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SUBJECT CODE: (AT2316)
Lecturer
Dr. / Mohamed Abd El-hafiz
E-mail : Eng.Mohamed.Hafiz@gmail.Com
Method of Assessment
60 Written examination
15 Oral examination
Practical/laboratory
10
work
Other Assignments/class
15
work
100 Total
Subject Main Titles
1. Stopping Distance And its Calculations
Driver reaction time : (t1 - t0) = 0.1 to 0.2 s Braking time: (t4 t3)
Initial system response time: (t2 t1) Release time: (t5 t4)
Step 1:
Brake Balance Front-to-Rear: Proper balance ensures directional
stability while braking for lightly and fully laden operating
conditions,
Step 3:
Brake Pedal Force and Booster: For a specified pedal force and pedal
travel, the vacuum booster or hydro-boost size is determined based on
safety standards and human factors limitations. An adjustable brake
pedal may have to be considered to accommodate small and large
drivers.
Step 6:
Specific Design and Wear Measures: The sizes of brake pads or width
of brake linings are checked against a number of specific design
measures to ensure acceptable pad wear and rotor life, as well as brake
fade performance.
Step 7:
Brake Temperature and Cooling: With brake balance and brake
sizes established, brake temperatures are determined for maximum
braking and loading conditions and checked against limit values.
Step 8:
Parking Brake System: With the wheel brakes established, the
parking brake is designed in terms of location (front, rear, or drive
shaft) and hill-holding capacity, as well as deceleration capability.
Human factors are considered in terms of location and modulation.
Step 9:
Braking-in-a-Turn: With the entire brake system established,
the braking performance while turning is analyzed in terms of
tire-road friction utilization for a specified lateral acceleration.
In particular, the rake pedal force or deceleration at which the
brake of the first inner wheel will lock is determined.
Step 10:
Safety Standards: The braking performance of the vehicle is
evaluated with respect to any applicable safety standard,
industry practice, global compliance and certification, and
customer expectations.
Brake System Design/Testing Checkpoints
1) Braking Effectiveness.
2) Braking Efficiency
3) Stopping Distance, Lightly and Fully Laden
4) Response Time
5) Partial Brake System Failure
6) Brake Fluid Volume Analysis
7) Thermal Analysis
8) Emergency or Parking Brake
9) Specific Design Measures
10) In-Use Factors
11) Component Sizing
12) Safety Regulations
Pedal Force and Pedal Travel
For brakes without a booster, the brake system should be designed so that
for a maximum pedal force of 445 to 489 N, a theoretical deceleration of 1 g
is achieved when the vehicle is loaded at GVW (Gross Vehicle Weight;
Maximum pedal travel between fully released and the point where the
master cylinder piston bottoms out should not exceed 150 mm.
The associated pedal travel should not exceed 75 to 90 mm for cold (less than 366 K
or 200F) brakes.
The booster characteristic should increase linearly with pedal force and pedal travel.
Hydraulic brake line pressure rise time delays of 100 ms for single, and up to 180 ms for
double diaphragm boosters must be considered.
Parking Brake
with a hand force of not more than 356 N (80 lb) or a foot
force of less than 445 N (100 lb). With the apply force
limitations stated,
Brake Factor
Definition of Brake Factor
The brake factor is defined as the ratio of total
drum or rotor drag Fd to the application force Fa
against one shoe or pad:
For a standard caliper disc brake with two brake pads
producing drag forces on the in- and out-board sides of the
rotor, the brake factor is
Braking efficiency
The brake factor BF is defined as the ratio of total drum or rotor drag
Fd to the application force Fa against one shoe
P = Fp p p / Amc
Fp = pedal force, N
A typical value for the pedal lever efficiency is 0.8, which includes
the efficiency of the master cylinder including return springs.
The braking force Fx per axle is obtained from the
definition of the brake factor from
Pushout pressures for drum brakes are determined by the shoe return
spring force and wheel cylinder area, and may assumes values as high
as 70 to 172 N/cm2 (100 to 250 psi).