Browse Topic: Brake master cylinders

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Development of an Imperceptible Brake Failure Control Technology and Real Vehicle Application10-09-02-00154/26/2025
With the advancement of control technology in the automotive field, there is a possibility of cross-system redundant control between various actuators. As for the braking system, current brake-by-wire system often uses mechanical backup braking methods to give the vehicle a certain braking capacity after failure. However, in the mechanical backup braking mode, the brake master cylinder is connected to the supporting wheel cylinder, and the brake assist is lost, which leads to an increase in brake pressure and makes it difficult for the driver to step on the brake pedal. Meanwhile, due to the limitation of the brake master cylinder stroke, the maximum braking deceleration of the vehicle is only 3 m/s2 after the driver fully presses the brake pedal. The above two defects greatly affect the safety of the vehicle during backup braking. To solve the above problems, this article takes electric vehicles as the research object, designs a new type of hydraulic circuit for the braking system, and develops a backup braking method that integrates the drive motor and electronic parking system. This article builds a vehicle simulation model and selects real vehicles for actual testing. The results showed that in backup braking mode, the driver obtained the braking sensation during normal braking, and the maximum braking deceleration of the vehicle reached 10 m/s2. Overall, the backup braking method designed in this article effectively solves the drawbacks of the current brake-by-wire system and improves the safety of vehicles during backup braking.
Tian, Boshi, Li, Liang, Liao, Yinsheng, Lv, Haijun, Hu, Zhiming, Sun, Yue, Qu, Wenying
Research on Pressure Control Methods for a Dual-Source Electro-Hydraulic Brake System with Redundant Braking Function2025-01-87164/1/2025
This paper presents a novel Dual-source Electro-Hydraulic Brake system (D-EHB) that incorporates a redundant braking module to enhance safety and reliability. The D-EHB is designed to address the critical issue of brake failure in vehicles, which can lead to severe accidents. The D-EHB system comprises two independent units: the Main Brake Unit (MBU) and the Redundant Brake Unit (RBU). Each unit has its own hydraulic power source. The MBU's hydraulic pressure is generated by a combination of a servo motor, ball screw, and servo piston, while the RBU has a simpler structure, with hydraulic pressure generated by a motor and plunger pump combination. Mathematical models for each component of the D-EHB have been developed and validated using AMESim. The mathematical models of each part were then combined to design a wheel cylinder hydraulic pressure estimation algorithm that can calculate the wheel cylinder pressure based on motor and valve output signals, making the system applicable to vehicles without pressure sensors in the wheel cylinders. Given the distinct characteristics of the MBU and RBU, different pressure control methods were proposed. The MBU control leverages the P-V characteristics of the servo cylinder and employs Sliding Mode Control (SMC), with the target position of the servo cylinder piston as the control output, ensuring that the hydraulic pressure of the servo cylinder quickly and accurately reaches the desired value, while maintaining robust performance. The RBU control is based on the overflow characteristics of the solenoid valve and uses proportional control. Simulations and bench tests were conducted to compare the pressure control performance of the RBU with that of the MBU. The results demonstrate that the MBU exhibits excellent control accuracy and response speed, while the RBU, although not as precise as the MBU, still meets the braking requirements.
Wang, Wenqiang, Zhao, Xuezhi, Shangguan, Wen-Bin, Ren, Bingyu
An Improved AEB Control System Based on Risk Factors with Consideration of Vehicle Stability2024-01-23314/9/2024
Intelligent vehicle-to-everything connectivity is an important development trend in the automotive industry. Among various active safety systems, Autonomous Emergency Braking (AEB) has garnered widespread attention due to its outstanding performance in reducing traffic accidents. AEB effectively avoids or mitigates vehicle collisions through automatic braking, making it a crucial technology in autonomous driving. However, the majority of current AEB safety models exhibit limitations in braking modes and fail to fully consider the overall vehicle stability during braking. To address these issues, this paper proposes an improved AEB control system based on a risk factor (AERF). The upper-level controller introduces the risk factor (RF) and proposes a multi-stage warning/braking control strategy based on preceding vehicle dynamic characteristics, while also calculating the desired acceleration. Furthermore, a lower-level PID-based controller is designed to track the desired acceleration and compute the corresponding brake master cylinder pressure and throttle opening using an established inverse longitudinal dynamics model. Furthermore, to address vehicle stability during braking, an Anti-lock Braking System (ABS) controller is integrated with the proposed AERF. The effectiveness of the AERF is validated through software co-simulation and hardware-in-the-loop testing (HIL). The results demonstrate that the AERF can maintain a safe braking distance within 2 meters under Euro NCAP standard conditions, with excellent tracking performance of the actual braking deceleration and an error rate below 5%, ensuring a high level of system safety.
Guo, Shaozhong, Guo, Jun, Zhang, Yunqing, Wu, Jinglai
Design and Analysis of Double Piston Brake Caliper for SAE BAJA Vehicle2023-01-51522/23/2024
The braking system in a vehicle is one of the most important systems, which provides safety and control of the vehicle to the drivers. In this braking system the calipers play a crucial part of transferring the force of the master cylinder to the disc and stopping the vehicle. This caliper is of many types and variants. In which we are presenting a study on the design and analysis of a double piston floating caliper which will be used in BAJA vehicle. This double piston caliper is designed for the replacement of OEM calipers which are in use, which have many drawbacks. The designing of the caliper is done using Solidworks 2022 and the analysis is done with the help of Altair Hyperworks. Finite element analysis (FEA) is employed to simulate stress distribution within the caliper structure and predict potential failure points, contributing to the caliper's reliability and durability. This double piston floating caliper offers a greater braking performance than the other used calipers as it is been designed for the needs of the ATV.
CHIRANJEEV SANJAY, P., Ravi Kumar, L., Gananathji Naveen, Kishore S., Rikesh, T.
Research on Cooperative Adaptive Cruise Control (CACC) Based on Fuzzy PID Algorithm2023-01-06824/11/2023
For cooperative adaptive cruise control (CACC) system, a robust following control algorithm based on fuzzy PID principle is adopted in this paper. Firstly, a nonlinear vehicle dynamics model considering the lag of driving force and acceleration constraints was established. Then, with the vehicle’s control hierarchic, the upper controller takes the relative speed between vehicles and the spacing error as inputs to output the following vehicle's target acceleration, while the lower controller takes the target acceleration as inputs and the throttle opening and brake master cylinder pressure as outputs. For the setting of target spacing, this paper additionally considers the relative speed between vehicles and the acceleration of the front vehicle. Through testing, compared with the traditional variable safety distance model, the average distance reduces by 5.43% when leading vehicle is accelerating, while increases by 2.74% in deceleration. For the fixed-speed cruise mode, a set of logic judgment algorithm is used to replace the traditional method of designing an extra set of PID controller, which reduces the algorithm complexity while achieving the same control effect. Finally, Simulink/Carsim co-simulation test was carried out in different conditions. The distance error was less than 0.2m under the variable speed following condition, and the spacing error was less than 0.8m under the sudden braking condition where the acceleration of the pilot vehicle was -0.7g. The vehicle can easily switch smoothly between the following mode and the constant speed mode under the cutting-in and cutting-out conditions of the leading vehicle. Our system meets the safety requirements under all conditions, the changing trend of the speed curve and acceleration curve of the following car in each working condition and is more moderate than that of the front car, so as to ensure the comfort of passengers.
Zhu, Mingyang, Tan, Gangfeng
Redundancy Control of Anti-lock Braking System Based on Electro-hydraulic Braking System10-07-01-00049/13/2022
As the basic function of the active safety configuration of a vehicle, the anti-lock braking system will compromise the driving safety if it fails. Based on the self-designed electro-hydraulic braking system, this article proposes an anti-lock brake redundant control architecture. The electro-hydraulic braking system is mainly composed of four parts: a brake pedal unit, a hydraulic drive unit, a brake execution unit, and a control unit. The mechanical structure is compact and exquisite, and the system has the function of precise and adjustable hydraulic pressure. The control architecture adopts a hierarchical control design, which is mainly composed of an upper wheel slip rate controller and a lower hydraulic pressure controller. Both the upper and lower controllers use a sliding mode variable structure control to improve the robustness and accuracy of the control. The upper slip rate controller outputs the desired master cylinder hydraulic pressure with the optimum slip rate of the rear wheels of the vehicle as the control target. The lower hydraulic pressure controller outputs the desired torque of the motor with the desired master cylinder hydraulic pressure as the target and achieves hydraulic pressure regulation of the master cylinder by controlling the motor motion. To verify the effectiveness of the algorithm, co-simulation and a hardware-in-the-loop test platform are built. Anti-lock braking tests are carried out under different typical working conditions: low-adhesion road, high-adhesion road, butt road, and split road. The results show that when the anti-lock braking system fails, the redundant control algorithm can achieve effective slip rate control under different driving road conditions and meets the anti-lock brake redundant control requirements. This study provides a reference for the development of low-cost anti-lock braking redundancy functions for vehicles equipped with electro-hydraulic braking systems.
Liu, Yiping, Pei, Xiaofei, Guo, Xuexun
Self-Propelled Sweepers and Scrubbers Dual Position Driving Controls and DisplaysJ1791_202205 (Current)5/16/2022
This SAE standard applies to self-propelled driver operated sweepers and scrubbers as defined in SAE J2130-1.
MTC2, Sweeper, Cleaner, and Machinery
Service Maintenance of SAE J1703 and SAE J1704 Brake Fluids in Motor Vehicle Brake SystemsJ1707_202106 (Current)6/10/2021
This SAE Recommended Practice provides basic recommendations for dispensing and handling of SAE J1703 and SAE J1704 Brake Fluids by Service Maintenance Personnel to assure their safe and effective performance when installed in or added to motor vehicle hydraulic brake actuating systems. This document is concerned only with brake fluid and those system parts in contact with it. It describes general maintenance procedures that constitute good practice and that should be employed to help assure a properly functioning brake system. Recommendations that promote safety are emphasized. Specific step-by-step service instructions for brake maintenance on individual makes or models are neither intended nor implied. For these, one should consult the vehicle manufacturer’s service brake maintenance procedures for the particular vehicle. Vehicle manufacturer’s recommendations should always be followed.
Brake Fluids Standards Committee
A Passenger Car Brake Pedal Feel Analysis Model Based on Integrated Brake by Wire System2021-01-09754/6/2021
The fully decoupled brake by wire system is a complex system consisting of mechanical components such as springs and rubber and hydraulic structural components coupled together. Compared to conventional braking systems, it is characterized by the full decoupling of the brake pedal from the brake wheel cylinders in normal braking mode, and the pressure fluctuations in the wheel cylinders do not affect the pedal feel. In order to predict brake pedal feel in a passenger car, a dynamic model was developed for both normal and backup braking modes, taking into account the variation of the volume modulus of the brake fluid and the frictional forces of the master cylinder pistons. The influence of different pedal input speeds on the pedal feel characteristic curve was analyzed using static vehicle tests and the related parameters of the braking system were identified in order to correct the design data. Subsequently, a dynamic test of the vehicle pedal feel was conducted to establish a quadratic graph of pedal stroke, pedal force, servo cylinder pressure and vehicle longitudinal deceleration. The accuracy of the dynamics model was verified using vehicle tests, and we believe that this new dynamics model of the decoupled brake system can accurately predict brake pedal feel and can be used for the design and optimization of the brake system.
Yin, Faguo, Wang, Minghui, Jiang, Yongfeng, Kang, Yingzi
Research of the Inductive Sensor of the Electropneumatic Clutch Control System for the Mechanical Transmission at Change of Ambient Temperature2021-01-06794/6/2021
This article describes experimental research results of the inductive sensor of the electropneumatic clutch control system for the mechanical transmission. Inductive sensors are used to determine the position of the car body, the position of the controls and the position of the rod of the clutch control actuator. The design of the clutch pedal position sensor is proposed, which can be brought into line with the master cylinder to unify the clutch control systems. Complete unification of the automated electropneumatic clutch control system for trucks will allow creating modifications in which it is possible to completely abandon the use of brake fluid in the drive, which will improve the ergonomic and environmental performance of the vehicle. The advantages of such sensors are the ability to receive a signal in digital form without additional converters, the ability to work using only two wires, no contact between moving parts, resistance to aggressive environments and compact size. The disadvantage is the influence of ambient temperature on the electrical parameters of the sensor (inductance and resistance) and on the measuring circuit of the electronic control unit. The temperature effect creates significant deviations in the data received by the processor. During the laboratory experimental study, the influence of ambient temperature on the measurement data in the temperature range of -45°С + 45°С was determined separately for the sensor and for the sensor with the measuring system. Significant nonlinearity of the characteristic was determined. The effect of spontaneous operation of the clutch control system during changes in ambient temperature was experimentally obtained. The influence of temperature change on the measuring range of the inductive sensor is also revealed. The transfer characteristic of the sensor (% /mm) is determined. The approach that provides a stable transfer characteristic within the specified temperature range is proposed.
Mikhalevich, Mykola Grygorovych, Oleksandr, Dziubenko, Leontiev, Dmitry, Bogomolov, Viktor, Klimenko, Valeriy, Yarita, Alexandr, Chevychelova, Olena
Graphic Symbols for Aircraft Hydraulic and Pneumatic SystemsAS1290C (Current)2/12/2021
This SAE Aerospace Standard (AS) provides a system of graphic symbols and line codings that are intended primarily for usage in hydraulic and pneumatic system schematic diagrams for all types of aircraft.
A-6 Aerospace Actuation, Control and Fluid Power Systems
Real-World Application of Variable Pedal Feeling Using an Electric Brake Booster with Two Motors2020-01-164510/5/2020
A new type of electric brake booster, which can control brake pedal feeling completely with software, has been developed to explore how a brake system can be used to differentiate and personalize vehicles. In the future, vehicles may share an increasing amount of hardware and rely more heavily on software to differentiate between models. Car sharing, vehicle subscriptions, and other new business models may create a new emphasis on the personalization of vehicles that may be achieved most cost effectively by using software. This new brake booster controls the brake pedal force and brake pressure independently based on the brake pedal stroke so that the pedal feeling is completely defined by software. The booster uses two electric motors and one master cylinder. One electric motor controls the pedal force and provides an assist force that amplifies the force that the driver applies to the brake pedal. The second electric motor moves the master cylinder piston independently of the brake pedal stroke and is used to control the brake pressure. To confirm the real-world feasibility of this concept, the booster was installed in an actual vehicle. The evaluation of this vehicle confirmed that software-defined pedal feeling is feasible to implement in a real vehicle. Pedal feeling as good as that of a mass produced vehicle could be achieved, and the pedal feeling could be quickly and easily changed without the time and expense required to change brake hardware. Additionally, using this new booster, new types of pedal feeling that are not possible to achieve on a conventional vacuum booster vehicle could be easily implemented with software.
Kakizoe, Kenta, Bull, Marshall
Aerospace - Impulse Testing of Hydraulic ComponentsARP1383C (Current)2/24/2020
This SAE Aerospace Recommended Practice (ARP) defines impulse test procedures that are recommended for hydraulic components.
A-6 Aerospace Actuation, Control and Fluid Power Systems
Development of Parametrically Integrated Software Platform for Passenger Car Brake System2019-01-12314/2/2019
The hydraulic servo brake system for passenger car plays a central role in occupant protection, which directly affects the automotive active safety and road handling. In this paper, an integrated parameterized software platform of hydraulic servo brake systems is proposed to realize fast and efficient braking system development. At first, according to the structure and working principle of the hydraulic servo brake system, the relationship among amount of fluid required for brake caliper, pedal feel and performance of the brake system is analyzed. Then, based on kinematics and dynamics of the hydraulic servo brake system, a simulation model for analyze pedal feel and amount of fluid required for brake caliper is built in AMESim, which is composed of brake pedal, vacuum booster, brake master cylinder, brake hoses and brake calipers, etc. In addition, the accuracy of the simulation model is verified by bench tests, and the significantly influential factors on the amount of fluid required for brake calipers are analyzed through orthogonal experimental design. The ranking of their influence is diameter of brake wheel cylinder D first, piston ring stiffness K second, and followed by gap δ. Finally, the “ECE” regulation and enterprise standards are used to evaluate the design of the automotive brake system, and an optimization solution is proposed based on evaluation results. With a friendly visual interface and integration technology, the design of the hydraulic servo brake system can be quickly implemented on this software platform, including component characteristics, brake performance calculations, simulation analysis, and regulatory determination. This research can be used as an important reference for obtaining the optimal braking performance of passenger cars, and also provides a theoretical basis for design of brake-by-wire system.
Pan, Jin, Guo, Xuexun, Zhou, Wei, Pei, Xiaofei, Pan, Hao, Zhang, Jie
Light Vehicle Dry & Wet Stopping Distance Test ProcedureJ2909_201806 (Current)6/12/2018
This document establishes best practices to measure vehicle stopping distance on dry or wet asphalt in a straight path of travel intended for the purpose of publishing stopping distance by manufacturers and media organizations for vehicles with original equipment tires. It is recommended that the test method within be adopted for all vehicles less than 4536 kg (10000 pounds) GVWR. This procedure is typically used with initial speeds of 100 km/h and 60 mph, but other speeds may be used. Since tires play a significant role in stopping distance, this procedure covers tire types typically used as original equipment on new vehicles including all-season, summer, and all-terrain tires. This document may serve as a procedural guideline for all tire types, but the surface temperature correction formulas in this procedure were developed using all-season tires and may not be applicable to other tire types.
Highway Tire Committee
Modeling, Simulation and Experimental Analysis of Brake Pedal Feel for Passenger Car2017-01-13713/28/2017
Brake pedal feel plays an important role in the driver's comprehensive subjective feeling when braking, which directly affects the active safety and riding comfort of passenger car. A systematical mathematical model of the vehicle brake system is built in according with the structure and system characteristics of hydraulic servo brake system. A complete hydraulic servo brake system simulation model composed of brake pedal, vacuum booster, brake master cylinder, brake pipe, brake wheel cylinders, brake calipers is established in AMESim. The effects of rubber reaction plate stiffness, rubber valve opening, brake master cylinder piston, brake caliper, brake pipe deformation and friction liner deformation on brake pedal feel are considered in this model. The accuracy of this model is verified by real road vehicle tests under static and dynamic two different conditions. The influence of six structural parameters of vacuum booster, brake pipe and brake caliper on brake pedal feel are analyzed in detail. Finally, based on the evaluation system of BFI, the influence degree of different factors in different levels on the brake pedal feel are discussed through the orthogonal experiment design. The optimal scheme of brake pedal feel is put forward based on the sensitivity of various factors and validated by experiment. This study can serve as important reference for obtaining the best brake pedal feel, and also provides the theoretical basis for pedal simulator design and braking intention recognition in Brake-by-wire.
Pan, Hao, Guo, Xuexun, Pei, Xiaofei, Dong, Xingzhi
Strength and Durability Testing for Automotive Hydraulic Brake ComponentsJ2995_201703 (Current)3/13/2017
To assess the strength and durability for hydraulic brake components as a function of test conditions. These conditions may include: braking torque, hill-holding, braking forces, hydraulic pressure, brake temperatures, environmental and corrosion effects, vibration, and time. This RP includes a systematic reference to other test methods and provides new test methods for durability life prediction based on the VDA 311 for operating strength for brake calipers. When using AK load collectives from vehicle testing for life prediction, the nominal vehicle life corresponds to 300000 km. Braking torques and forces take into account inputs from non-ABS, ABS, EPB, and ESC systems. It also applies to gasoline, diesel, hybrid, and electric vehicles. This RP applies to vehicles below 4540 kg of GVWR. With the appropriate engineering review and assessment for a given test program, this RP can apply (or be used) to scale the duty cycle (or special collective) to reflect regional, on-road special applications, or vehicles up to 7 tons of GVWR. Except for the AK load collectives, which have proven correlation to customer usage, the damage content of other procedures requires (a) the quantification with actual laboratory testing to develop the corresponding S/N curves, and (b) the calculation of the equivalent damage at the test conditions for a given load collective. The hydraulic components covered by this RP include: a Non-vacuum apply system (brake booster and master cylinder) b ABS modules c Service, IPB, and EPB calipers d Proportioning valves e Wheel cylinders This RP has an accompanying electronic appendix with the tabular presentation as a spreadsheet of different test procedures by type and by component.
Hydraulic Brake Components Standards Committee
Mechanical Systems Physics-of-Failure Analysis Experimental ValidationJ2869_201608 (Current)8/4/2016
This report details continuing work examining the fatigue life durability of a US Army Trailer. This report describes, through example, a process to evaluate and reduce the experimental data needed for a Mechanical Systems Physics-of-Failure analysis. In addition the report describes the process used to validate the computer simulation models.
G-41 Reliability
Co-Simulation Research of Integrated Electro-Hydraulic Braking System2016-01-16474/5/2016
A program of integrated electro-hydraulic braking system is proposed, and its structural composition and working principle are analyzed. According to the structural and mechanical characteristics of all key components, through some reasonable assumptions and simplifications, a motor, a brake master cylinder, four brake wheel cylinders, solenoid valves and an ESP (Electronic Stability Program) algorithm model is set up and simulations of typical braking conditions are carried out based on the Matlab/Simulink. Finally, after the assembly of each sub-model is complete and combining a vehicle which is set up in CarSim software environment, simulation tests and comprehensive performance analysis of the active safety stability control for a vehicle in double lane change and single lane change situations are carried out respectively. According to the dynamic characteristic curves of system, the effects of different structural and control parameters on braking performance are analyzed. To improve overall braking performance, the results would help to match and optimize system parameters, and provide reference data for further clarifying ideas and goals of parameters optimization. The vehicle control results show that the proposed integrated electrohydraulic braking system has characteristics of a simple structure, very low cost, a good controllability, could be easily integrated with ABS (Anti-lock Braking System), TCS (Traction Control System), ESP and other intelligent electronic control braking functions, and has more extensive application value.
Li, Jing, Yang, Xiong, Miao, Hui, Shi, Zheng Tang
Brake Hydraulic Component Low Pressure Flow Rate MeasurementJ2994_201508 (Current)8/11/2015
The SAE Recommended Practice specifies a standardize method and test procedure to measure low pressure differential (< 1bar) brake component brake fluid flow performance. The standard can be utilized for flow measurements across hydraulic brake components such as master cylinders, apply system to chassis controls piping, or other sources of flow restriction in the low pressure side of the hydraulic brake system. It covers materials, manufacturing processes, and general properties required to meet the wide range of service encountered in automotive application. This specification covers only low pressure differential fluid flow and does not include measurement recommended practice for High Pressure differential (> 1 bar) flows.
Hydraulic Brake Components Standards Committee
Brake Master Cylinder Reservoir Diaphragm GasketJ1605_201411 (Current)11/26/2014
This SAE Standard covers performance requirements and methods of test for master cylinder reservoir diaphragm gaskets that will provide a functional seal and protection from outside dirt and water.
Hydraulic Brake Components Standards Committee
Service Maintenance of SAE J1703 and J1704 Brake Fluids in Motor Vehicle Brake SystemsJ1707_201111 (Historical)11/21/2011
This SAE Recommended Practice provides basic recommendations for dispensing and handling of SAE J1703 and SAE J1704 Brake Fluids by Service Maintenance Personnel to assure their safe and effective performance when installed in or added to motor vehicle hydraulic brake actuating systems. This document is concerned only with brake fluid and those system parts in contact with it. It describes general maintenance procedures that constitute good practice and that should be employed to help assure a properly functioning brake system. Recommendations that promote safety are emphasized. Specific step-by-step service instructions for brake maintenance on individual makes or models are neither intended nor implied. For these, one should consult the vehicle manufacturer’s service brake maintenance procedures for the particular vehicle. Vehicle manufacturer’s recommendations should always be followed.
Brake Fluids Standards Committee
Mechanical Systems Physics-of-Failure Analysis Experimental ValidationJ2869_201008 (Historical)8/30/2010
This report details continuing work examining the fatigue life durability of a US Army Trailer. This report describes, through example, a process to evaluate and reduce the experimental data needed for a Mechanical Systems Physics-of-Failure analysis. In addition the report describes the process used to validate the computer simulation models.
Ground Vehicle Reliability Committee
Light Vehicle Dry Stopping DistanceJ2909_201005 (Historical)5/25/2010
This document establishes best practices to measure vehicle stopping distance on dry asphalt in a straight path of travel intended for the purpose of publishing stopping distance by manufacturers and media organizations. It is recommended that the test method within be adopted for all vehicles less than 10 000 lb (4536 kg) GVWR. This procedure is typically used with initial speeds of 100 km/h and 60 mph, but other speeds may be used.
Highway Tire Committee
Borate Ester Based Brake FluidsJ1704_200809 (Historical)9/12/2008
This SAE standard covers motor vehicle brake fluids of the nonpetroleum type for use in the braking system of any motor vehicle such as a passenger car, truck, bus, or trailer. This standard covers different levels of performance properties compared to the SAE J1703 and SAE J1705 documents on brake fluids. These fluids are not intended for use under arctic conditions or in braking systems requiring the use of mineral oil based hydraulic fluid. These fluids are designed for use in braking systems fitted with rubber cups and seals made from styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM).
Brake Fluids Standards Committee
Low Water Tolerant Brake FluidsJ1705_200707 (Historical)7/16/2007
This SAE Recommended Practice was prepared by the Motor Vehicle Brake Fluids Subcommittee of the SAE Hydraulic Brake Actuating Systems Committee to provide engineers, designers, and manufacturers of motor vehicles with a set of minimum performance standards in order to assess the suitability of silicone and other low water tolerant type brake fluids (LWTF) for use in motor vehicle brake systems. These fluids are designed for use in braking systems fitted with rubber cups and seals made from natural rubber (NR), styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM). In the development of the recommended requirements and test procedures contained herein, it is concluded that the LWTFs must be functionally compatible with existing motor vehicle brake fluids conforming to SAE J1703 and with braking systems designed for such fluids. To utilize LWTFs to the fullest advantage, they should not be mixed with other brake fluids. Inadvertent mixtures of LWTFs with fluids meeting SAE J1703 are not known to have any adverse effects on performance, but all combinations have not been tested. Vehicle manufacturer's recommendations should be followed where indicated. These fluids are not necessarily suitable for use in central hydraulic or pumped systems and are not intended for use below temperatures of −50 °C (−58 °F). Brake fluids covered under this document are not required to tolerate water and extreme caution should be exercised to prevent accidental entry of water which might lead to brake failure. Other performance characteristics of these LWTFs not covered in this document are discussed in Appendix A.
Brake Fluids Standards Committee
Service Brake Structural Integrity Requirements—Truck and BusJ1404_200705 (Historical)5/17/2007
This SAE Recommended Practice presents requirements for the structural integrity of the brake system of all new trucks, buses, and combinations of vehicles designed for roadway use and falling into the following classifications: a Truck and Bus—Over 4500 kg (10 000 lb) GVWR b Combination Vehicles—Towing vehicle over 4500 kg (10 000 lb) GVWR The requirements are based on data obtained from SAE J294.
Truck and Bus Foundation Brake Committee
Self-Propelled Sweepers and Scrubbers Dual Position Driving Controls and DisplaysJ1791_200704 (Historical)4/30/2007
This SAE standard applies to self-propelled driver operated sweepers and scrubbers as defined in SAE J2130.
MTC2, Sweeper, Cleaner, and Machinery
Hydraulic Wheel Cylinders for Automotive Drum BrakesJ101_200608 (Historical)8/16/2006
This document specifies minimum performance and durability requirements for satisfactory vehicle usage, and it is applicable to wheel cylinder assemblies from commercial production, after production shipment, shelf storage, and remanufacture (factory rebuild).
Hydraulic Brake Components Standards Committee
Brake Master Cylinder Plastic Reservoir Assembly for Road VehiclesJ2053_200608 (Current)8/16/2006
This SAE Standard specifies the performance test procedures and requirements of a plastic reservoir assembly suitable for use on a Hydraulic Brake Master Cylinder (reference SAE J1153). Intended usage is for on-road vehicles using brake fluid conforming to FMVSS 116 (DOT 3), SAE J1703, and SAE J1704 specifications. This document includes the cap/cover and diaphragm as integral parts of the reservoir assembly. The fluid level sensor (FLS) is also included as an integral part of the assembly. However, additional FLS standards and/or requirements are applicable and necessary which are not covered in this document.
Hydraulic Brake Components Standards Committee
Concepts from DetroitAUTOFEB05_012/1/2005
January's North American International Auto Show (NAIAS) was the backdrop for a number of interesting concept vehicles with cutting-edge technology and styling that foreshadows new cars and trucks of the not-too-distant future. The following pages highlight the technology of the unveiled concepts, and next month's issue of Automotive Engineering International will review new production models for 2006 and beyond.
Shelf Storage of Hydraulic Brake ComponentsJ1825_200501 (Historical)1/5/2005
This SAE Information Report is the listing of recommendations for shelf storage for hydraulic brake components. Included in brake components are wheel cylinders, master cylinders, combination valves, and disc brake caliper assemblies. This document is not a specification. This document embodies the analyses and experiences of many users and manufacturers. Where specific manufacturers' recommendations are made, those recommendations shall supersede the recommendations of this document. This document lists the successful procedures and practices associated with brake components based on long experience of a wide cross section of manufacturers and users. The practices are expected to be applied to all brake components where SAE standards are applicable.
Hydraulic Brake Components Standards Committee
Brake Master Cylinder for Secure Brake Feel and Improved System Failure Performance2003-01-330410/19/2003
The brake master cylinder for a heavy weight vehicle which can offer the optimal braking effect and brake feel has been developed. This brake master cylinder has mechanical type work-bore switching mechanism without electric control system between the conventional master cylinder and the conventional vacuum type booster, it combines enough braking effect during a vacuum failure condition with the secure brake feel during the normal condition. This master cylinder operates in large bore during the normal operation and enables secure brake feel. It operates in smaller bore during a vacuum failure condition and enhances braking effect. The work-bore switching unit has a sealing pressure chamber of a large diameter, the work-bore switching action is carried out by open/close operation of the bore switching valve which has built-in this unit. Moreover, this open/close operation of the valve utilizes change in relative displacement of booster's input/output rods which is characteristic of conventional vacuum booster. Thus, the vacuum failure detection and the increase output pressure are performed mechanically. By this development, it has contributed to the design of the optimal brake system.
Goto, Yuji, Yasuda, Atsushi, Ishida, Satoshi
Automotive Hydraulic Brake System—Metric Tube ConnectionsJ1290_200210 (Historical)10/31/2002
This SAE Standard documents dimensional metric specifications for hydraulic brake system tubing with flared ends, threaded ports, and male tube nuts for the interconnection of major components in automotive hydraulic brake systems. The purpose of this document is to recommend preferred metrically dimensioned components (including alternative choices), that are intended to be functionally compatible with International Organization for Standardization Specification, ISO 4038. Some applications may require sizes of forms other than those shown herein, and this document does not preclude such other details when they are required.
Automotive Brake and Steering Hose Standards Comm
Self-Propelled Sweepers and Scrubbers Dual Position Driving Controls and DisplaysJ1791_200208 (Historical)8/30/2002
This SAE standard applies to self-propelled driver operated sweepers and scrubbers as defined in SAE J2130.
MTC2, Sweeper, Cleaner, and Machinery
Service Maintenance of SAE J1703 and J1704 Brake Fluids in Motor Vehicle Brake SystemsJ1707_200201 (Historical)1/16/2002
This SAE Recommended Practice provides basic recommendations for dispensing and handling of SAE J1703 and J1704 Brake Fluids by Service Maintenance Personnel to assure their safe and effective performance when installed in or added to motor vehicle hydraulic brake actuating systems. This document is concerned only with brake fluid and those system parts in contact with it. It describes general maintenance procedures that constitute good practice and that should be employed to help assure a properly functioning brake system. Recommendations that promote safety are emphasized. Specific step-by-step service instructions for brake maintenance on individual makes or models are neither intended nor implied. For these, one should consult the vehicle manufacturer’s service brake maintenance procedures for the particular vehicle. Vehicle manufacturer’s recommendations should always be followed.
Brake Fluids Standards Committee
2002 Supplier TechnologyAUTOOCT01_0210/1/2001
As automakers increase outsourcing, suppliers are taking on more responsibility for developing increasingly complex systems and components. This special edition of Tech Briefs highlights some of the many supplier contributions to 2002 passenger cars. The 2002 Cadillac Seville STS will trade in its continuously variable road-sensing suspension (CVRSS) struts in midyear 2002 for Delphi Automotive Systems' next-generation variable damping system, MagneRide, which provides controlled, independent damping at all four corners of the vehicle. “(It) is an evolutionary, not revolutionary, technology,” said Fred Wood, Development Engineer for the Seville, noting that not much has changed from the current suspension system other than the damper. Even so, MagneRide reacts at least five times faster than the current damper, said Wood, and will enable improved handling, ride quality, and road isolation as well as safety. As opposed to valve-based systems, the MagneRide semi-active suspension system has a monotube design with no electromechanical valves or small moving parts for quieter operation-an industry first, according to the Troy, Ml-based supplier. MagneRide consists of magneto-rheological (MR) fluid-based monotube struts and shock absorbers; a sensor set that consists of a relative position sensor between each control arm and the body as well as a lateral accelerometer and a steering-wheel angle sensor, which are also part of the Stabilitrak system (a yaw rate sensor is used indirectly by the MagneRide system in active-brake-apply events); an onboard controller; and an optional leveling compressor module, which has underbody or engine-compartment packaging capabilities and integrates with the existing sensors and controller.
Trends in advanced chassis controlAUTOSEP01_019/1/2001
Motorola vehicle system developers examine the state-of-the-art microprocessor and other electronics technologies driving the development of advanced braking, steering, suspension control, and collision warning/avoidance systems. Electronically controlled chassis systems have enhanced safety enormously by optimizing the interface between tire and road surface, either in the longitudinal, lateral, or vertical directions. Antilock braking systems (ABS), four-wheel drive (4WD), and traction control systems (TCS) are three popular technologies that optimize dynamic stability in the longitudinal direction. Conventional 4WD systems typically use a transfer box with a viscous coupling that engages when a difference in the rotation speed between front and rear wheels occurs. However, newer electronically controlled systems are more efficient, according to Motorola product developers, because considerable slip is not required before the 4WD operates, and driveline torsion as well as traction and braking capacity can be better optimized. In the vertical direction, roll stabilization and active-suspension systems can be implemented, although they are still in their infancy in terms of production applications. Sensors that detect vehicle roll can also be used for rollover protection systems as well as for roof and curtain airbags.
Hydraulic Power Assist Brake Booster Test ProcedureJ1807_200011 (Historical)11/3/2000
This SAE Standard applies to direct acting hydraulic power assist brake boosters only, of the type which provide “push through” manual braking of the static brake circuit(s) via a separate master cylinder, in event of inoperative power assistance similar to existing vacuum boosters (SAE J1808), for passenger cars and light trucks [4500 kg GVW (10 000 lb)].
Hydraulic Brake Components Standards Committee
Borate Ester Based Brake FluidsJ1704_200010 (Historical)10/1/2000
This SAE Recommended Practice was prepared to provide engineers, designers, and manufacturers of motor vehicles with a set of minimum performance standards which covers the next level of performance properties above those of the present SAE J1703 brake fluid standard. These fluids are not intended for use under arctic conditions or in braking systems requiring the use of mineral oil based hydraulic fluid. These fluids are designed for use in braking systems fitted with rubber cups and seals made from natural rubber (NR), styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM). These fluids are not designed to operate in a pumped or a clutch braking system, especially those hydraulic systems requiring a mineral oil based fluid.
Brake Fluids Standards Committee
Motor Vehicle Brake FluidJ1703_200010 (Historical)10/1/2000
This SAE Standard covers motor vehicle brake fluids of the nonpetroleum type for use in the braking system of any motor vehicle such as a passenger car, truck, bus, or trailer. These fluids are not intended for use under arctic conditions. These fluids are designed for use in braking systems fitted with rubber cups and seals made from natural rubber (NR), styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM).
Brake Fluids Standards Committee
Service Brake Structural Integrity Requirements—Vehicles Over 4500 kg (10 000 lb) GVWRJ1404_200006 (Historical)6/8/2000
This SAE Recommended Practice presents requirements for the structural integrity of the brake system of all new trucks, buses, and combinations of vehicles designed for roadway use and falling into the following classifications: a Truck and Bus—Over 4500 kg (10 000 lb) GVWR b Combination of Vehicles—Towing vehicle over 4500 kg (10 000 lb) GVWR The requirements are based on data obtained from SAE J294 JAN93.
Truck and Bus Foundation Brake Committee
Dynamometer Effectiveness Characterization Test for Passenger Car and Light Truck Brake Friction ProductsJ2430_199908 (Historical)8/30/1999
This SAE Recommended Practice establishes an inertia dynamometer test procedure, using exemplar caliper disc or drum brakes, to characterize the effectiveness of brake friction products for passenger cars and light trucks, up to and including 3500 kg GVW. SAE J2430 provides a method of characterizing friction material effectiveness, using vehicle specific brake hardware and test conditions that approximate those for U.S. mandated new vehicle brake tests.
Brake Dynamometer Standards Committee
Brake System Dynamometer Test Procedures—Passenger CarJ212_199801 (Historical)1/1/1998
This SAE Recommended Practice establishes a uniform laboratory dynamometer method of testing all classes of passenger car brake systems.
Brake Dynamometer Standards Committee
Shelf Storage of Hydraulic Brake ComponentsJ1825_199801 (Historical)1/1/1998
This SAE Information Report is the listing of recommendations for shelf storage for hydraulic brake components. Included in brake components are wheel cylinders, master cylinders, combination valves, and disc brake caliper assemblies. This document is not a specification. This document embodies the analyses and experiences of many users and manufacturers. Where specific manufacturers' recommendations are made, those recommendations shall supersede the recommendations of this document. This document lists the successful procedures and practices associated with brake components based on long experience of a wide cross section of manufacturers and users. The practices are expected to be applied to all brake components where SAE standards are applicable.
Hydraulic Brake Components Standards Committee
RUBBER CUPS FOR HYDRAULIC ACTUATING CYLINDERSJ1601_199707 (Historical)7/1/1997
These specifications cover molded cups 51 mm (2 in) in diameter and under, compounded from high temperature resistant rubber for use in hydraulic actuating cylinders employing motor vehicle brake fluid conforming to the requirements specified in SAE J1703 and SAE J1705. These specifications cover the performance tests of hydraulic brake cups under specified conditions and do not include requirements relating to chemical composition, tensile strength, and elongation of the rubber compound. Disc brake seals are not covered by this document.
Hydraulic Brake Components Standards Committee
LOW WATER TOLERANT BRAKE FLUIDSJ1705_199505 (Historical)5/1/1995
This SAE Recommended Practice was prepared by the Motor Vehicle Brake Fluids Subcommittee of the SAE Hydraulic Brake Actuating Systems Committee to provide engineers, designers, and manufacturers of motor vehicles with a set of minimum performance standards in order to assess the suitability of silicone and other low water tolerant type brake fluids (LWTF) for use in motor vehicle brake systems. These fluids are designed for use in braking systems fitted with rubber cups and seals made from natural rubber (NR), styrenebutadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM). In the development of the recommended requirements and test procedures contained herein, it is concluded that the LWTFs must be functionally compatible with existing motor vehicle brake fluids conforming to SAE J1703 and with braking systems designed for such fluids. To utilize LWTFs to the fullest advantage, they should not be mixed with other brake fluids. Inadvertent mixtures of LWTFs with fluids meeting SAE J1703 are not known to have any adverse effects on performance, but all combinations have not been tested. Vehicle manufacturer's recommendations should be followed where indicated. These fluids are not necessarily suitable for use in central hydraulic or pumped systems and are not intended for use below temperatures of −50 °C (−58 °F). Brake fluids covered under this document are not required to tolerate water and extreme caution should be exercised to prevent accidental entry of water which might lead to brake failure. Other performance characteristics of these LWTFs not covered in this document are discussed in Appendix A.
Brake Fluids Standards Committee
RUBBER SEALS FOR HYDRAULIC DISC BRAKE CYLINDERSJ1603_199501 (Historical)1/10/1995
This SAE Standard describes the performance and part requirements for elastomeric seals used in highway vehicle disc brake calipers. Seals covered by this specification may be the solid section type (square, rectangular, O-ring, etc.) mounted stationary in the cylinder bore or on the movable piston. The specification contains the following major sections: a Resistance to Fluid at Elevated Temperature—Physical Stability [loose parts in 120 °C ± 2 °C (248 °F ± 3.6 °F) brake fluid for 70 h] b Resistance to Fluid at Elevated Temperature—Precipitation Characteristics [loose parts in 120 °C ± 2 °C (248 °F ± 3.6 °F) brake fluid for 70 h] c Resistance to Elevated Temperatures in Dry Air [loose parts in 175 °C ± 2 °C (347 °F ± 3.6 °F) air for 22 h] d Ambient Temperature Stroking Test [tested in brake assembly for 500 000 cycles to 7 MPa ± 0.3 MPa (1000 psi ± 50 psi)] e High Temperature Stroking Test [tested in brake assembly for 70 h (70 000 strokes) at 120 °C ± 2 °C (248 °F ± 3.6 °F) to 7 MPa ± 0.3 MPa (1000 psi ± 50 psi)] f Low Temperature Leakage Test [tested in brake assembly for 120 h at −40 to −43 °C (−40 to −45.4 °F)] g Cycling Humidity Storage Corrosion Test [tested in brake assembly for 14 days at 95% humidity cycling between 21 to 46 °C (69.8 to 114.8 °F)]
Automotive Brake and Steering Hose Standards Comm
MOTOR VEHICLE BRAKE FLUIDJ1703_199501 (Historical)1/1/1995
This SAE Standard covers motor vehicle brake fluids of the nonpetroleum type for use in the braking system of any motor vehicle such as a passenger car, truck, bus, or trailer. These fluids are not intended for use under arctic conditions. These fluids are designed for use in braking systems fitted with rubber cups and seals made from natural rubber (NR), styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM).
Brake Fluids Standards Committee
LOW WATER TOLERANT BRAKE FLUIDSJ1705_199412 (Historical)12/1/1994
This SAE Recommended Practice was prepared by the Motor Vehicle Brake Fluids Subcommittee of the SAE Hydraulic Brake Actuating Systems Committee to provide engineers, designers, and manufacturers of motor vehicles with a set of minimum performance standards in order to assess the suitability of silicone and other low water tolerant type brake fluids (LWTF) for use in motor vehicle brake systems. These fluids are designed for use in braking systems fitted with rubber cups and seals made from natural rubber (NR), styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM). In the development of the recommended requirements and test procedures contained herein, it is concluded that the LWTFs must be functionally compatible with existing motor vehicle brake fluids conforming to SAE J1703 and with braking systems designed for such fluids. To utilize LWTFs to the fullest advantage, they should not be mixed with other brake fluids. Inadvertent mixtures of LWTFs with fluids meeting SAE J1703 are not known to have any adverse effects on performance, but all combinations have not been tested. Vehicle manufacturer's recommendations should be followed where indicated. These fluids are not necessarily suitable for use in central hydraulic or pumped systems and are not intended for use below temperatures of -50 °C (-58 °F). Brake fluids covered under this document are not required to tolerate water and extreme caution should be exercised to prevent accidental entry of water which might lead to brake failure. Other performance characteristics of these LWTFs not covered in this document are discussed in Appendix A.
Brake Fluids Standards Committee
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