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1、Chassis Department of C&C Trucks Co.,Ltd.Research Institute 2015年年9月月 September,2015Brake System Introduction0 第一部分第一部分 概述概述 Chapter 1 Overview 第二部分第二部分 制动系统构造制动系统构造 Chapter 2 Brake System Construction 第三部分第三部分 制动系统工作原理制动系统工作原理 Chapter 3 Operating Principle of Brake System 第四部分第四部分 制动系统主要部件功用及工作原理制动
2、系统主要部件功用及工作原理 Chapter 4 Functions and Operating Principle of Main Brake System Components 第五部分第五部分 制动系统装配调校注意事项制动系统装配调校注意事项 Chapter 5 Precaution for Assembling and Adjustment of Brake System 第六部分第六部分 制动系统故障及排除制动系统故障及排除 Chapter 6 Brake System Problems and Troubleshooting目录目录 Contents11、制动系的功用：、制动系的功用
3、：Functions of Brake System:使行驶的汽车减速或停车；使行驶的汽车减速或停车；Decelerate or stop the running vehicle;使下坡行驶的汽车车速保持稳定；使下坡行驶的汽车车速保持稳定；Keep the speed stable when the vehicle is driven on the downhill;使已停驶的汽车在原地（包括在斜坡上）驻留不动。使已停驶的汽车在原地（包括在斜坡上）驻留不动。Leave the stopped vehicle in original location(including on the slope
4、).2、制动系的类型：、制动系的类型：Types of Brake System:行车制动：通过操纵制动踏板实现行车制动：通过操纵制动踏板实现 Service brake:it is achieved by operating the brake pedal 驻车制动：通过操纵驻车制动手柄实现驻车制动：通过操纵驻车制动手柄实现 Parking brake:it is achieved by operating the parking brake handle应急制动：与驻车制动相结合，通过操纵驻车制动手柄实现应急制动：与驻车制动相结合，通过操纵驻车制动手柄实现 Emergency brake:
5、Combining with the parking brake,it is achieved by operating the parking brake handle辅助制动：通过操纵驾驶室内辅助制动按钮实现辅助制动：通过操纵驾驶室内辅助制动按钮实现 Supplemental brake:it is achieved by operating the supplemental brake button in the cab3、制动系的组成：、制动系的组成：Components of Brake System:供能装置：如空压机、储气筒等供能装置：如空压机、储气筒等 Supply devic
6、e:such as air compressor,air reservoir控制装置：如制动踏板、手阀等控制装置：如制动踏板、手阀等 Control device:such as brake pedal,parking brake传能装置：如各控制阀及管路元件等传能装置：如各控制阀及管路元件等 Transmission device:such as various control valves and pipe components执行装置：如制动器等执行装置：如制动器等 Execution device:such as brake一、概述一、概述 Chapter 1 Overview2驻车手
7、手阀+挂挂车手手阀Parking Brake+Trailer Parking Brake 前前盘式制式制动器器+气室气室Front Disc Brake+Air Chamber 挂挂车连接接头及管路及管路Trailer Connector and Pipeline制制动大管束及散管大管束及散管 Big Brake Pipe Bundle and Separate Pipes后后ABS电磁磁阀 Rear ABS Solenoid Valve前前ABS电磁磁阀Front ABS Solenoid Valve挂挂车阀Trailer Valve空空压机机Air Compressor制制动踏板踏板+脚脚
8、阀Brake Pedal+Service Brake制制动硬管硬管Brake Hard Pipe限限压阀Relief Valve四回路四回路Four-circuit干燥器干燥器 Dryer差差动阀Differential Valve继动阀Relay Valve后后桥盘式制式制动器及制器及制动气室气室 Rear Axle Disc Brake and Brake Chamber储气筒模气筒模块Air Reservoir Module排气制排气制动蝶蝶阀Exhaust Brake Butterfly Valve二、制动系统构造二、制动系统构造 Chapter 2 Brake System Cons
9、truction多通接多通接头Multi-way Connector前前继动阀Front Relay Valve储气筒气筒Air Reservoir适配适配阀Adaptation Valve挂挂车ABS电磁磁阀ABS For Trailer变速箱速箱+缓速器速器Transmission and Retarder储气筒气筒Air Reservoir3 联合卡车制动系统整车布置简图联合卡车制动系统整车布置简图 Complete Vehicle Layout of C&C Trucks Brake System整车从布置上大致可分为：供能、控制和执行元件三个部分。整车从布置上大致可分为：供能、控制和
10、执行元件三个部分。The complete vehicle can be roughly divided into three parts according to its arrangement:supply,control and executive components.供能元件即从空压机至干燥器再到四回路、储气筒等的相关元件及管路；供能元件即从空压机至干燥器再到四回路、储气筒等的相关元件及管路；Supply components contain the air compressor,dryer,four-circuit,air reservoir and other related c
11、omponents and pipelines;控制元件即踏板、脚阀、手阀、继动阀、差动阀，及连接各控制阀之间的若干管路；控制元件即踏板、脚阀、手阀、继动阀、差动阀，及连接各控制阀之间的若干管路；Control components contain the pedal,service brake,parking brake,relay valve,differential valve and the several pipes between the control valves;执行元件即气路终端制动器及相关执行气路。执行元件即气路终端制动器及相关执行气路。Executive compone
12、nts are the brakes at the end of the air circuits and the relevant executive air circuits.执行元件部分行元件部分Executive Component Part供能元件部分供能元件部分 Supply Component Part控制元件部分控制元件部分 Control Component Part4 1.联合卡车制动系统工作原理详见下图（以联合卡车制动系统工作原理详见下图（以42牵引车为例）牵引车为例）1.See the following drawing for the operating princi
13、ple of C&C trucks brake system(take 64 tractor for example)从图中可以看出，整个制动气路大致可分为：行车制动、驻车制动、辅助制动及其余辅助用气等。下面将分别对这几种制从图中可以看出，整个制动气路大致可分为：行车制动、驻车制动、辅助制动及其余辅助用气等。下面将分别对这几种制动方式的工作原理作以详细介绍。动方式的工作原理作以详细介绍。As seen from the drawing,the whole brake air circuit is roughly divided into:service brake,parking brake,
14、supplemental brake,other auxiliary air and ect.Next,the operating principles of these braking methods will be described in detail.三、制动系统工作原理三、制动系统工作原理 Chapter 3 Operating Principle of Brake System5a.行车制动：行车制动：Service Brake:联联合合卡卡车车行行车车制制动动采采用用双双回回路路气气压压制制动动系系统统。即即前前行行车车制制动动回回路路和和后后行行车车制制动动回回路路，二二者者彼
15、彼此此独独立立。见见下下图图线线条条加加粗粗部分，其中红色代表前行车制动回路，绿色代表后行车制动回路。部分，其中红色代表前行车制动回路，绿色代表后行车制动回路。The C&C truck service brake uses the double-circuit pneumatic brake system.It includes the front service brake circuit and the rear service brake circuit,which are independent.As shown by the bold lines in the drawing,th
16、e red represents the front service brake circuit,the green represents the rear service brake circuit.脚脚阀 Service Brake踏板踏板Pedal制制动气室气室 Brake Chamber制制动器器 Brake行行车制制动操操纵装置装置 Service Brake Operating Device行行车制制动执行装置行装置 Service Brake Execution Device6当当需需要要车车辆辆减减速速或或遇遇红红绿绿灯灯等等其其余余路路况况需需要要临临时时停停车车时时，驾驾驶
17、驶员员踩踩下下制制动动踏踏板板，顶顶杆杆下下移移，推推动动制制动动总总阀阀8的的顶顶杆杆座座下下移移，消消除除排排气气间间隙隙，制制动动总总阀阀排排气气阀阀门门关关闭闭，进进气气阀阀门门被被打打开开，这这时时由由后后桥桥储储气气筒筒4过过来来的的控控制制气气流流经经制制动动总总阀阀上上腔腔流流向向后后继继动动阀阀10的的控控制制口口，通通过过气气流流压压力力打打开开继继动动阀阀进进气气阀阀门门，这这时时由由后后桥桥储储气气筒筒过过来来的的供供能能气气流流便便经经继继动动阀阀进进出出气气口口，到到后后桥桥行车气室行车气室14，从而实现中后桥的行车制动；，从而实现中后桥的行车制动；When it
18、is necessary to decelerate the vehicle or stop it temporarily as encountering the traffic light or other road conditions,the driver depresses the brake pedal,the push rod is moved downward,the push rod seat of the brake valve 8 is pushed downward to eliminate the exhaust clearance,the exhaust valve
19、of the brake valve is closed and the intake valve is opened.At this time,the controlled air flow from the rear axle air reservoir 4 passes through the upper chamber on the brake valve,flowing into the control port of the rear relay valve 10,the intake valve of the relay valve is opened by the air fl
20、ow pressure,then the supply air flow from the rear axle air reservoir passes through the inlet and the outlet of the relay valve,flowing into the rear axle service brake chamber 14,it achieves the service braking of the center rear axle.与与此此同同时时，由由前前桥桥储储气气筒筒5过过来来的的控控制制气气流流经经制制动动总总阀阀下下腔腔流流向向前前继继动动阀阀1
21、0的的控控制制口口，通通过过气气流流压压力力打打开开继继动动阀阀进进气气阀阀门门，这时由后桥储气筒过来的供能气流便经继动阀进出气口，到前桥制动气室这时由后桥储气筒过来的供能气流便经继动阀进出气口，到前桥制动气室13，实现前桥行车制动。，实现前桥行车制动。At the same time,the controlled air flow from the front axle air reservoir 5 passes through the lower chamber on the brake valve,flowing into the control port of the front r
22、elay valve 10,the intake valve of the relay valve is opened by the air flow pressure,then the supply air flow from the front axle air reservoir passes through the inlet and the outlet of the relay valve,flowing into the front axle brake chamber 13,achieving the service braking of the front axle.对于牵引
23、车，由制动总阀过来的行车制动控制气流同时流向挂车阀对于牵引车，由制动总阀过来的行车制动控制气流同时流向挂车阀17控制口，控制挂车制动。控制口，控制挂车制动。For the tractors,the service brake controlled air flow from the brake valve flows into the control port of the trailer valve 17 to control the trailer brake.7b.驻车制动：驻车制动：Parking Brake:驻驻车车制制动动用用于于使使已已停停驶驶的的汽汽车车在在原原地地（包包括括在
24、在斜斜坡坡上上）驻驻留留不不动动。联联合合卡卡车车驻驻车车制制动动采采用用手手控控阀阀弹弹簧簧储储能能制制动动。见见下下图图线条加粗部分，蓝色代表主车驻车制动回路，黄色代表挂车驻车控制气路。线条加粗部分，蓝色代表主车驻车制动回路，黄色代表挂车驻车控制气路。The parking brake is used to keep the stopped vehicle in original location(including on the slope).The C&C truck parking brake uses the energy stored in the parking brake s
25、pring to operate the brake.As shown by the bold lines in the drawing,the blue represents the main vehicle parking brake circuit,the yellow represents the trailer parking control air circuit.驻车手手阀Parking Brake 驻车制制动操操纵装置装置 Parking Brake Operating Device弹簧制簧制动气室气室 Spring Brake Cylinder 制制动器器 Brake驻车制制
26、动执行装置行装置 Parking Brake Execution Device8当当需需要要车车辆辆停停驻驻时时，驾驾驶驶员员拉拉动动驻驻车车手手阀阀手手柄柄12，手手阀阀进进气气阀阀门门关关闭闭，排排气气阀阀门门打打开开，这这时时由由驻驻车车手手阀阀到到差差动动式式继继动动阀阀11的的控控制制气气流流便便经经驻驻车车手手阀阀排排气气口口排排出出，施施加加在在差差动动式式继继动动阀阀控控制制口口上上的的气气压压解解除除，差差动动式式继继动动阀阀进进气气阀阀门门关关闭闭，排排气气阀阀门门打打开开，这这时时中中后后桥桥弹弹簧簧制制动动气气室室14的的压压缩缩空空气气便便由由制制动动软软管管流流向向
27、差差动动式式继继动动阀阀，经经差差动动式式继继动动阀阀排排气气口口排排出出，弹弹簧簧释释放放，从而实现驻车制动。从而实现驻车制动。When it is necessary to park the vehicle,the driver pulls the parking brake handle 12,the intake valve of the parking brake is closed,the exhaust valve is opened,then the controlled air flow from the parking brake to the differential r
28、elay valve 11 is discharged from the exhaust port of the parking brake,the air pressure applied to the control port of the differential relay valve is released,the intake valve of the differential relay valve is closed,and the exhaust valve is opened,then the compressed air from the center rear axle
29、 spring brake chamber 14 flows to the differential relay valve through brake hoses,and is discharged from the exhaust port of the differential relay valve,the spring is released,achieving the parking brake.对对于于牵牵引引车车，由由驻驻车车手手阀阀到到挂挂车车手手阀阀18的的控控制制气气流流同同时时经经驻驻车车手手阀阀排排气气口口排排出出，挂挂车车手手阀阀排排气气阀阀门门打打开开，由由挂挂车
30、车手手阀阀到到挂挂车阀车阀17的驻车控制口的控制气流经挂车手阀排气口排出，从而控制挂车驻车制动。的驻车控制口的控制气流经挂车手阀排气口排出，从而控制挂车驻车制动。For the tractors,the controlled air flow from the parking brake to the trailer parking brake 18 is discharged from the exhaust port of the parking brake,the exhaust valve of the trailer parking brake is opened,and the c
31、ontrolled air flow from the trailer parking brake to the trailer valve 17 is discharged from the exhaust port of the trailer parking brake to control the trailer parking brake.9 c.辅助制动：辅助制动：Supplemental Brake:辅辅助助制制动动是是主主要要用用于于汽汽车车下下长长坡坡时时，持持续续的的减减速速或或保保持持车车速速稳稳定定，并并减减轻轻或或解解除除行行车车制制动动装装置置的的负负荷荷，从从而而
32、提提高高坡坡道行车安全，提高制动器使用寿命。道行车安全，提高制动器使用寿命。The supplemental brake is operating when the vehicle runs on a long downhill,it reduces the speed constantly or keeps the speed stable and reduces or releases the loads on the service brake device to improve the driving safety on slopes and increase the brakes s
33、ervice life.联联合合卡卡车车辅辅助助制制动动分分为为：压压缩缩释释放放制制动动+排排气气制制动动(YC6K12)、压压缩缩释释放放制制动动（ISME）、泄泄气气制制动动+排排气气制制动动(YC6K10)、排气制动（、排气制动（YC6MK）。）。The C&C truck supplemental brake is divided into:compression release brake+exhaust brake(YC6K12),compression release brake(ISME),bleeder brake+exhaust brake(YC6K10),exhaust
34、 brake(YC6MK).COMPRESSION RELEASE BRAKE(ENGINNE BRAKE)压缩释放制放制动器器(发动机制机制动器器)BLEEDER BRAKE泄气制泄气制动器器EXHAUST BRAKE排气制排气制动器器Intergrated 集成式Full Cycle 全循环Fix Orifice 固定泄气孔Bolt-On 螺栓连接式Common Rail 共轨Constant Pressure 恒压10压缩释放制动：压缩释放制动：Compression Release Brake:压压缩缩释释放放制制动动是是在在发发动动机机压压缩缩冲冲程程上上止止点点，打打开开排排气气门
35、门，使使高高压压气气体体经经排排气气门门排排出出，使使得得做做功功冲冲程程中中无无能能量量返返回回活活塞塞，造成能量净损失，以达到缓速目的；整个过程，发动机就相当于一吸收能量的空气压缩机。造成能量净损失，以达到缓速目的；整个过程，发动机就相当于一吸收能量的空气压缩机。The compression release brake opens the exhaust valve when the engine compression stroke is at the top dead center,so that the high pressure gas is discharged from th
36、e exhaust valve and no energy returns to the piston during the power stroke,resulting in the net energy loss and achieving the goal of slowing down the speed;during the whole process,the engine services as an air compressor to absorb the energy.Intake 进气气Compression 压缩Release 释放放Expansion膨膨胀Exhaust排
37、气排气11 泄气制动：泄气制动：Bleeder Brake:泄气制动是在发动机四个工作冲程中排气门均打开，在压缩冲程中，压缩气体经微小打开的排气门排出，在膨胀冲泄气制动是在发动机四个工作冲程中排气门均打开，在压缩冲程中，压缩气体经微小打开的排气门排出，在膨胀冲程中无能量返回活塞；同时在排气冲程中，安装在排气管上的排气蝶阀关闭，形成排气背压，为排气冲程提供阻力，程中无能量返回活塞；同时在排气冲程中，安装在排气管上的排气蝶阀关闭，形成排气背压，为排气冲程提供阻力，使发动机降速，从而实现整车缓速。使发动机降速，从而实现整车缓速。Bleeder brake opens the exhaust valv
38、e during the four engine strokes.The compressed air is discharged from the exhaust valve that is opened slightly during the compression stroke,no energy returns to the piston during the expansion stroke;while,the exhaust butterfly valve installed on the exhaust pipe is closed in the exhaust stroke t
39、o form the exhaust back pressure and provide the resistance to the exhaust stroke,then the engine speed is reduced,achieving the goal of slowing down the complete vehicles speed.Intake 进气气Compression 压缩Expansion膨膨胀Exhaust排气排气12排气制动：排气制动：Exhaust Brake:排排气气制制动动是是通通过过关关闭闭安安装装在在排排气气管管上上的的蝶蝶形形阀阀门门，阻阻止止发发
40、动动机机排排气气冲冲程程中中的的气气流流流流出出，增增加加排排气气背背压压，在在发发动动机机排排气冲程提供阻力，使发动机降速，实现制动。气冲程提供阻力，使发动机降速，实现制动。The exhaust brake prevents the air flow generated in the engine exhaust stroke from being discharged by closing the butterfly valve installed on the exhaust pipe,increases the exhaust back pressure,provides the r
41、esistance during the engine exhaust stroke,reduces the engine speed,and achieves the braking.13 d.应急制动：应急制动：d.Emergency Brake:应应急急制制动动用用于于主主制制动动供供能能装装置置出出现现压压力力过过低低等等故故障障时时，通通过过应应急急制制动动装装置置实实现现汽汽车车制制动动。联联合合卡卡车车应应急急制制动动与与驻驻车车制动相结合，控制及执行装置同驻车制动。制动相结合，控制及执行装置同驻车制动。When the main brake supply device has
42、problems such as low pressure,the emergency brake uses the emergency brake device to operate the vehicle braking.The C&C truck combines the emergency brake with parking brake,and its control and execution device are same with the parking brake.14干燥器干燥器 Dryer空压机空压机Air Compressor排气蝶阀排气蝶阀Exhaust Butter
43、fly Valve继动阀继动阀Relay Valve 差动阀差动阀Differential Valve 挂车阀挂车阀Trailer Valve四回路四回路Four-circuit 储气筒储气筒Air Reservoir 制动踏板制动踏板Brake Pedal盘式制动器盘式制动器 Disc Brake 制动总阀制动总阀 Brake Valve电子制动系统电子制动系统Electric Brake System挂车手阀挂车手阀Trailer Parking Brake 四、制动系统主要部件功用及工作原理四、制动系统主要部件功用及工作原理 Chapter 4 Functions and Operati
44、ng Principle of Main Brake System Components驻车手阀驻车手阀Parking Brake151.空压机空压机 1.Air Compressor a.功功用用：空空压压机机作作为为发发动动机机附附件件装装与与发发动动机机上上，由由发发动动机机驱驱动动，向向制制动动系系统统及及其其它它辅辅助用气系统提供能量。助用气系统提供能量。a.Functions:The air compressor is installed to the engine as an engine accessory.It is driven by the engine,and supp
45、lies energy to the brake system and other auxiliary gas systems.b.分类：目前联合卡车使用的有内卸荷（分类：目前联合卡车使用的有内卸荷（ISME）和外卸荷（）和外卸荷（YC）两种。）两种。b.Classification:The C&C truck now uses two types:the internal unloading(ISME)and the external unloading(YC).c.工作原理：工作原理：c.Operating Principle:空压机具有与发动机类似的曲柄连杆机构。空压机具有与发动机类似的
46、曲柄连杆机构。The air compressor has a crank link mechanism just like that of the engine.发发动动机机运运转转时时，空空压压机机随随之之运运转转。当当活活塞塞下下行行时时，外外界界空空气气经经进进气气歧歧管管（增增压压进进气气）或或空空滤滤后后（自自然然吸吸气气）被被吸吸人人气气缸缸；活活塞塞上上行行时时，缸缸内内空空气气即即被被压压缩缩，压压力力升升高高、克克服服排排气气阀阀弹弹簧簧的的顶顶紧紧力力使使排排气气门门开开启启，压压缩缩空空气气便便经经出出气气口口流流向向干干燥燥器器及及后后续续制动气路，从而实现向制动气路
47、供气制动气路，从而实现向制动气路供气。When the engine is running,the air compressor is running.When the piston is moving downward,the outside air is absorbed into the cylinder through the intake manifold(boosted air intake)or the air cleaner(natural aspiration);when the piston is moving upward,the air in the cylinder
48、is compressed,the pressure is boosted,and the exhaust valve is opened by the jacking force used to overcome the exhaust valve spring,then the compressed air flows to the dryer and the following brake air circuits through the outlet to supply air for the brake air circuits.162.干燥器干燥器 2.Dryera.功功用用：对对
49、来来自自空空压压机机的的压压缩缩空空气气进进行行吸吸附附干干燥燥，防防止止管管路路及及系系统统内内其其他他金金属属件件锈锈蚀蚀、橡橡胶胶件件龟龟裂裂、润润滑滑脂脂分分解解、管管路路堵堵塞塞等等故故障障，增增加加制制动动系系统统的的可可靠靠性性。集集成成的的调调压压阀阀能能自自动动调调节节系系统统压压力力，集集成成的的安安全全阀阀可可防防止止气气路路过过压压，集集成成的的加加热热装装置能避免总成冬季冻结失效。置能避免总成冬季冻结失效。a.Functions:Absorb and dry the compressed air from the air compressor,prevent the
50、pipeline and other metal parts in the system from corrosion,prevent the cracked rubber parts,dissociation of the grease,the blocked pipeline and other troubles,enhance the reliability of the brake system.The integrated pressure regulating valve can adjust the system pressure automatically,the integr