Brake System

PEMERINTAH KOTA SUKABUMI DINAS PENDIDIKAN DAN KEBUDAYAAN

SEKOLAH MENENGAH KEJURUAN NEGERI 1SUKABUMI Jl. Kabandungan No. 90 Telp.(0266) 222305 Fax (0266)233552 Sukabumi 43113

Website http://www.smkn1-smi.org email: info@[email protected]

BRAKE

SYSTEM

AUTOMOTIVE DEPARTMENT

2008

i

PREFACE

Module is compiled to use training system being based on interest to teach skill at

work. Training pursuant to interest standard that is a way of which nationally have been

agreed on about forwarding of skill, knowledge and attitude used for the duty of certain

work with especial emphasis at aspect what can be conducted by someone as result of in

following network activity of training. One of the important characteristic about training base

on interest is emphasis at training have the character of individually for the work of actual at

work.

This module can be used by participant of training and education and also instructor /

instructor to give study activity at participant of training and education relate to interest unit

according to Mechanic interest standard of Automotive with interest unit title "Brake System"

which comprising skill and knowledge for the work of to repair.

In general fill this module consider fully the condition of training of organization and

skill management of adapted for by training and education requirement of industry without

there is diffraction at individual sector, to support mentioned, this module will be considered

the followings :

Requirement of participant of training and education

Conditions of organization

Time which available to conducting training and education

Training situation.

Strategy of forwarding of which is used and assessment techniques which is

presented in this interest unit module is not have the character of obliged to but

representing minimum prerequisite which must be used as by guidance of usage of module.

Consumer of this module is pushed to use various experience learn previously covering

knowledge, skill and also experiences learn the other to develop knowledge and skill which

included in this module and also so that can ascertain relevansi activity of training and

education with requirement of work in industry.

Compiler

ii

TABLE OF CONTENTS

PAGE

PREFACE …………………………………………………………………………………… i

TABLE OF CONTENTS……………………………………………………………………………………… ii

MAP DOMICILE MODULE ………………………………………………………………… iii

GLOSSARIUM ..............……………………………………………………………… iv

ANTECEDENT ………………………………………………………………………………

A. DESCRIPTION …………………………………………………………………………

B. SUB-TERMS ……………………………………………………………………………………

C. MODULE USING GUIDANCE ……………………………………………………

D. ULTIMATE PURPOSES ………………………………………………………………………………

E. COMPETENSI …………………………………………………………………………………

F. CHECKING ABLITY…………………………………………………………………………

LESSON ……………………………………………………………………………………..

A. PLAN LEARN STUDENT…………………………………………………………

B. ACTIVITY LEARN………………………………………………………………………

1. Activity Learn 1 : Brake System …………………………..

a. Target Activity Learn 1 ……………………………………………….

b. Theory 1 …………………………………………………………………

c. Ambit 1 ……………………………………………………………………..

d. Duty1 ……………………………………………………………………….

e. Formative Test 1 ……………………………………………………………………

f. Formative answer key 1 ……………………………………………

g. Sheet Assessment 1 ………………………………………………….

EVALUATION ………………………………………………………………………………………

A. KNOWLEDGE TEST …………………………………………………………………………………

B. ANSWER TEST ……………………………………………………………………………

C. ASSESSMENT EVALUATION………………………………………………….

D. CRITERION PASS ……………………………………………………………………

CONCLUSION…………………………………………………………………………………

BIBLIOGRAPHY…………………………………………………………………………………

iii

MAP DOMICILE MODULE

OPKR40-016B

OPKR 40-014B

OPKR 40-009B

OPKR 40-004B

OPKR 40-003B

OPKR 30-007B

OPKR 30-017B

OPKR 30-010B

OPKR 30-003B

OPKR 30-013B

OPKR 30-004B

OPKR 30-002B

OPKR 30-001B

OPKR 20-010B

OPKR 20-012B

OPKR 20-001B

OPKR 20-010B

OPKR 20-017B

OPKR 20-014B

OPKR 40-002B

OPKR 40-001B

OPKR 10-018B OPKR 40-008B OPKR 40-012B OPKR 50-002B

OPKR 50-007B

OPKR 50-009B

OPKR 50-008B

OPKR 50-011B

OPKR 10-003B

OPKR 10-002B OPKR 10-001B OPKR 10-005B

OPKR 10-006B

OPKR 50-001B

OPKR 40-019B OPKR 40-017B OPKR 10-019B OPKR 10-009B OPKR 10-010B

OPKR 10-017B

OPKR 10-015B

OPKR 50-019B

iv

LIST TITLE MODULE. No KODE Judul Modul

1 OPKR 10-001B Execution of conservancy/ component service (Pelaksanaan pemeliharaan/ servis komponen)

2 OPKR 10-002B Installation of hydraulic system (Pemasangan sistem hidrolik)

3 OPKR 10-003B Conservancy / hydraulic system service (Pemeliharaan/servis sistem hidrolik)

4 OPKR 10-005B Conservancy / service and repair of air compressor and components (Pemeliharaan/servis dan perbaikan kompresor udara dan komponen-komponennya)

5 OPKR 10-006B Execute procedure of welding, soldering, and amputation with heat and warm-up (Melaksanakan prosedur pengelasan, pematrian, dan pemotongan dengan panas dan pemanasan)

6 OPKR 10-009B Read and understanding of technique picture (Pembacaan dan pemahaman gambar teknik)

7 OPKR 10-010B Usage and conservancy of measuring instrument (Penggunaan dan pemeliharaan alat ukur)

8 OPKR 10-016B Follow health procedure and Usage working safety (Mengikuti prosedur kesehatan dan keselamatan kerja)

9 OPKR 10-017B Usage and conservancy of equipments and supply of workplace (Penggunaan dan pemeliharaan peralatan dan perlengkapan tempat kerja)

10 OPKR 10-018B Constribution communications at work (Konstribusi komunikasi di tempat kerja)

11 OPKR 10-019B Execution of handling operation manually (Pelaksanaan operasi penanganan secara manual)

12 OPKR 20-001B Conservancy / service engine and components (Pemeliharaan/servis engine dan komponen-komponennya)

13 OPKR 20-010B Conservancy / cooler system service and components (Pemeliharaan/servis sistem pendingin dan komponen-komponennya)

14 OPKR 20-011B Repair of cooler system and components (Perbaikan sistem pendingin dan komponen-komponennya)

15 OPKR 20-012B Overhaul Component cooler system (Overhaul komponen sistem pendingin)

16 OPKR 20-014B Conservancy/service gasoline fuel system (Pemeliharaan/servis sistem bahan bakar bensin) [of] /

17 OPKR 20-017B Conservancy/ service diesel fuel system (Pemeliharaan/servis sistem injeksi bahan bakar diesel)

18 OPKR 30-001B service clutch and system operation components ( Pemeliharaan/servis kopling dan komponen-komponennya sistem pengoperasian)

19 OPKR 30-002B Repair of clutch and components (Perbaikan kopling dan komponen-komponennya)

20 OPKR 30-003B Clutch Overhaul and components (Overhaul kopling dan komponen-komponennya)

21 OPKR 30-004B Conservancy/service manual transmission (Pemeliharaan/servis transmisi manual)

22 OPKR 30-007B Conservancy/ service automatic transmission (Pemeliharaan/servis transmisi otomatis)

23 OPKR 30-010B Conservancy/ service final unit drive/ differential (Pemeliharaan/servis unit final drive/ gardan)

24 OPKR 30-013B Conservancy / service wheel axis activator (Pemeliharaan/servis poros roda penggerak)

25 OPKR 30-014B Repair of wheel countershaft (Perbaikan poros penggerak roda)

26 OPKR 40-001B Assembling and installation of system put on the brakes and its components (Perakitan dan pemasangan sistem rem dan komponen-komponennya)

27 OPKR 40-002B Conservancy / system service put on the brakes (Pemeliharaan/servis sistem rem)

28 OPKR 40-003B Repair of system put on the brakes (Perbaikan sistem rem)

29 OPKR 40-004B Overhaul system component put on the brakes (Overhaul komponen sistem rem)

30 OPKR 40-008B Inspection of system drive (Pemeriksaan sistem kemudi)

31 OPKR 40-009B Repair of system drive (Perbaikan sistem kemudi)

32 OPKR 40-012B Inspection of system of suspensi (Pemeriksaan sistem suspensi)

33 OPKR 40-014B Conservancy / system service of suspensi (Pemeliharaan/servis sistem suspensi)

34 OPKR 40-016B Balans wheel / Free tire (Balans roda/ban)

35 OPKR 40-017B (installing and tuning wheel) Melepas, memasang dan menyetel roda

36 OPKR 40-019B Unloading, repair, and installation of external tire and inner tube and also its component ( Pembongkaran, perbaikan, dan pemasangan ban luar dan ban dalam serta komponennya)

37 OPKR 50-001B Examination, conservancy / service and replacement of light Repair battery (Pengujian, pemeliharaan/servis dan penggantian baterai)

v

No KODE Judul Modul

38 OPKR 50-002B Repair network/ system electric (Perbaikan ringan pada rangkaian/ system kelistrikan)

39 OPKR 50-007B Installation, examination, and repair of lighting system and of wiring (Pemasangan, pengujian, dan perbaikan sistem penerangan dan wiring)

40 OPKR 50-008B Installation, examination, and repair of peacemaker electric system (Pemasangan, pengujian, dan perbaikan sistem pengaman ke listrikan )

41 OPKR 50-009B Installation of equipment of electric of addition ( assesoris) (Pemasangan kelengkapan kelistrikan tambahan) (assesoris)

42 OPKR 50-011B Repair of Ignition system (Perbaikan sistem Pengapian)

43 OPKR 50-019B Service system of AC ( Memelihara/servis sistem AC) (Air Conditioner)

1

CHAPTER 1

A. Description

Learning this lesson, our students are required to master both the basic

concepts and theories of Brake system. The following are the sub

competencies:

1. Following the procedures at the work place to identify the

functions and basic concepts about Brake system.

2. Students should be able to explain Regenerative Brake Cooperative

Control .

3. Students should be able to describe Brake ECU.

4. Students should be able to describe Skid Control ECU.

5. Students should be able to describe Enhanced VSC system .

6. Students should be able to describe Enhanced VSC operation

B. Sub-terms

This module is basic the knowledge, so the terms are not based on the

previous modules but it requires students knowledge themselves. For

instance:

1. Work principles of mechanic energy and electric energy from their

physic.

2. Attitude: work concentration, discipline to words the rules, etc.

C. Module Using Guidance

1. For Students

To get maximum learning result, in learning this lesson, students

should follow these steps to use this module:

- Read and understand properly the materials on the learning

process.

- Do every assignments to know how far the students understand the

material for each learning activity.

- In doing not only theoritical but also practical, pay attention to

these rules:

2

Pay attention to the directions of safety rules.

Understands every procedures of practice.

Before doing the practice, identify the tools and material

needed precisely.

Use the proper tool for each procedures.

To do unclear practice procedures, students should ask the tutor

or instructor.

After students finish practicing, put the tools back to their

places.

- If the students don’t get the skills required (fail to get the skill),

repeat all the process by asking the tutor/ instructor.

2. Teacher Roles

Teacher roles for each learning process are:

- Helping students in preparing and planning the learning process.

- Guide the students through giving practice duties which explained

in each process.

- Helping students to decide and acces additional sources.

- Organizing team work if necessary.

- Planning to bring an expert or a teacher/ tutor from an industry to

accompany the teacher if necessary.

D. Ultimate Purposes

After learning all the materials in this module, students shoul be able to:

1. Apply the safety rules, work and environment healty guidance at

their workplaces.

2. Mention the functions Brake system.

3. Explain the functions Regenerative Brake Cooperative Control.

4. Describe the functions Brake ECU

5. Describe Skid Control ECU.

6. Describe Enhanced VSC system .

7. Describe Enhanced VSC operation

3

CHAPTER II

BRAKE SYSTEM

Overview

The hybrid vehicle brake system includes both standard hydraulic brakes

and a unique regenerative braking system that uses the vehicle's momentum to

recharge the battery. As soon as the accelerator pedal is released, the HV ECU

initiates regenerative braking. MG2 is turned by the wheels and used as a

generator to recharge the batteries. During this phase of braking, the hydraulic

brakes are not used. When more rapid deceleration is required, the hydraulic

brakes are activated to provide additional stopping power. To increase energy

efficiency the system uses the regenerative brakes whenever possible. Selecting

•B" on the shift lever will maximize regenerative efficiency and is useful for

controlling speeds downhill. In `B' mode about 30% of the energy is recovered.

If either the regenerative or hydraulic braking system fails, the remaining

system will still work. However, the brake pedal will be harder to press and the

stopping distance will be longer. In this situation, the brake system warning light

will illuminate.

NOTE

The battery will accept charge up to an instantaneous rate of 20 to 21 KWH.

Much of the energy from light braking at high speeds and harder braking at lower

speeds can be recovered. Excess energy over the charging limits is wasted as heat

in the brakes just as in other cars. At this time there is no way for the customer to

know the limit of regenerative energy recovery.

Brake System Components

4

Regenerative Brake Cooperative Control

Regenerative brake cooperative control balances the brake force of the

regenerative and hydraulic brakes to minimize the amount of kinetic energy lost to

heat and friction. It recovers the energy by converting it into electrical energy.

To convert kinetic energy to electrical energy the system uses MG2 as a

generator. The drive axle and MG2 are joined mechanically. When the drive

wheels rotate MG2 it tends to resist the rotation of the wheels, providing both

electrical energy and the brake force needed to slow the vehicle. The greater the

battery charging amperage, the greater the resistance.

On the '04 & later Prius, the increased power output of MG2 provides

increased regenerative brake force. In addition, the distribution of the brake force

has been improved through the adoption of the Electronically Controlled Brake

(ECB) system, effectively increasing the range of the regenerative brake. These

attributes enhance the system's ability to recover electrical energy which

contributes to fuel economy.

Regenerative Brake System

5

Brake ECU

The Brake ECU communicates with the HV ECU based on signals

received from sensors. The controls include:

Conventional brake control

ABS with EBD control

Regenerative brake cooperative control

Skid Control ECU

Brake control processing is moved to the Skid Control ECU which

maintains communication with the EPS ECU and the HV ECU based on signals

received from sensors. The controls include:

Conventional brake control

ABS with EBD control

Brake Assist

Enhanced VSC

Regenerative brake cooperative control

Enhanced VSC System

The Enhanced VSC system is available on the '04 & later Prius. The

following are two examples that can be considered as circumstances in which tires

exceed their lateral grip limit. The Enhanced VSC system is designed to help

control the vehicle behavior by controlling the motive force and the brakes at each

wheel when the vehicle is meets one of these two conditions:

When the front wheels lose grip in relation to the rear wheels (front wheel

skid tendency known as `understeer')

When the rear wheels lose grip in relation to the front wheels (rear wheel

skid tendency, or `oversteer')

Enhanced VSC Operation

When the skid control ECU determines that the vehicle exhibits a tendency

to understeer or oversteer, it decreases the engine output and applies the brake of a

6

front or rear wheel to control the vehicle's yaw moment. The basic operation of

the Enhanced VSC is described below. However, the control method differs

depending on the vehicle's characteristics and driving conditions.

When the skid control ECU determines that there is a large front wheel

skid tendency, it counteracts in accordance with the extent of that tendency. The

skid control ECU controls the motive power output and applies the brakes of the

front wheel of the outer circle in the turns and rear wheels in order to restrain the

front wheel skid tendency.

When the skid control ECU determines that there is a large rear wheel skid

tendency, it counteracts in accordance with the extent of that tendency. It applies

the brakes of the front wheel of the outer circle of the turn and generates an

outward moment of inertia in the vehicle, in order to restrain the rear wheel

tendency. Along with the reduction in the vehicle speed caused by the braking

force, the vehicle's stability is ensured. In some cases the skid control ECU

applies the brake of the rear wheels, as necessary.

Cooperative Control with EPS

Enhanced VSC provides the steering assist to facilitate steering operation

for the driver depending on vehicle situations. This is accomplished through

coordination of cooperative control with EPS in addition to the general VSC

control.

Cooperative Control with EPS

7

Brake Pedal Stroke Sensor

This sensor contains a contact variable resistor and detects the extent of

the brake pedal stroke and transmits it to the skid control ECU.

SERVICE TIP

To install a brake pedal stroke sensor, which is available as a service part,

perform the following procedures:

The sensor lever is secured with a pin to •0" stroke. (Do not detach the

pin until the installation has been completed.)

In this state, install the sensor on the brake pedal (in the OFF state) on the

vehicle.

After completing the installation, firmly press the brake pedal once to

break off the pin that is securing the sensor in place.

Make sure the broken pin does not remain in the sensor lever.

Stroke Simulator

The stroke simulator is located between the master cylinder and the brake

actuator. It generates a pedal stroke in accordance with the driver's pedal effort

during braking. Containing two types of coil springs with different spring

constants, the stroke simulator provides pedal stroke characteristics in two stages

in relation to the master cylinder pressure.

Stroke Simulator

8

Power Source Backup Unit

In the '04 & later Prius, the power source backup unit has been adopted as

an auxiliary power source in order to supply power to the brake in a stable

manner. This unit contains 28 capacitor cells, which store an electrical charge

provided by the (12V) vehicle power supply. When the voltage of the (12V)

vehicle power supply drops, the electrical charge stored in the capacitor cells is

used as an auxiliary power supply to the brake system. The electrical charge

stored in the capacitor cells becomes discharged when the HV system stops

operating after the power switch is turned OFF.

Power Source Backup Unit

Fail-Safe

If the ABS, Enhanced VSC or Brake Assist System malfunctions, the Skid

Control ECU disables that system but allows the other systems to function

normally.

DRC C1215/15, C1216/16 Linear Solenoid Positive Voltage Malfunction

DTC C1215/15 may be detected when the ignition switch is ON, the

voltage of terminal +BS in the brake ECU is 2.5V or less, and continues for 0.5

9

seconds or more. It also may be detected while a vehicle is driven at a speed

5�mph or more, the voltage of terminal +BS in the brake ECU is 9V or less and

continues for 10 seconds or more.

DTC C1216/16 may be detected when the ignition switch is ON, the

voltage of the terminal +BS in the brake ECU is 17V or more, and continues for

1.2 seconds or more. For both codes check the battery, the charging system and

the power source circuit. The trouble areas for both codes may include the battery,

the charging system or the power source circuit.

DTC C1259/59 Malfunction In HV ECU

If any trouble occurs in the HV control system, the ECU prohibits

Regenerative Braking System (RBS) control. If the conditions below continue for

0.02 seconds DTC C1259/59 will set:

The voltage of the terminal IG2 in the brake ECU is 10.5V or less and

continues for 1.5 seconds.

Regenerative malfunction occurs on the HV ECU side.

NOTE

This DTC is set with most HV ECU codes and is usually the lowest priority when

sent with other DTCs.

10

CHAPTER III EVALUATION

A. ASSESSMENT INSTRUMENT 1. Mentioning components of Brake System!

2. Describe about Regenerative Brake Cooperative Control!

3. Describe about Brake ECU! 4. Mentioning function of Skid control ECU!

5. Mentioning function of Enhanced VSC System! 6. Mentioning function of Enhanced VSC Operation!

B. ANSWER KEY

1. Component Barke system:

2. Regenerative brake cooperative control balances the brake force of the

regenerative and hydraulic brakes to minimize the amount of kinetic energy lost

to heat and friction. It recovers the energy by converting it into electrical energy 3. Brake ECU : The Brake ECU communicates with the HV ECU based on signals

received from sensors. The controls include: Conventional brake control

ABS with EBD control

Regenerative brake cooperative control 4. Skid Control ECU : Brake control processing is moved to the Skid Control ECU

which maintains communication with the EPS ECU and the HV ECU based on signals received from sensors

5. Enhanced VSC System : The Enhanced VSC system is available on the '04 & later Prius. The following are two examples that can be considered as

circumstances in which tires exceed their lateral grip limit. The Enhanced VSC

system is designed to help control the vehicle behavior by controlling the motive force and the brakes at each wheel when the vehicle

6. Enhanced VSC Operation : When the skid control ECU determines that the vehicle exhibits a tendency to understeer or oversteer, it decreases the engine

output and applies the brake of a front or rear wheel to control the vehicle's yaw

moment. The basic operation of the Enhanced VSC is described below. However, the control method differs depending on the vehicle's characteristics and driving

conditions.

11

C. CRITERION PASS.

Aspect Score (1-10)

wight Value Boldness

Correctness 2 Condition pass,

minimum value 70 with score

each; every

minimum aspect 7.

Accuracy 1 Time 1

Total Score

Pass category :

70 s.d. 79 : fulfilling minimum criterion with tuition 80 s.d. 89 : fulfilling minimum criterion without tuition

90 s.d. 100 : above minimizing without tuition.

12

CHAPTER IV

CONCLUSION

Interest of "Brake System" have to well posted by before studying bases

of automotive.

After student feel to master existing interest sub, student can request

interest test, interest test done/conducted by theoritical and practical. Theoretical

test by student answer question which is on evaluation problem, while test of

practical with interest to demonstration had at teacher / instructor. Teacher /

instructor will assess pursuant to existing observation sheet, from here student

interest can know.

To student which have reached minimum pass condition can continue to

next module, but if/when minimum condition of pass not yet been reached hence

have to repeat this module, or part of which do not pass and because do not be

allowed to take next module.