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Brake systems
We all know that pushing down on the brake pedal slows a car to a stop. But how does this happen? How does your car transmit the force from your leg to its wheels? How does it multiply the force so that it is enough to stop something as big as a car?
Brake Image Gallery
Layout of typical brake system.? See more brake images.
When you depress your brake pedal, your car transmits the force from your foot to its brakes through a fluid. Since the actual brakes require a much greater force than you could apply with your leg, your car must also multiply the force of your foot. It does this in two ways:
· Mechanical advantage (leverage)
· Hydraulic force multiplication
The brakes transmit the force to the tires using friction, and the tires transmit that force to the road using friction also. Before we begin our discussion on the components of the brake system, we'll cover these three principles:
· Leverage
· Hydraulics
· Friction
Leverage and Hydraulics
In the figure below, a force F is being applied to the left end of the lever. The left end of the lever is twice as long (2X) as the right end (X). Therefore, on the right end of the lever a force of 2F is available, but it acts through half of the distance (Y) that the left end moves (2Y). Changing the relative lengths of the left and right ends of the lever changes the multipliers.
The pedal is designed in such a way that it can multiply the force from your leg several times before any force is even transmitted to the brake fluid.
The basic idea behind any hydraulic system is very simple: Force applied at one point is transmitted to another point using an incompressible fluid, almost always an oil of some sort. Most brake systems also multiply the force in the process. Here you can see the simplest possible hydraulic system:
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Simple hydraulic system
In the figure above, two pistons (shown in red) are fit into two glass cylinders filled with oil (shown in light blue) and connected to one another with an oil-filled pipe. If you apply a downward force to one piston (the left one, in this drawing), then the force is transmitted to the second piston through the oil in the pipe. Since oil is incompressible, the efficiency is very good -- almost all of the applied force appears at the second piston. The great thing about hydraulic systems is that the pipe connecting the two cylinders can be any length and shape, allowing it to snake through all sorts of things separating the two pistons. The pipe can also fork, so that one master cylinder can drive more than one slave cylinder if desired, as shown in here:
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Master cylinder with two slaves
The other neat thing about a hydraulic system is that it makes force multiplication (or division) fairly easy. If you have read How a Block and Tackle Works or How Gear Ratios Work, then you know that trading force for distance is very common in mechanical systems. In a hydraulic system, all you have to do is change the size of one piston and cylinder relative to the other, as shown here:
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Hydraulic multiplication
To determine the multiplication factor in the figure above, start by looking at the size of the pistons. Assume that the piston on the left is 2 inches (5.08 cm) in diameter (1-inch / 2.54 cm radius), while the piston on the right is 6 inches (15.24 cm) in diameter (3-inch / 7.62 cm radius). The area of the two pistons is Pi * r2. The area of the left piston is therefore 3.14, while the area of the piston on the right is 28.26. The piston on the right is nine times larger than the piston on the left. This means that any force applied to the left-hand piston will come out nine times greater on the right-hand piston. So, if you apply a 100-pound downward force to the left piston, a 900-pound upward force will appear on the right. The only catch is that you will have to depress the left piston 9 inches (22.86 cm) to raise the right piston 1 inch (2.54 cm).
A Simple Brake System
Before we get into all the parts of an actual car brake system, let's look at a simplified system:
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A simple brake system
You can see that the distance from the pedal to the pivot is four times the distance from the cylinder to the pivot, so the force at the pedal will be increased by a factor of four before it is transmitted to the cylinder.
You can also see that the diameter of the brake cylinder is three times the diameter of the pedal cylinder. This further multiplies the force by nine. All together, this system increases the force of your foot by a factor of 36. If you put 10 pounds of force on the pedal, 360 pounds (162 kg) will be generated at the wheel squeezing the brake pads.
There are a couple of problems with this simple system. What if we have a leak? If it is a slow leak, eventually there will not be enough fluid left to fill the brake cylinder, and the brakes will not function. If it is a major leak, then the first time you apply the brakes all of the fluid will squirt out the leak and you will have complete brake failure.
Drum brakes work on the same principle as disc brakes: Shoes press against a spinning surface. In this system, that surface is called a drum.
Figure 1. Location of drum brakes.? See more drum brake pictures.
Many cars have drum brakes on the rear wheels and disc brakes on the front. Drum brakes have more parts than disc brakes and are harder to service, but they are less expensive to manufacture, and they easily incorporate an emergency brake mechanism.
In this edition of HowStuffWorks, we will learn exactly how a drum brake system works, examine the emergency brake setup and find out what kind of servicing drum brakes need.
Figure 2. Drum brake with drum in place
Figure 3. Drum brake without drum in place
Let's start with the basics.
The Drum Brake
The drum brake may look complicated, and it can be pretty intimidating when you open one up. Let's break it down and explain what each piece does.
Figure 4. Parts of a drum brake
Like the disc brake, the drum brake has two brake shoes and a piston. But the drum brake also has an adjuster mechanism, an emergency brake mechanism and lots of springs.
First, the basics: Figure 5 shows only the parts that provide stopping power.
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Figure 5. Drum brake in operation
When you hit the brake pedal, the piston pushes the brake shoes against the drum. That's pretty straightforward, but why do we need all of those springs?
This is where it gets a little more complicated. Many drum brakes are self-actuating. Figure 5 shows that as the brake shoes contact the drum, there is a kind of wedging action, which has the effect of pressing the shoes into the drum with more force.
The extra braking force provided by the wedging action allows drum brakes to use a smaller piston than disc brakes. But, because of the wedging action, the shoes must be pulled away from the drum when the brakes are released. This is the reason for some of the springs. Other springs help hold the brake shoes in place and return the adjuster arm after it actuates.
Brake Adjuster
For the drum brakes to function correctly, the brake shoes must remain close to the drum without touching it. If they get too far away from the drum (as the shoes wear down, for instance), the piston will require more fluid to travel that distance, and your brake pedal will sink closer to the floor when you apply the brakes. This is why most drum brakes have an automatic adjuster.
Figure 6. Adjuster mechanism
Now let's add in the parts of the adjuster mechanism. The adjuster uses the self-actuation principle we discussed above.
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Figure 7. Drum brake adjuster in operation
In Figure 7, you can see that as the pad wears down, more space will form between the shoe and the drum. Each time the car stops while in reverse, the shoe is pulled tight against the drum. When the gap gets big enough, the adjusting lever rocks enough to advance the adjuster gear by one tooth. The adjuster has threads on it, like a bolt, so that it unscrews a little bit when it turns, lengthening to fill in the gap. When the brake shoes wear a little more, the adjuster can advance again, so it always keeps the shoes close to the drum.
Some cars have an adjuster that is actuated when the emergency brake is applied. This type of adjuster can come out of adjustment if the emergency brake is not used for long periods of time. So if you have this type of adjuster, you should apply your emergency brake at least once a week.
Servicing
The most common service required for drum brakes is changing the brake shoes. Some drum brakes provide an inspection hole on the back side, where you can see how much material is left on the shoe. Brake shoes should be replaced when the friction material has worn down to within 1/32 inch (0.8 mm) of the rivets. If the friction material is bonded to the backing plate (no rivets), then the shoes should be replaced when they have only 1/16 inch (1.6 mm) of material left.
Photo courtesy of a local AutoZone store
Figure 9. Brake shoe
Just as in disc brakes, deep scores sometimes get worn into brake drums. If a worn-out brake shoe is used for too long, the rivets that hold the friction material to the backing can wear grooves into the drum. A badly scored drum can sometimes be repaired by refinishing. Where disc brakes have a minimum allowable thickness, drum brakes have a maximum allowable diameter. Since the contact surface is the inside of the drum, as you remove material from the drum brake the diameter gets bigger.
Figure 10. Brake drum
制動(dòng)系統(tǒng)
眾所周知，踩下制動(dòng)踏板可以使汽車(chē)減速至停止。但這是如何產(chǎn)生的呢？汽車(chē)是如何將力從你的腿傳遞到車(chē)輪的呢？汽車(chē)是如何將力放大到足夠大以致可以將像汽車(chē)一樣大的東西制動(dòng)的呢？
制動(dòng)系統(tǒng)組件
當(dāng)你踩下制動(dòng)踏板的時(shí)候，汽車(chē)通過(guò)液體把力從腳傳遞到制動(dòng)器。因?yàn)橹苿?dòng)器需要的真正力量比你的腿能提供的要大的多，所以汽車(chē)必須放大腳產(chǎn)生的力
有兩種方式：
機(jī)械杠桿作用
液力放大
制動(dòng)器通過(guò)摩擦把力傳遞給輪胎，并且輪胎也是通過(guò)摩擦把力傳遞給路面的。 在我們討論制動(dòng)系統(tǒng)的組成之前，先來(lái)介紹以下三條原則：
杠桿
液力
摩擦力
杠桿和液力
在下面的圖中，一個(gè)力F加在杠桿的左端。左端的杠桿長(zhǎng)度（2X）是右端（X）的兩倍。因此杠桿右端可施加的力為2F ，但是右端移動(dòng)的距離(Y)是左端距離(2Y)的一半。改變杠桿的左端和右端的長(zhǎng)度可以改變放大系數(shù)。
任何液壓系統(tǒng)背后的基本原理都是非常簡(jiǎn)單的：作用在某一點(diǎn)力通過(guò)通常是油一類(lèi)的不可壓縮的液體傳遞到另一點(diǎn)。大多數(shù)的制動(dòng)系統(tǒng)也在這個(gè)過(guò)程中放大力。下面的是最簡(jiǎn)單的液壓系統(tǒng)：
簡(jiǎn)單液壓系統(tǒng)
在上圖中，兩個(gè)活塞放在兩個(gè)充滿油的玻璃液壓缸中并且由充滿油的管道相連。如果在一個(gè)活塞上施加一個(gè)向下的力，那么力將通過(guò)管道中的油傳遞到第二個(gè)活塞。因?yàn)橛鸵菏遣豢蓧嚎s的，所以傳遞效率很好，大部分的作用力都傳遞到了另一個(gè)活塞。
液壓系統(tǒng)的好處連接兩液壓缸的管道可以是任何長(zhǎng)度和形狀，這樣就可以使管道彎曲的通過(guò)兩活塞之間的各種部件。管道也可以是分叉的，如果有需要的話，這樣一個(gè)主缸可以驅(qū)動(dòng)數(shù)個(gè)副缸。如下圖所示：
帶有兩個(gè)副缸的主缸
液壓系統(tǒng)的另一個(gè)好處是產(chǎn)生放大（或者縮?。?力相當(dāng)?shù)厝菀住Ｈ绻阋蛔x過(guò)滑車(chē)設(shè)備工作原理或者齒輪齒數(shù)比原理，那么你就會(huì)知道在機(jī)械系統(tǒng)中把力轉(zhuǎn)化為距離處理是很常見(jiàn)的。在液壓系統(tǒng)中，我們所要做的就是相對(duì)地改變一組活塞和液壓缸的尺寸。如下圖所示：
液壓增力原理
為了確定上圖中的放大因子，先由觀察活塞的尺寸開(kāi)始。假設(shè)左邊活塞的直徑為2英尺（5.08cm而右邊的直徑為6英尺（15.24cm）。兩個(gè)活塞的面積是Pi * r2 。因此左面活塞的面積是3.14，而右面的面積是28.26。右面活塞的面積是左邊的九倍大。這就意味著無(wú)論在左面的活塞上施加多大的力，在右面的活塞上就會(huì)輸出九倍于左面的力。所以，如果在左邊活塞上施加100磅向下的力，那么在右面活塞上將產(chǎn)生900磅向上的力。唯一的補(bǔ)償是左面的活塞要移動(dòng)9英尺（22.86cm）來(lái)使右面提升1英尺（2.54cm）
一個(gè)簡(jiǎn)單的制動(dòng)系統(tǒng)
在我們深入了解一個(gè)真實(shí)的制動(dòng)系統(tǒng)的各部分之前，讓我們先來(lái)看一個(gè)簡(jiǎn)化的系統(tǒng)：
我們可以看到踏板到樞軸的距離是液壓缸到樞軸距離的4倍，所以施加在踏板上的力在傳遞到液壓缸之前將被增加4倍。我們還可以看到制動(dòng)缸的直徑是踏板缸直徑的3倍。這就將力進(jìn)一步放大了九倍。最終這個(gè)系統(tǒng)將腿上的力增加了36倍。所以，如果在踏板上施加10磅的力，將在擠壓制動(dòng)帶的輪上產(chǎn)生369磅（162kg）的力。
下面是這種簡(jiǎn)單系統(tǒng)所存在的問(wèn)題。要是系統(tǒng)有泄漏該怎么辦呢？如果是輕微泄漏，最終將會(huì)沒(méi)有足夠的油使制動(dòng)缸充滿，并且制動(dòng)器將停止工作。如果是嚴(yán)重泄漏，那么在你制動(dòng)的第一時(shí)間，所有的油液將從泄露處噴射而出，并且制動(dòng)系統(tǒng)將徹底地不起作用。
鼓式制動(dòng)器的工作原理和盤(pán)式制動(dòng)器是一樣的：制動(dòng)面接觸一個(gè)磨砂的表面。在這個(gè)系統(tǒng)中，那個(gè)表面稱(chēng)作制動(dòng)鼓
圖1.制動(dòng)鼓的位置
許多汽車(chē)的后輪安裝鼓式制動(dòng)器，而盤(pán)式制動(dòng)器安裝在前面。鼓式制動(dòng)器比盤(pán)式制動(dòng)器有更多的零件并且更難檢修。 但是制造成本相對(duì)便宜，還有鼓式制動(dòng)器容易組裝一個(gè)緊急使用的制動(dòng)裝置。
在本版本的How StuffWorks中，我們將詳盡了解鼓式制動(dòng)系統(tǒng)是如何工作的。考察緊急制動(dòng)系統(tǒng)的組成，并且找到鼓式制動(dòng)器需要何種檢修工作。
圖2. 有鼓的鼓式制動(dòng)器
圖3.未安裝鼓的鼓式制動(dòng)器
讓我們基礎(chǔ)開(kāi)始：
鼓式制動(dòng)器
鼓式制動(dòng)器可能看起來(lái)比較復(fù)雜，它可以是很復(fù)雜的，當(dāng)你打開(kāi)一個(gè)的時(shí)候。讓我們拆開(kāi)它，并解釋每一塊的作用。
圖4. 鼓式制動(dòng)器的組成
如盤(pán)式制動(dòng)器，鼓式制動(dòng)器有兩個(gè)制動(dòng)蹄和一個(gè)活塞。 But the drum brake also has an adjuster mechanism, an emergency brake mechanism and lots of springs .但是鼓式制動(dòng)器也有一個(gè)調(diào)節(jié)機(jī)制，緊急剎車(chē)機(jī)制和大量的彈簧 。
首先，基礎(chǔ)知識(shí)： 圖5顯示只有部分提供的制動(dòng)力。
圖5.工作狀態(tài)下的鼓式制動(dòng)器
當(dāng)你踩下剎車(chē)踏板時(shí)，活塞推動(dòng)緊靠著鼓的制動(dòng)蹄。 That's pretty straightforward, but why do we need all of those springs?這是很簡(jiǎn)單的，但為什么我們需要所有這些彈簧呢？
這使它變的有點(diǎn)復(fù)雜許多鼓式制動(dòng)器是自增力式的。圖5表明，當(dāng)制動(dòng)蹄與鼓相接觸的時(shí)候，兩者間有一個(gè)楔入運(yùn)動(dòng)，這起到了產(chǎn)生更多的力量將制動(dòng)蹄向鼓擠壓。
由楔入運(yùn)動(dòng)提供的額外制動(dòng)力使得鼓式制動(dòng)器可以使用比盤(pán)式制動(dòng)器更小的活塞。
但是由于這種楔入運(yùn)動(dòng)，在制動(dòng)釋放的時(shí)候制動(dòng)蹄必須從鼓拉離開(kāi)。這是使用其中部分彈簧的原因。其它彈簧的作用是將制動(dòng)蹄固定并且驅(qū)動(dòng)調(diào)節(jié)臂返回。
制動(dòng)調(diào)節(jié)器
為了使鼓式制動(dòng)器正確的工作，制動(dòng)蹄必須緊貼著鼓但是不碰到它。如果離鼓太遠(yuǎn)的話，活塞將需要更多的油液以通過(guò)那段距離，并且當(dāng)你制動(dòng)時(shí)，制動(dòng)踏板將下行而離地板更近。這就是為什么大多數(shù)的鼓式制動(dòng)器有一個(gè)自動(dòng)調(diào)節(jié)裝置的原因。
圖6.調(diào)節(jié)機(jī)構(gòu)
現(xiàn)在讓我們?cè)诎颜{(diào)節(jié)機(jī)構(gòu)也加進(jìn)來(lái)，這個(gè)調(diào)節(jié)器使用的是上面討論過(guò)的自增力原理。
圖7.工作狀態(tài)下的鼓式制動(dòng)調(diào)節(jié)器
在圖7中，我們可以看到由于摩擦片的磨損，這使得制動(dòng)蹄和鼓之間形成更大的空間。每次車(chē)停下的時(shí)候，相反的是制動(dòng)蹄被拉的和鼓更緊。當(dāng)間隙變的足夠大時(shí)，調(diào)節(jié)杠桿足夠擺動(dòng)推進(jìn)調(diào)節(jié)齒輪先前轉(zhuǎn)動(dòng)一個(gè)齒。調(diào)節(jié)裝置有一個(gè)行程，就像一個(gè)螺栓，以便當(dāng)它轉(zhuǎn)動(dòng)時(shí)旋開(kāi)一點(diǎn)點(diǎn)，延長(zhǎng)以填補(bǔ)間隙。當(dāng)制動(dòng)蹄進(jìn)一步磨損，調(diào)節(jié)器又可以再向前。所以它總是保持制動(dòng)蹄緊靠著鼓。
有些汽車(chē)緊急剎車(chē)時(shí)有一個(gè)被驅(qū)動(dòng)的調(diào)節(jié)器。如果緊急制動(dòng)很長(zhǎng)一段時(shí)間沒(méi)有使用，這種類(lèi)型的調(diào)節(jié)器可以產(chǎn)生調(diào)節(jié)作用。所以如果你有這種類(lèi)型的調(diào)節(jié)器，你應(yīng)該每周至少使用一次緊急制動(dòng)裝置。
檢修
鼓式制動(dòng)器最常見(jiàn)的檢修是更換制動(dòng)蹄。一些鼓式制動(dòng)器在背面設(shè)置了一個(gè)檢查孔，通過(guò)這個(gè)孔，你可以看到制動(dòng)蹄上還剩余多少摩擦材料。當(dāng)摩擦材料
磨損到鉚釘內(nèi)1/32英寸（0.8mm）時(shí)，必須更換制動(dòng)蹄。如果摩擦材料和墊板直接連接（無(wú)鉚釘），那么當(dāng)摩擦材料只剩下1/16英寸（1.6mm）時(shí)，就該換制動(dòng)蹄了。
圖9.制動(dòng)蹄
正如在盤(pán)式制動(dòng)器中，深的刻痕可能會(huì)磨穿到制動(dòng)鼓。如果一個(gè)磨損的制動(dòng)蹄使用過(guò)長(zhǎng)的時(shí)間，把摩擦片固定到墊板上鉚釘可以將制動(dòng)鼓摸出一條凹槽。一個(gè)嚴(yán)重磨損的制動(dòng)鼓有時(shí)可以被修補(bǔ)修復(fù)。盤(pán)式制動(dòng)器有最小允許厚度，鼓式制動(dòng)器有一個(gè)最大允許直徑。因?yàn)榻佑|表面是鼓的內(nèi)側(cè)。當(dāng)你將材料從制動(dòng)器中取出時(shí)，制動(dòng)鼓的直徑變大了。
圖10.制動(dòng)鼓
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