Students Learn About:
historical developments of braking systems including band, drum, disc, ABS, regenerative brake systems and the automotive hand brake
engineering innovations in braking systems and their effect on people’s lives
environmental implications from the use of materials in braking systems
Students Learn To:
identify historical developments in braking systems
explain the principles of braking systems
examine the changing applications of materials used in components of braking systems
discuss the social implications of technological change in braking systems
External contracting brakes are sometimes used for parking brakes on motor vehicles, for cranes, and for controlling the speed of auxiliary equipment drive shafts.
In operation, the brake band (or shoe) of an external contracting brake is tightened around the rotating drum by moving the brake lever. The brake band is made of comparatively thin, flexible steel, shaped to fit the drum, with a frictional lining riveted to the inner surface. his flexible band cannot withstand the high pressure required to produce the friction needed to stop a heavily loaded or fast-moving vehicle, but it works well as a parking brake or hold brake.
The modern automobile drum brake was first used in a car made by Maybach in 1900, although the principle was only later patented in 1902 by Louis Renault. He used woven asbestos lining for the drum brake lining, as no alternative dissipated heat like the asbestos lining, though Maybach had used a less sophisticated drum brake. In the first drum brakes, levers and rods or cables operated the shoes mechanically. From the mid-1930s, oil pressure in a small wheel cylinder and pistons (as in the picture) operated the brakes, though some vehicles continued with purely mechanical systems for decades. Some designs have two wheel cylinders.
This design has many advantages over the contracting band brake. First, the shoes are enclosed in the drum so the friction lining is away from water and dirt, so they last longer. The drum brake also exhibits servo-assistance, in both forward and reverse; reverse travel. Some front drum brakes use two leading shoes to improve braking efficiency.
One disadvantage of disc brakes is that they have no natural servo-assistance, so the force at the pedal is very large. To reduce the effort the pedal force is "boosted". A vacuum booster, running off the engine manifold (or a vacuum pump in the case of diesels), achieves this. This magnifies the pedal effort the driver provides and improves stopping performance. Should a vacuum booster fail, then the effort needed to stop a disc brake car is very large.
In Australia there is still concern about the performance of ABS brakes on gravel roads. Gravel roads need the wheels to lock and dig through the loose surface to the harder surface beneath, but as an ABS brake equipped car will not allow this to happen, an ABS equipped car will not stop as well on gravel. This is usually not a major concern for Japanese or European car designers.
Gasoline vehicles: The braking occurs when you’re in gear and take your foot off the accelerator. That’s because the throttle valve (which is in control of airflow into the engine) closes, leading to a decrease of air and creating a vacuum. This vacuum slows down the vehicle because it makes it harder for the engine cylinders to work, creating the force that slows the truck.
Diesel vehicles: Diesel engines don’t typically have throttle valves like gasoline engines do. Therefore, the manufacturer will add a throttle valve to the exhaust side. When the pistons force exhaust out, the throttle will close and create pressure, which resists the engine and slows the truck.
Exhaust braking: like engine braking, is all in the name. With this braking process, the exhaust path for the truck is closed. Because there is nowhere for the exhaust to go, it is compressed, creating force on the engine’s pistons that slows the truck. This is due to the back-pressure (the reversed movement of the exhaust gases back toward the engine). It’s so effective that drivers don’t even need to put their foot on the brake to slow down much of the time.
Regenerative braking systems (RBSs) are a type of kinetic energy recovery system that transfers the kinetic energy of an object in motion into potential or stored energy to slow the vehicle down, and as a result increases fuel efficiency.[2] These systems are also called kinetic energy recovery systems. There are multiple methods of energy conversion in RBSs including spring, flywheel, electromagnetic and hydraulic. More recently, an electromagnetic-flywheel hybrid RBS has emerged as well. Each type of RBS utilizes a different energy conversion or storage method, giving varying efficiency and applications for each type.
RBSs are installed along the drive train or fitted to the drive wheels of a vehicle where they inhibit the motion of the wheels using magnetic fields or mechanical torque. These methods of motion inhibition allow energy to be generated under braking, as opposed to friction brakes which simply waste away energy to slow the vehicle by turning the kinetic energy into thermal energy. Due to the maximum charging rate of the energy storage mechanisms, the braking force from a RBS is limited. Therefore, a traditional friction brake system is required to maintain the safe operation of a vehicle when heavy braking is necessary. RBS can improve fuel consumption and reduce the overall braking load taken on by the vehicles friction brakes, reducing the wear on the brake pads.[3]
RBSs are used in almost every electric vehicles and hybrid electric vehicles. In addition, public transportation such as buses and bullet trains make use of RBSs to decrease the environmental impacts of the transportation fleet and save money.
In road vehicles, the parking brake, also known as a handbrake or emergency brake (e-brake), is a mechanism used to keep the vehicle securely motionless when parked. Parking brakes often consist of a cable connected to two wheel brakes, which is then connected to a pulling mechanism. In most vehicles, the parking brake operates only on the rear wheels, which have reduced traction while braking. The mechanism may be a hand-operated lever, a straight pull handle located near the steering column or a foot-operated pedal located with the other pedals.
While most automatic transmission vehicles have parking brakes, it is often not engaged by drivers when parking. However, it is recommended to use it, as the parking pawl in the gearbox could fail due to stress or another vehicle striking the car, causing the car to roll. Also, regular use of the parking brake reduces the chance of corrosion by keeping the cables in-motion. In manual transmission vehicles, the parking brake can be engaged to help keep the vehicle stationary. When parking on an uphill gradient, it is recommended that the front wheels face away from the curb. This would prevent the car from rolling into the roadway by using the curb to block the front passenger tire in the event of a parking brake failure. Similarly, on a downhill gradient, the front wheels should face the curb for the same reason, and the wheels should face to the right on an uncurbed road regardless of orientation. In a manual transmission, leaving the car in first gear (or in reverse if pointing downhill) is also advised, as the engine will prevent the car from rolling if the parking brake fails.
The parking brake in most vehicles is still completely mechanical. Traditionally engaged by pulling a lever, the cables manually engage part of the car's braking system, usually the rear disk or drum brakes. The mechanical nature allows the driver to apply the brake even if the main hydraulic brake system fails.
Pictograph symbols and/or lights may be used to indicate the location of a parking brake, its application or release.
Improved stopping power means cars can travel faster while still stopping safely.
The increased speed is a double-edged sword, because although cars now travel faster they are potentially less safe, as other systems such as suspension and steering need to be upgraded to deal with increased speeds.
With the advent of drum brakes motor manufacturers started to fit four wheel brakes, thus making cars safer.
The drum brake handles poor weather conditions better than the contracting band brake, so it is possible to use the car in rain and snow; previously that may have been dangerous.
Cars are more effective at stopping at higher speeds.
Improved heat dissipation over the drum brakes means safer continual braking effort (such as is required when descending a hill).
Disc brakes provide improved braking in poor weather conditions.
They are easily adapted to computer controls such as ABS.
Of all materials used in braking systems, the asbestos formerly used in brake linings had the greatest impact on people. Prior to 1902 brake linings were leather or woven cotton, with poor thermal stability and low coefficient of friction, but in 1902 Herbert Food developed woven asbestos lining. Asbestos gave the brake lining greater stability at higher temperatures, thus the linings were more resistant to "brake fade" (i.e. as the brakes become hot the frictional force available for braking is reduced).
Although this new asbestos lining was great for heat resistance, there were major health problems associated with asbestos. If the asbestos is broken into fibres it can be inhaled, lodge in the lungs and cause lung cancer. Of greatest concern are the long "blue asbestos" fibres. Workers in asbestos mines risk lung cancer. As a consequence asbestos linings are not fitted to newer cars while in Europe asbestos linings are banned.
When car brakes are applied, the brake linings wear away to small fibres. Although these fibres are not linked directly to cancer, care should be taken when cleaning the brakes in case there are some fibres (whether asbestos or not) remaining around the brake assembly, particularly for drum brakes. These fibres should not be inhaled.