Air Brake Systems: Safe Stopping of heavy vehicles
The safe stopping of heavy-duty vehicles is critical for the safety of the load being transported and the safety of the drivers. This is where air brake systems come into play. These systems exhibit superior performance in heavy load and high speed situations where hydraulic braking systems are inadequate.
Basic Components of Air Brake System
Air brake systems have a complex structure and provide effective braking through the harmonious operation of many components. These components are as follows:
- Air Compressor: Driven by the engine, this part compresses the air it receives from the atmosphere and sends it to the system.
- Air Tanks: Compressed air is stored in these tanks and supplied to the system when needed.
- Brake Pedal Valve: The force applied by the driver to the brake pedal is converted into compressed air through this valve.
- Brake Cylinders: Compressed air is converted into mechanical energy through these cylinders and transmitted to the brake pads.
- Brake Pads and Disc/Campanes: With the force from the brake cylinders, pressure is applied to the disks or drums on the wheels and the vehicle is stopped.
- Relay Valves: Provides fast and balanced distribution of air pressure during braking.
- Load Adjustment Valves: Automatically adjusts the brake pressure according to the load condition of the vehicle, thus providing a balanced braking.
- Dryer: removes moisture from the air, extending the life of the air brake system.
Advantages of Air Brake System
- Provides effective braking at heavy loads and high speeds.
- More durable than hydraulic brake systems.
- Provides a safe stop in emergency situations.
- Thanks to the load adjustment valves, balance is provided according to variable loads.
Disadvantages of Air Brake System
- Since it has a complex structure, maintenance and repair requires expertise.
- It is more costly than hydraulic brake systems.
- It should be checked regularly for air leaks.
Air Brake System Maintenance and Safety
Regular maintenance is essential for safe and efficient operation of air brake systems. Particular attention should be paid to problems such as air leaks, moisture and compressor malfunctions. Periodic maintenance should be carried out by specialized technicians and original spare parts should be used.
Working Principle of Air Brake System:
- Air Compressor and Air Tanks:
- The air compressor, driven by the engine, compresses atmospheric air. The compressed air is stored in air tanks. This storage ensures that the compressed air required for braking is constantly available.
- The pressure in the air tanks is controlled by a pressure regulator. This regulator ensures that the pressure in the system remains at a certain level.
- Brake Pedal and Valves:
- When the driver presses the brake pedal, this action triggers the release of compressed air through a valve.
- The valves ensure that the air pressure is directed towards the brake cylinders. These valves are precisely designed and adjust the air pressure in proportion to the force the driver applies to the pedal.
- Brake Cylinders and Brake Mechanism:
- When compressed air reaches the brake cylinders, it is converted into a mechanical movement. This movement pushes the brake pads against the brake discs or drums.
- The friction between the brake pads and the disks/drum allows the vehicle to slow down or stop.
- Auxiliary Systems:
- ABS (Anti-lock Braking System): Prevents the wheels from locking, allowing the driver to maintain steering control.
- EBS (Electronic Brake System): Provides more precise and balanced braking by electronically controlling braking operations.
- ASR (Anti-Slip Regulation): Provides traction control by preventing the wheels from skidding.
- Retarder: It is an auxiliary braking system, generally used in heavy vehicles. It uses the resistance of the engine or an electrical mechanism to slow the speed of the vehicle, thus reducing the load on the service brakes.
Advantages of Air Brake Systems:
- High Braking Power: Provides effective braking even on vehicles carrying heavy loads.
- Durability: More durable and long-lasting than hydraulic brake systems.
- Safety: Provides a safe stop in emergency situations and offers a higher level of safety with auxiliary systems.
Disadvantages of Air Brake Systems:
- Complex Construction: Maintenance and repair requires expertise.
- Cost: More costly than hydraulic brake systems.
- Air Leaks: If air leaks occur in the system, braking performance may be reduced.
Maintenance and Safety Tips:
- Regularly drain the water from the air tanks, as moisture can cause corrosion in the system.
- Air hoses and connection points should be checked regularly and checked for leaks.
- The brake pads and disks/drums should be checked regularly and worn parts replaced.
- Make sure that the compressor is working properly and carry out the necessary maintenance.
Air Production and Distribution:
- Air Compressor Details:
- Air compressors are usually powered by the engine's crankshaft or an electric motor.
- Compressors can be single or multi-cylinder and can produce air at different pressures.
- The efficient operation of the compressor ensures that the air pressure in the system is stable.
- Air Dryers and Filters:
- Moisture and particles in the air can cause corrosion and malfunctions in the system.
- Air dryers keep the system dry by absorbing moisture from the air.
- Air filters remove dust and dirt from the air, extending the life of valves and cylinders.
- Air Pipes and Connections:
- Air pipes are made of high pressure resistant materials.
- Connection points are specially designed to prevent leaks.
- It is important to check the air pipes regularly and replace damaged pipes.
Braking Mechanism Details:
- Brake Cylinders and Bellows:
- Brake cylinders convert compressed air into mechanical motion.
- The brake bellows transmit the motion from the cylinders to the brake pads.
- The robustness of the bellows ensures that the braking force is applied correctly.
- Brake Pads and Discs/Campanes:
- Brake pads are made of materials with a high coefficient of friction.
- Disc brakes offer better cooling and braking performance than drum brakes.
- It is important to regularly inspect the brake pads and discs/drum brakes and replace worn parts.
- Load Sensing and Brake Adjustment:
- Load sensing valves adjust brake pressure according to the load condition of the vehicle.
- This ensures that the vehicle brakes evenly and prevents skidding.
- Correct operation of the load sensing system is especially important in cornering and sudden braking.
Auxiliary Brake Systems Details:
- Retarder Systems:
- Retarders work on different principles, such as engine exhaust brakes or electric brakes.
- They prevent the service brakes from overheating during long descents and heavy loads.
- The use of retarders extends the life of the brake pads and discs/pads.
- Electronic Control Systems (EBS, ABS, ASR):
- Systems such as EBS, ABS and ASR improve braking performance and vehicle stability.
- These systems prevent the wheels from locking, skidding and skidding.
- The correct functioning of electronic control systems is critical for safe driving.
Maintenance and Safety Recommendations:
- Regularly check the air pressure in the system.
- Regularly drain the water from the air tanks.
- Checking air pipes and connection points for leaks.
- Regular inspection of brake pads, discs/drums and bellows.
- Periodic maintenance of the compressor and other components.
