Brake system

Overview
Components of brake system
Overview
Stucture of wheel brake
Overview
Stucture of center brake

Center brake, installed at the

transmission output shaft or
propeller shaft of the heavy trucks,
is used as a parking brake
preventing the vehicle movement
while parked.
Overview
Hand brake
Brake shoe expands and apples the braking as lever and wire are pulled.
Overview
Foot brake
Foot brake, used to reduce or stop the vehicle in motion, is applied by
pressing the brake pedal with the foot. Mechanical brake, hydraulic bra
ke, hydro vac brake, hydro air vac brake and aerial brake belong to this
foot brake type.
Overview
Air brake
Overview
Hydro vac brake
Overview
Hydro air vac brake
Hand brake
Center brake
In this type, lining is assembled with rivets inside the metal brake band
and installed with bracket. Once brake lever is pulled, pull rod is also
pulled, and then holding cam shrinks the brake band and holds the drum
forcibly resulting braking.
Hand brake
Wheel brake
Rear brake shoes move to hold drums through the combination of cable
and rod when the lever is pulled. Equalizer is installed to apply the braking
force equally to both wheels.
Foot brake
Brake shoe
Brake shoe, attached with lining with rivet or adhesives, generates a
braking force as it contacts drum by wheel cylinder piston. Return spring
is installed to return the shoe to the original position when the master
cylinder pressure is released and hold down spring keeps the shoe at
the right position.
Foot brake
Brake drum
Drum requirements are as follows.
① Light in weight and enough strength.
② Static and dynamic balance
③ No overheating with good cooling.
④ High wear resistance
Foot brake
Disc brake
Since disc rotates as exposed to the air, it rarely shows fade
phenomena and it’s auto adjusting brake type. It consists of disc turning
with wheels, pad generating braking force together with disc and caliper,
which is fixed to the spindle or plate supporting pad and piston
Basic of hydraulic brake
Movement of Piston A is delivered to piston B

we can use liquid as media to relay the movement because liquid

is not compressed even when pressurized.
Basic of hydraulic brake
Relay of the force
When the load of 300 kgf is applied to piston A, piston B can hold the lo
ad of 300 kgf too if the diameters of both pistons are the same as show
n below.
Basic of hydraulic brake
Magnification of force

Using Pascal’s principle, if 100 kgf is applied to the piston A of 5kgf/cm²

as shown below, the unit pressure applied to piston A is 100kgf/5cm=20
kgf/cm, and this unit pressure is applied to piston B. Since the area of pi
ston B is 10cm², the force magnified is 20kgf×10cm²=200kgf.
Basic of hydraulic brake
Principle of hydraulic pressure
This picture shows two cylinders of the same area connected with the pipe. If
the cylinders and pipe are filled with liquid and the piston weights are the
same, pistons left and right will be positioned at the same level. If the force is
applied to the right side piston, the force will be transferred to left side piston to
raise the piston position. If the cylinder areas are the same, right side piston
will rise as much as the left side piston drops. However, if the cylinder areas
are different from each other, things are not like that. If the right side cylinder is
2 times larger than that of left side cylinder, piston will move only half of the
right side piston distance. Though, force will be doubled if the travel distance is
half.
Structure and operation of hydraulic brake
Master cylinder
Master cylinder generates hydraulic pressure as brake pedal is pressed and
consists of cylinder body, oil reservoir tank and cylinder components such as
piston, piston cup, check valve, piston return spring etc. There are 2 types of
master cylinder: single master cylinder of one piston and tandem master
cylinder of 2 pistons. Currently tandem master cylinder is used.
Structure and operation of hydraulic brake
Operation of tandem master cylinder
Tandem master cylinder has 2 systematic circuits operating independently on
front and rear wheels to raise the stability of the hydraulic brake. The oil reservoir
tank, installed at upper side of the cylinder, is divided for front and rear wheel
braking respectively. 2 pistons are assembled in the cylinder. Piston at the push
rod is for rear wheels in the case. Return spring and stopper set the piston
positions, and return springs are installed at front and rear pistons respectively.
In addition, compensation holes, bleeder holes and check valves are installed at
each piston.
Structure and operation of hydraulic brake
Wheel cylinder

Wheel cylinder presses brake

shoe to drum by the hydraulic
pressure transferred from
master cylinder and consists
of cylinder body, piston and
piston cup. Cylinder body
consists of oil hole connected
to pipes, bleeder screw to
remove the air inside the
circuit and expansion spring
inside the cylinder to push
piston cup to be ajar always.
Hydraulic brake
Structure and operation (Double anchor type)
Double anchor type consists of 2 anchor pins and two brake shoes and only the
corresponding shoe performs self-reaction. Anchor pins are biased to adjust the
brake drum gap.
Hydraulic brake
Structure and operation (Anchor link type)
Anchor link type consists of 1 anchor pin, 2 brake shoes and 2 links. Brake
shoes at both sides expand by the pivot to contact the drum when hydraulic
pressure is applied to wheel cylinder.
Then, brake shoe moves link pin with pivot to be adjusted automatically with
drum. In addition, to control the double adjustment of brake drums, adjusting
wheels are installed at both sides of wheel cylinders.
Hydraulic brake
Structure and operation (Single acting two leading shoe type )
Single two leading shoe type, using 2 brake shoes and 2 single diameter wheel
cylinders, shows great braking force since both brake shoes perform self-
reaction when brake is applied in forward movement. However, braking force
will be reduced to 1/3 when brake is applied in reverse movement since both
shoes will be trailing shoes without self-reaction.
This type is used for rear drum brake of KIA K2700.
Hydraulic brake
Structure and operation (Double acting two leading shoe type)
Double acting two leading shoe type, consists of 2 identical diameter wheel
cylinders and 4 anchor pins, changes fixed side depending on the rotational
direction of the brake drum and it provides greater braking force since both
shoes become leading shoes of self-reaction when braked in forward or reverse
movement.
Hydraulic brake
Structure and operation (Non-servo brake)
In non-servo brake, only corresponding shoe has self-reaction when brake is
applied. Forward shoe has self-reaction only in forward movement and reverse
shoe has self-reaction in reverse movement.
Hydraulic brake
Structure and operation (Uni-servo type)
In uni-servo type, secondary shoe has self-reaction too when shifted by the prim
ary shoe by the wheel cylinder piston so that both shoes becomes leading shoe
s. However, braking force reduces both shoes become trailing shoes in reverse
movement. The shoe shows the self-reaction first is called primary shoe and the
other is called secondary shoe.
Hydraulic brake
Structure and operation (Duo-servo type)
In duo-servo type, fixed side changes depending on the rotational direction of
drum when brake shoe is pressed to drum so that it generates greater braking
force since both shoes have self-reaction in either forward or reverse moveme
nt. In addition, the shoe shows the self-reaction first is called primary shoe an
d the other is called secondary shoe. This type is used for rear drum brakes of
HMC H100 Truck, H100 and KIA Pregio.
Hydraulic brake
Self-reaction of brake drum and shoe
If braking is applied to the brake drum in rotation, shoe tends to rotate with
drum due to the frictional force and it shows bigger frictional force because of
the bigger expansion force as a result. This is called self-reaction of brake
drum and shoe. Self-reaction shoe is called leading shoe and the other shoe of
opposite direction of the drum rotation tends to fall apart from drum and is
called trailing shoe.
Hydraulic brake
Automatic gap adjusting brake
If the gap between shoe and drum is large, the movement also increases and if
gap reaches to certain point, adjusting lever moves to next notch of adjusting
wheel. If the brake pedal is released under this condition, Shoe B is pressed to
anchor pin again to loosen the adjusting cable so that adjusting lever returns to
its original position by the spring tension by rotating the adjusting wheel one
notch. So the gap between shoe and drum reduces
Air brake
Advantages and disadvantages of air brake

1) Advantages of air brake

① It is not restricted by the vehicle weight.
② Braking performance does not drop conspicuously even if the air leaks.
③ No vapor lock.
④ Braking force is controlled by the pedal stroke.
(Braking force is proportional to the pedal stroke).
⑤ The more pressure of compressed air, the bigger braking force.
⑥ It can be used together with horn, air spring etc.
⑦ Trailer connection is easy and remote control is possible.

2) Disadvantages of air brake

① Air compressor operation consumes some of engine output.
② Expensive and complex.
Air brake
Piping and structure of air brake
Air brake
General structure of air brake (Compression system)

Air compressor is driven by V belt

connected to the engine crankshaft
and produces compressed air as
rotating 1/2 speed of the engine
revolutions. Unload valve, installed at
the air intake, prevents excessive air
compression together with air
pressure regulator and regulates the
air pressure inside air storage tank
constantly.
Air brake
General structure of air brake (Air pressure regulator & unloader valve)
Air pressure regulator lifts up the valve as the compressed air through air intak
e from air tank overcomes the spring tension when the internal pressure of air
storage tank exceeds 5∼7kgf/cm². Therefore, air compressor stops operation
since compressed air activates on the upper side of unloader valve to open by
pushing down the unloader valve. Besides, unloader valve returns to original p
osition to restart air compression when air pressure inside the air storage tank
drops below the specification.

(a) Air pressure regulator (b) Unloader valve

Air brake
General structure of air brake (Brake valve )

Brake valve opens and closes by the

brake pedal and controls the braking
force by controlling compressed air
supply from the air tank depending on
the pedal stroke. In other words, upper
plunger presses the main spring and
closes exhaust valve and then, open
the supply valve. And then,
compressed air from air tank is sent to
quick release valve of front brake,
relay valve for rear brake and every
brake chamber so that braking
performance is enhanced. If the pedal
is released, plunger returns to its
original position to open exhaust valve
and exhaust the air used for braking.
Air brake
General structure of air brake (Quick release valve )
Quick release valve opens brake chamber valve to open both holes to front
brake chamber when pedal is pressed and compressed air runs through the
inlet from brake valve. So, compressed air activates on the brake chamber to
apply brake on the wheels. If the pedal is released, pressure on the inlet
reduces as the air exhausts from the brake valve. Then, valve returns to
original position by the spring tension to open exhaust hole so that air in the
front brake chamber exhausts quickly to release the brake.
Air brake
General structure of air brake (Relay valve)
When pedal is pressed and air pressure from brake valve activates, relay valve
supplies the air directly to rear brake chamber to apply brake on the wheels by
moving the diaphragm downward to close the exhaust valve and open the
supply valve. If the pedal is released and pressure on the diaphragm from
brake valve reduces below the internal pressure of brake chamber, diaphragm
moves up to release the brake until chamber pressure balances the pressure
on the diaphragm by exhausting air rapidly.
Air brake
General structure of air brake (Brake chamber)

If the pedal is pressed and

compressed air monitored from
brake valve comes into chamber
diaphragm pushes the spring and
moves. So, push rod rotates the
cam through slack adjuster so
that brake shoe expands to press
the drum to apply the brake. If the
pedal is released, diaphragm
returns by the spring tension to
release the brake.
Air brake
Operation of air brake

1) When pedal is pressed

When the pedal is pressed, compressed air activates on the front brake
chamber through quick release valve depending on the pedal stroke. At
the same time, compressed air is supplied to relay valve to activate the
rear brake chamber. Then, push rod rotates the cam through the slack
adjuster to press the brake shoe to drum to apply the brake

2) When pedal is released

When the pedal is released, brake valve, quick release valve, relay valve
activates and exhausts the compressed air in the brake chamber quickly
to release the brake.
Air brake
Operation of air brake
Servo brake
General
here are 2 types of servo brakes. The one is vacuum servo brake (Hyd
ro vac) which uses the difference between the vacuum (negative press
ure) from engine stroke and atmospheric pressure to amplify the braki
ng force in hydraulic brake. The other is air servo brake (hydro air vac)
which uses the difference between compressed air and atmospheric p
ressure.

Air servo brake (hydro air vac) has additional air compressor and air st
orage tank and operating principle is the same with that of hydro vac.
Servo brake
Hydro vac
Hydro vac allows the braking with a general hydraulic brake when servo brake f
ails, since it uses the difference between the vacuum of engine intake manifold
and atmospheric pressure.

There are 2 types of hydro vac. The one is direct controlling (master vac) type fo
r passenger cars and light trucks in which master cylinder and servo brake are i
nstalled in a unit. The other is remote controlling type (hydro vac) in which mast
er cylinder and servo brake are separately installed.

Types of hydro vac

1) Direct controlling type
2) Remote controlling type
Servo brake
Hydro vac (Direct controlling type)
In direct controlling type, operation rod pushes poppet and valve plunger when
brake pedal is pressed so that poppet is adhered to power piston seat to close
the vacuum valve and vacuum supply to cylinder (booster) A and B is shut. At
the same time, plunger falls off the poppet and air valve opens so that filtered
air is supplied to power cylinder B and power piston pushes the push rod of
master cylinder to operate servo brake.
Servo brake
Hydro vac (Direct controlling type)

When the pedal is released, air

valve closes as valve plunger
returns its original position by
the spring tension. And power
piston returns to its original
position by the master cylinder
reaction and the tension of the
diaphragm return spring when
the pressures of power cylinder
A and B becomes equal.

[Operation state of direct controlling type ]

Servo brake
Hydro vac (Remote controlling type)
Remote controlling type consists of hydraulic system (hydraulic brake and
hydraulic cylinder) and vacuum system (power cylinder, power piston, relay
valve, valve piston and check valve).
Servo brake
Hydro vac (Remote controlling type)
a. When brake pedal is pressed

Master cylinder oil flows to wheel cylinder through piston check valve when the
pedal is pressed. At the same time, hydraulic pressure activates on the relay
valve piston, too. If the hydraulic pressure on the relay valve piston, piston
moves to close the vacuum valve by placing the diaphragm in between so that
vacuum supply to power cylinder A and B is shut. Then, air valve opens so that
atmospheric pressure comes into power cylinder A.

Therefore, poser piston moves from A to B to move hydraulic piston through

push rod. When hydraulic piston moves, yoke adhered to stop washer falls off.
Then, check valve closing shuts the oil flow between master cylinder and
wheel cylinder and brake is applied as hydraulic cylinder oil is sent to wheel
cylinder.
Servo brake
Hydro vac (Remote controlling type)
a. When brake pedal is pressed

Vacuum valve Hydraulic piston

Air valve
Servo brake
Hydro vac (Remote controlling type)
b. When brake pedal is released

When the pedal is released, hydraulic pressure of master cylinder on relay

valve piston reduces so that diaphragm spring returns the piston and air valve
shuts to block the air inflow. And then, vacuum valve opens as it falls off
diaphragm.

Now, the pressure difference between both power cylinders disappears so that
power piston and hydraulic piston return their original positions by the return
spring tension. Oil pressure on the wheel cylinder returns to master cylinder as
check valve of hydraulic piston opens.
Servo brake
Hydro vac (Remote controlling type)
Brake pedal
b. When brake pedal is released Piston relay
valve
Check Intake
Master cylinder valve manifold

Vacuum Air
valve
filter
Hydraulic
cylinder
Wheel cylinder

Check
ball
Vacuum
valve Power piston Return spring Hydraulic
Power piston piston Check ball
Push road

Piston
Air Yoke
stop
valve
washer
Servo brake
Hydro air vac
Hydro air vac amplifies the braking force using the difference between compres
sed air and atmospheric pressure and is used for large buses and trucks. Since
it consists of air compressor, air tank, pressure regulator, it is more expensive t
han hydro vac.
Servo brake
Hydro air vac (Operation)

1) When brake pedal is applied

When the brake pedal is pressed, master cylinder oil activates on hydraulic
cylinder and relay valve piston to close atmospheric valve and open air valve.
Then, air flows into the rear side of power piston and air at the opposite side
exhausts through atmospheric hole. Power piston moves and supplies
sufficiently pressurized oil to wheel cylinder by pushing hydraulic piston so that
brake shoe presses drum to apply the brake.

2) When brake pedal is released

When brake pedal is released, power piston returns to its original position by
return spring because master cylinder pressure reduces. Then, spring returns
the relay valve to close air valve and opens atmospheric valve so that
pressures at both sides of power piston stabilizes to atmospheric pressure and
status returns to what it is before operation as the air exhausts from the back of
power piston. So, returns spring releases the brake shoe contacting the drum.
Servo brake
Hydro air vac (Operation)
Servo brake
Hydro air vac (Advantages and disadvantages)

1) Advantages
① Powerful braking force can be obtained even with small diameter of power piston.
② It consumes relatively less air.
③ It provides bigger braking force because the maximum pressure of compressed air is

5~7kgf/cm².

2) Disadvantages
① Structure is complex and manufacturing cost is expensive.
② Operation of air compressor consumes engine output.
Disc brake
Principle
Disc type hydraulic brake generates braking force by pressing the pad strongly
to both sides of round plate type disc which is turning with wheels as shown in
the figure below. Since disc type hydraulic brake has good heat radiation due to
the rotation exposed to the air, it provides a stable braking performance
because of low deterioration in braking performance with the repeated use in
high speed driving.
Disc brake
Advantages and disadvantages
(1) Advantages
① It provides excellent heat radiation because discs are exposed to air.
② It provides stable braking performance because fade is prevented.
③ There is less chance of partial braking because absence of self reaction provides
stable braking performance between left and right wheels.
④ It provides stable braking performance due to low deterioration in braking
performance with the repeated use.
⑤ Water or mud can be detached easily from disc.
⑥ Brake pedal stroke seldom changes because disc hardly deforms with a heat.
⑦ It provides easy check and maintenance.

(2) Disadvantages
① It requires strong force to push pad since the frictional are is small.
② Pad material requires high strength.
③ It requires strong brake pedal efforts.
④ It is expensive in structure.
Disc brake
Types of disc brake
Disc brake can be classified into fixed caliper type (opposite piston disc brake)
and floating caliper type. The one generates braking force as cylinder at both
sides of caliper press brake pads to discs. The other generates braking force
as whole caliper moves because cylinder is installed only at one side.
Disc brake
Fixed caliper type
Fixed caliper consists of disc rotating together with wheels and caliper fixed to
transaxle or strut. Cylinders are installed at both sides of caliper. Piston and
automatic adjuster are integrated into cylinder. When master cylinder supplies
hydraulic pressure to caliper cylinder, piston presses pads to both sides of
discs to apply the braking. This type was used at the initial stage of disc brake
in domestic market but not in use any longer.
Disc brake
Floating caliper type

This type generates braking force by

moving the caliper to the right and left
direction in which one cylinder is
installed at the side of caliper and one
piston is installed inside. If piston
presses pad to disc as hydraulic
pressure is supplied from master
cylinder, reaction force moves caliper
and to press the other pad to the disc
so that braking force generates. This
type is disc brake type, which are
currently used for most compact
passenger cars.
Disc brake
Floating caliper type (Operation)
Floating caliper type consists of disc
rotating together with wheels, floating
type caliper, piston and boot assembled
to caliper, whose functions are as follows.
When hydraulic pressure activates in the
cylinder, piston moves to a direction as
shown in the figure to press the pad
installed right side of the caliper to disc.
Since the identical hydraulic pressure,
simultaneously applied to right side of the
cylinder, pulls the caliper to B direction so
that pad installed at the left side of caliper
is pressed to the disc. In addition, piston
seal adjusts the gap between disc and
pad as done in the fixed caliper type.
Disc brake
Floating caliper type (Advantages and disadvantages)

(1) Advantages
① it is simply structured and light weighted.
② It is free from vapor lock since cylinder is installed where ventilates well.
③ It has less chance of oil leaks because of small number of components.

(2) Disadvantages
① Piston travel should be large.
② Alien substances such as dust may prevent the smooth travel.
③ Pad is liable to partial wear.
Disc brake
Warning system in case of pad wear
When brake pad thickness is reduced to 2 mm, wear indicator beeps the
warning sound as it touches the brake disc to inform the driver of timing of brake
pad change.
Disc brake
Automatic gap adjuster
Automatic gap adjuster moves the
piston forward automatically to maintain
the gap with the disc constantly when
the pad is worn, and rubber piston seal
adjusts the gap with disc automatically.
As shown in the right side figure,
pressure is applied to pad to apply the
braking as piston deforms the seal
when hydraulic pressure is supplied
from master cylinder. When the
hydraulic pressure is released, piston
seal pull the piston by the piston seal
elasticity and returns to keep the
constant gap between disc and pad all
the time.
Load Sensing Proportioning Valve
It is installed between master cylinder and rear wheel cylinder. Brake
hydraulic pressure of rear wheel cylinder is controlled after sensing
vehicle weight when brake is applied. Then, braking force distribution
between front and rear wheels can be obtained.
Operation
Valve piston pushes up the piston with the hydraulic pressure applied on master
cylinder A plus spring tension. Then, reaction force of hydraulic pressure
generates on wheel cylinder B. When the brake pedal is pressed, spring tension
lifts the ball to open the path so that hydraulic pressure is transferred to wheel
cylinder. Then, hydraulic pressure of master cylinder increases to a specified
pressure and force on B exceeds the force on A.
Now, piston moves down and shut the path to reduce the pressure.
If master cylinder pressure increases further when the path is closed, increased
hydraulic pressure is applied on A. Then, piston moves up and ball opens the
path so that hydraulic pressure moves to wheel cylinder.
Since master cylinder pressure applies on the wheel cylinder and B together
when the path is open, piston moves down and closes the path to repeat the
pressure reduction.
Load Sensing Proportioning Valve
Operation
Anti-lock Brake System
Advantages of ABS
Anti-lock Brake Systems are designed to prevent wheel lockup under he
avy braking conditions on any type of road condition.

The result is that, during heavy braking, the driver :

• retains directional stability(Vehicle Stability)

• stops faster (Shortened Stopping distance, except gravel, fresh snow..)

• retains maximum control of vehicle (Steerability)

Anti-lock Brake System
Advantages of ABS

<Braking without ABS> <Braking with ABS>

Low-μ Low-μ
High-μ road High-μ road
road road
Anti-lock Brake System
Construction

1. HCU (Hydraulic Control Unit)

2. ABSCM (ABS Control Module)
Proportioning valve 3. Wheel speed sensors
(Without EBD)
HCU 4. 4WD G-sensor
5. Stop light switch
6. Proportioning valve
ABSCM
(ABS model without EBD)
G-Sensor (with 4WD)
Anti-lock Brake System
Wheel speed sensor

1 Electronic Cable
2 Permanent Magnet
3 Housing
4 Housing Block
5 Pole Pin
6 Winding
7 Air gap
8 Tone wheel
Anti-lock Brake System
Wheel speed sensor

[Waveform at low speed] [Waveform at high speed]