are five of the most common ones: 1. Rubber Seal Failure: The wheel cylinder piston seal and dust boot are made of rubber. These seals become brittle with time and can fail with exposure to extreme heat or due to natural wear and tear. When they fail, your vehicle may have a brake fluid leak, and the hydraulic pressure will drop in the braking system, compromising your braking performance. 2. Worn Pistons: Pistons are meant to be a specific diameter relative to your cylinder bore size. However, with time, pistons can wear down and won’t fit snugly in the cylinder bore anymore. If this happens, there’s a risk of a piston seal leaking or the piston rocking, which can increase wear. Process of Changing Wheel Cylinders 3. Stuck Pistons: The cylinder bore is supposed to have a smooth surface. However, corrosion and pitting can develop in the cylinder bore due to exposure to moisture in the brake fluid, which can cause your piston to get stuck. Stuck pistons result in a drum brake that won’t release, creating major braking problems in your drum brake system. 4. Pistons that Slip Out of the Bore: Excessive brake drum wear can create enough space for pistons to slip out of the cylinder bore utterly. At this point, your drum brakes won’t work at all. 5. Cracked Cylinder Body: Older wheel cylinders can split and crack under pressure, leak brake fluid, and compromise function. Note: While it seems like a relatively simple component, replacing or fixing a bad wheel cylinder isn’t straightforward because of its location and how it works with the rest of your drum brake system. Link: Changing Wheel Cylinder https://www.youtube.com/watch?v=GIWYkCOPAQ0 Drum Brake Replacement Techniques INTRODUCTION Drum brakes have long been a fundamental component of automotive braking systems, known for their durability and reliability. Understanding the process of replacing drum brakes is crucial for maintaining vehicle safety and performance. This overview explores the essential steps and components involved in drum brake replacement, highlighting the intricate assembly and functionality that ensures effective braking. Drum brakes consist of several key components, each playing a vital role in the braking mechanism. From brake shoes and springs to wheel cylinders and adjusters, these parts work in unison to convert mechanical energy into thermal energy, effectively slowing down or stopping a vehicle. Replacing drum brakes involves a systematic approach to disassembly, inspection, adjustment, and reassembly, ensuring optimal braking efficiency and safety. Throughout this discussion, we will delve into the detailed procedures required to replace drum brakes, emphasizing the importance of proper technique and attention to component function. By mastering these techniques, automotive professionals and enthusiasts alike can uphold brake system integrity and reliability, promoting safer driving experiences for all road users. Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Drum brakes are a type of brake that is typically used in two-wheeled or four- wheeled vehicles. The way drum brakes work on motorbikes and cars is almost the same. Drum brakes in cars usually use a hydraulic brake system because they have used hydraulic pressure to exert pressure on the brake pads. Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Replacement Techniques Drum Brake Replacement Techniques Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes  Remove both shoes and the self-adjuster as one unit.  Lay the old shoes on the ground next to the new ones  Sometimes the front and back shoes are different. The shoe with the shorter strip of lining usually goes towards the front.  Carefully tip the tops of the shoes inward to loosen the tension on the self-adjuster spring.  Remove the self adjuster.  Inspect and clean all brake parts to be reused and check for signs of damage or wear and replace as needed.  It is recommended to replace all the springs with a new set.  The adjuster should be unscrewed, cleaned and lubed with anti-seize.  Remove the spring and immediately hook it onto the new shoes exactly as you removed it.  Inspect the brake wheel cylinder for any signs of leakage and replace if needed. Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Steps on How to Replace Drum Brakes Brakes How to replace drumbrakes https://www.youtube.com/watch?v=Q5j3sKgNoEs&t=41s Clutch A clutch is the mechanical device that transfers all power from the engine into the transmission of a vehicle. Without a properly operating clutch, power transfer and gear shifting would be very difficult. The clutch is located between the engine flywheel and the transmission. Clutch Flywheel Pilot Bearing Clutch Disk Pressure Plate: Release Bearing Clutch fork and connecting linkage Bell housing or bellhousing- Clutch Master Clutch slave Suspension Suspension is the system of tires, tire air, springs, shock absorbers and linkages that connects a vehicle to its wheels and allows relative motion between the two. Suspension systems must support both road holding/handling and ride quality, which are at odds with each other. The tuning of suspensions involves finding the right compromise. It is important for the suspension to keep the road wheel in contact with the road surface as much as possible, because all the road or ground forces acting on the vehicle do so through the contact patches of the tires. The suspension also protects the vehicle itself and any cargo or luggage from damage and wear. The design of front and rear suspension of a car may be different. (2) Suspension System Components - YouTube Suspension System Automobiles were initially developed as self-propelled versions of horse-drawn vehicles. However, horse-drawn vehicles had been designed for relatively slow speeds, and their suspension was not well suited to the higher speeds permitted by the internal combustion engine. 1. Maximize the friction between the tires and road surface during acceleration, cruising and braking. 2. Provide steering stability with good handling 3. Comfort of the Passenger Parts of Suspension System Parts of Suspension System Parts of Suspension System Parts of Suspension System Types of Cooling System in Car Engine: Components & Function Ignition System Fuel System Lubrication System Starting System Starting System