Browse Topic: Air brakes
This recommended practice shall apply to all on-highway trucks and truck-tractors equipped with air brake systems and having a GVW rating of 26 000 lb or more
This SAE Recommended Practice shall cover mechanical-brake adjustment limit stroke indicators for actuators with visible exposed pushrods and electrical-brake adjustment limit stroke indicators for all air-brake actuators. This device shall indicate the foundation brake(s) may require adjustment or service when inspected per vehicle manufacturer's procedures. A measurement shall be made to determine actual stroke measurement for any system not factory calibrated. Stroke indication accuracy of an air-brake actuator can be assured only when all of its components are supplied by the original brake actuator manufacturer
In an air brake system, compressed air is used as an energy medium for braking applications, ensuring a good seal between the components is critical. The sealing performance of gaskets are significant for the product with joint features as it affects functionality and can cause a breakdown of the entire system; hence, finite element simulation of the sealing performance of gaskets is important for any product development. To simulate fluid interacting with gasket, a fluid-structure interaction (FSI) simulation is necessary by co-simulating a computation fluid dynamics (CFD) and finite element analysis (FEA) solvers to capture complex behavior of seal deformation under dynamic conditions during leakage, but it is a time-consuming process. In this article, the sealing performance of gaskets is studied in detail only till the start of leakage. It is not necessary to simulate the dynamic behavior of the seal beyond leakage to validate the sealing performance; hence, static nonlinear
The testing techniques outlined in this SAE Recommended Practice were developed as part of an overall program tor testing and evaluating fuel consumption of heavy duty trucks and buses. The technique outlined in this document provides a general description of the type of equipment and facility which is necessary to determine the power consumption of these engine-driven components. It is recommended that the specific operating conditions suggested throughout the test be carefully reviewed on the basis of actual data obtained on the specific vehicle operation. If specific vehicle application is not known, see SAE J1343
This coding system is intended to provide a convenient means of identifying the various tube, pipe, hydraulic hose type, and hose fittings not intended for use in aircraft and of transmitting technical or engineering information relating to them wherever drawings or other pictorial media may not be readily available. The code has been kept flexible to permit expansion to cover new fitting categories or styles and, if the need develops, the inclusion of additional materials. The system is also compatible with automatic data processing equipment. It is not intended that this code should supersede established systems or means of identification. Therefore, it should be the prerogative of the user to apply the code which best satisfies his requirements
This SAE Recommended Practice provides test performance requirements for air disc brake actuators for service and combination service parking brake actuators with respect to function, durability, and environmental performance when tested according to SAE J2902
This SAE Recommended Practice describes a marking system to distinguish long-stroke from standard stroke for service, parking, and combination air-brake actuators, and components. Said actuators are used for applying cam type foundation brakes by slack adjuster means
This SAE Recommended Practice (RP) establishes uniform powered vehicle-level test procedure for forward collision warning (FCW) and automatic emergency braking (AEB) used in trucks and buses greater than 10000 pounds (4535 kg) GVWR equipped with pneumatic brake systems for detecting, warning, and avoiding potential collisions. This RP does not apply to electric powered vehicles, trailers, dollies, etc., and does not intend to exclude any particular system or sensor technology. These FCW/AEB systems utilize various methodologies to identify, track, and communicate data/information to the operator and vehicle systems to warn, intervene, and/or mitigate in the momentary longitudinal control of the vehicle. This specification will test the functionality of the FCW/AEB (e.g., ability to detect objects in front of the vehicle), its ability to indicate FCW/AEB engagement and disengagement, the ability of the FCW/AEB to notify the human machine interface (HMI) or vehicle control system that an
This code is intended for commercial vehicles over 4500 kg (10 000 lb) with brake systems having typical service pressure ranges 0 to 14.1 mPa (0 to 2050 psi) hydraulic or 0 to 830 kPa (0 to 130 psi) air and is not directly applicable to vehicles with other systems. Air over hydraulic systems are to be tested as air systems
This SAE Recommended Practice is intended for qualification testing for brake drums used on highway commercial vehicles with air brakes using an inertia-dynamometer procedure. This document consists of two distinct tests: Part A, durability and speed maintenance test, and Part B, heat check drag sequence test. Each test can be considered to be an independent evaluation of the brake drum which tests different properties
This SAE Information Report establishes a minimum level of uniform recipes for contaminants which may be used when durability testing pneumatic components to obtain additional information on how a device may perform under more true-to-life operating conditions. This type of contamination testing, however, is not meant to replace the type of performance testing described in SAE J1409 and SAE J1410. Durability testing in the presence of contamination will yield results more reflective of actual in-service field conditions and provide an additional evaluation of pneumatic devices. While the contaminant supply rate and other test criteria of the device being tested must be set by the device manufacturer or user, the items covered in this document will be
This SAE Recommended Practice provides the test procedure and instructions for air braked single unit trucks, buses, and combination vehicles. Brake force distribution testing with systems post-reduced stopping distance changes is still appropriate; however, vehicles with electrononically controlled braking systems are not covered in this document and may need to be addressed in the future. It also provides recommendations for: a Instrumentation and equipment. b Vehicle preparation. c Calculating distribution of brake force
This SAE Recommended Practice is intended for measuring the static brake torque performance of a pnuematically actuated brake assembly, friction material, and drum/disc combination on an inertia brake dynamometer
This SAE Recommended Practice provides design, test, and performance guidelines on the comfort, fit, and convenience for active restraint systems for heavy trucks and multipurpose passenger vehicle applications over 10000 pounds gross vehicle weight rating (GVWR). The information pertains to the forward facing seating positions
This SAE Recommended Practice provides a field test procedure and instructions for air braked single unit trucks, buses, and combination vehicles. Brake force distribution field testing with systems post-reduce stopping distance changes is still appropriate, however, vehicles with electronically controlled braking systems are not covered in this document and may need to be addressed in the future. It also provides recommendations for: a Instrumentation and equipment. b Vehicle preparation. c Test of air-braked single and combination vehicles. d Calculation of brake force distribution. e This test procedure is intended to be used as a field procedure. If a more refined method, utilizing laboratory equipment, is required, refer to SAE J1505
This SAE Information Report lists common port connection types used in truck, bus, truck-trailer, converter dolly, and multi-purpose vehicles with air brake systems at the time of publication. The purpose of the document is to give system designers and users a starting point for connector selection and a reference to the standards that govern these connector types. Also included are notes on common practices associated with these ports. CAUTION: Consult the relevant standard for the connector before making a decision on suitability for use in a specific application
This SAE Recommended Practice establishes performance guidelines for the threshold pressure and brake force output of the brakes on the axles of air-braked towing trucks, truck-tractors, truck-trailers, and converter dollies with GVWRs over 4536 kg (10000 pounds) designed to be used on the highway in combination with other air-braked vehicles of this type in commercial operations
This SAE Recommended Practice applies to S-CAM, wedge, and disc air brake actuators where the stroke can be measured without disassembly from the brake
This SAE Recommended Practice identifies and defines terms specifically related to truck and bus braking systems including Antilock Brake Systems (ABS) and Electronically Controlled Braking Systems (ECBS
This SAE Recommended Practice provides instructions and test procedures for air braked vehicles including but not limited to trucks, truck-tractors, trailers, dollies, and buses used on highways but does not include off-highway vehicles
This Recommended Practice covers air braked trucks, truck-tractors, trailers and buses. It enumerates the identification and installation of the air brake components not covered in other SAE recommended practices and standards
This SAE Standard covers complete general and dimensional specifications for the various types of tube fittings intended for general application in the automotive, appliance, and allied fields. See SAE J1131 for the performance requirements of reusable (push to connect) fittings intended for use in automotive air brake systems. Flare type fittings shall be as specified in Figures 1 to 4 and Tables 3 to 5. NOTE—For sizes 3/16 to 3/8 and 1/2 to 3/4 the flare type fittings depicted in Figures 1A to 3C are identical with the corresponding refrigeration tube fittings specified in SAE J513. Special size combination fittings 3/16 to 3/8 and 1/2 to 3/4 shall be as specified in SAE J513. Inverted flared type fittings shall be as specified in Figures 5 to 11 and Tables 3, 6, 7, 8, and 9. Gages and gaging procedures pertaining to inverted flared tube fittings are given in Appendix A. NOTE—The seat dimensions specified in Table 6 are predicated on practical threading limitations in steel fittings
The braking capacity of reducing the speed or even keeping the vehicle stoped is extremely important in the design of any brake system, as more than meeting legislation requirements; it directly affects the safe operation of the vehicle and its users. A fundamental component, which requires notable attention, is the friction material, which is designed to establish a compromise between mechanical properties, friction coefficient, noise propensity, deformation, wear, among others. However, braking capacity is a combined response for several of these friction material properties, along with the performance of other brake system components, such as the brake chamber, disc and caliper. This work aims to analyze firstly the influence of the friction material deformation and secondly the brake system deformation on the total stroke of the brake chamber. To the first one, three different formulations of friction material, applied to commercial vehicles, were selected. For these materials
This SAE Information Report provides general information for installing and tightening fluid conductors and connectors. Following these guidelines, with the consistent proper use of torque wrenches, tightening procedures, and correct torque levels, will result in diminishing leaks and improving service life by avoiding hose twisting, tube binding, false torque, and improper joint closures. Since many factors influence the pressure at which a hydraulic system will or will not perform satisfactorily, this report should not be used as a “standard” nor a “specification,” and the values shown should not be construed as “guaranteed” minimums, maximums, or absolutes. This document is an information report to help users by gathering available information from the various connector standards and publishing the information in one source for easy retrieval and applied common usage. This SAE Information Report is primarily intended for mobile/stationary industrial equipment applications. Aircraft
This SAE Standard covers complete general and dimensional specifications for tube fittings of the spherical and flanged sleeve compression types for use in the piping of air brake systems on automotive vehicles. The spherical sleeve compression type Figures 1A to 5 and Tables 1 to 3 is intended for use with annealed copper alloy tubing per SAE J1149, Type 1. The flanged sleeve compression type Figures 6A to 11 and Tables 4 to 6 is intended for use with nylon tubing per SAE J844. It is not intended to restrict or preclude other designs of a tube fitting for use with SAE J844, air brake tubing. Performance requirements for SAE J844 are covered in SAE J1131. See SAE J1131 for the Performance Requirements of Reusable (Push to Connect) Fittings Intended for Use in Automotive Air Brake Systems. CAUTION: To assure satisfactory performance, tapered sleeve compression type fitting components (SAE J512) should not be intermixed with the spherical or flanged sleeve components, nor should the
This SAE Recommended Practice establishes a method of testing the structural integrity of the brake system of all new trucks, buses, and combination vehicles designed for roadway use and falling in the following classifications: a Truck and bus: Over 4500 kg (10000 pounds) GVWR b Combination vehicle: Towing vehicle over 4500 kg (10000 pounds) GVWR The test consists of two distinct tests: a structural endurance test followed by a structural ultimate strength test. NOTE: These two tests originated from separate procedures, and were combined in this recommended practice. Each test can be considered to be an independent evaluation of the service brake’s structure. Based on time available, cost limitations, and the desired evaluation and historical data available, either of these tests could be considered as a complete evaluation of the brake’s structure
Air brake systems and their reciprocating air compressors are incumbent, legislated, and mature technologies integral to commercial trucks and especially the Class 8 Diesel Semi-Truck industry. The introduction of the Class 8 Electric-Semi Truck (electric-semi) will displace diesel driven trucks over time. The air brake systems and the requirement for an air compressor will not be displaced for the foreseeable future and the requirements will be inherited by the new electric-semi industry. The industry shall have to work hard to optimize the air compressor for this new electric platform that demands high energy density, high efficiency, low mass, excellent NVH management, small space claim, high levels of durability and reliability, low and easy maintenance over a life of 20 years. As with all systems on an electric-semi truck the benefits must be delivered with the best-in-class total cost of ownership to ensure fleet customers’ switching costs are low and their investment has a rapid
This article describes the development of a low-cost rotary screw compressor technology to meet the requirements of a mini air compressor application for electric vehicle (EV) air brake and suspension systems. An existing rotor profile and size was initially used to build an “Alpha” compressor prototype. This was tested to provide data for analysis and numerical simulation to determine a smaller rotor size, rotor profile, and more efficient overall package for hybrid/EV air brake and suspension applications. From the “Alpha” prototype testing and analysis, the author identified the root causes of lower energy efficiency. To address these deficiencies and develop a foundation for an optimized solution for the intended application, the author developed a clean sheet design. A smaller diameter rotor set with high tip speed was developed using parameter calculations, working process simulation, and prototype test data analysis. By incorporating an innovative J-profile rotor screw lobe
Motor graders are used in many applications in the mining and construction field. Graders running in On-Road have to meet the RTO regulations. DGMS derives the norms and regulations applicable for equipments including motor graders operated in mines. BG825 model grader mounted with 16ft work blade is equipped with air actuated system for slow down and braking. The Study has been made to improve the confidence and reliability among the operator by increasing the no of brake actuation’s before the warning signal and also introduces the hand operated emergency brake to tackle unfavorable circumstance. The Modified air system has been implemented and tested as per the standard in the mines at customer site. The practical field test reveals that the increase in no of actuation’s and emergency brake introduction brings more operators confident and ensures safety at the higher order. Based on the feedback, the modified air brake system made as standard fitment in the present and future
This SAE Recommended Practice is intended to provide design, interchangeable dimensions, testing procedures, performance requirements, and minimum identification for gladhand-type air line couplers used to connect the brake systems of trucks, truck-tractors, trailers, and dollies when these vehicles are joined to operate as a combination unit
This SAE Standard is intended to establish uniform performance criteria and methods of testing compression tube fittings with SAE J844 air brake tubing as used in vehicular air brake systems. This document also establishes minimum qualifications for tensile and pressure capabilities, vibration durability under cyclic temperatures, serviceability, and fitting compatibility requirements. The specific tests and performance criteria applicable to the tubing are set forth in SAE J844. NOTE: The test values contained in this performance standard are for test purposes only. For environmental and usage limitations, refer to SAE J844. For fittings, a type of fitting for use with SAE J844 nonmetallic tubing is included in SAE J246; however, it is not intended to restrict or preclude the use of other designs of fittings that comply with this document
This article describes a case study applied in a commercial vehicle company, with a focus on analyzing and reducing process failures generated in the products' pneumatic brake system. The production method of the assembly line based on the concept of flexible sequencing, with alternation of models, which makes the assembly of the brake system complex, contributing to a potential scenario of failures such as leaks and loss of efficiency of the brake system. The methodology used based on the DMAIC method (Define, Measure, Analyze, Improve, Control) for failure analysis, together with Quality Tools, such as Brainstorming, Ishikawa, and Pareto Diagram. The results of the evaluations made it possible to identify the causes that had a strong relationship with the failure mode pointed out in the Process FMEA, generating an Action Plan for pneumatic leaks, thus achieving a significant reduction in the company's quality indicator, proving the importance and necessity of using failure analysis
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