Air brake (road vehicle)

An air brake or, more formally, a compressed air brake system, is a type of friction brake for vehicles in which compressed air pressing on a piston is used to apply the pressure to the brake pad needed to stop the vehicle. Air brakes are used in large heavy vehicles, particularly those having multiple trailers which must be linked into the brake system, such as trucks, buses, trailers, and semi-trailers, in addition to their use in railroad trains. George Westinghouse first developed air brakes for use in railway service. He patented a safer air brake on March 5, 1872. Westinghouse made numerous alterations to improve his air pressured brake invention, which led to various forms of the automatic brake. In the early 20th century, after its advantages were proven in railway use, it was adopted by manufacturers of trucks and heavy road vehicles.
Design and function.
Air brakes are typically used on heavy trucks and buses. The system consists of service brakes, parking brakes, a control pedal, and an air storage tank. For the parking brake, there is a disc or drum arrangement which is designed to be held in the 'applied' position by spring pressure. Air pressure must be produced to release these "spring brake" parking brakes. For the service brakes (the ones used while driving for slowing or stopping) to be applied, the brake pedal is pushed, routing the air under pressure (approx or 6.89–8.27 bar) to the brake chamber, causing the brake to be engaged. Most types of truck air brakes are drum brakes, though there is an increasing trend towards the use of disc brakes. The air compressor draws filtered air from the atmosphere and forces it into high-pressure reservoirs at around . Most heavy vehicles have a gauge within the driver's view, indicating the availability of air pressure for safe vehicle operation, often including warning tones or lights. A mechanical "wig wag" that automatically drops down into the driver's field of vision when the pressure drops below a certain point is also common. Setting of the parking/emergency brake releases the pressurized air in the lines between the compressed air storage tank and the brakes, thus allowing the spring actuated parking brake to engage. A sudden loss of air pressure would result in full spring brake pressure immediately.
A compressed air brake system is divided into a supply system and a control system. The supply system compresses, stores and supplies high-pressure air to the control system as well as to additional air operated auxiliary truck systems (gearbox shift control, clutch pedal air assistance servo, etc.).
Supply system.
The air compressor is driven by the engine either by crankshaft pulley via a belt or directly from the engine timing gears. It is lubricated and cooled by the engine lubrication and cooling systems. Compressed air is first routed through a cooling coil and into an air dryer which removes moisture and oil impurities and also may include a pressure regulator, safety valve and smaller purge reservoir. As an alternative to the air dryer, the supply system can be equipped with an anti-freeze device and oil separator. The compressed air is then stored in a supply reservoir (also called a wet tank) from which it is then distributed via a four-way protection valve into the primary reservoir (rear brake reservoir) and the secondary reservoir (front/trailer brake reservoir), a parking brake reservoir, and an auxiliary air supply distribution point. The system also includes various check, pressure limiting, drain and safety valves.
Wig wag.
Air brake systems may include a wig wag device which deploys to warn the driver if the system air pressure drops too low.
This device drops a mechanical arm into view when the pressure in the system drops below the threshold of sufficient pressure to reliably deploy the brakes.
An automatic wig wag will rise out of view when the pressure in the system rises above the threshold. The manual-reset type must be placed in the out-of-view position manually. Neither will stay in place unless the pressure in the system is above the threshold. The photo to the left shows a manual wig wag which the operator swings to the right out of view when the air pressure is above the threshold where it will remain as long as the pressure is sufficient.
Most U.S. state commercial driver's license manuals, published by the states’ Departments of Motor Vehicles or equivalents, describe this term.
Control system.
The control system is further divided into two service brake circuits, the parking brake circuit, and the trailer brake circuit. The dual service brake circuits are further split into front and rear wheel circuits which receive compressed air from their individual reservoirs for added safety in case of an air leak. The service brakes are applied by means of a brake pedal air valve which regulates both circuits. The parking brake is the air operated spring brake type where its applied by spring force in the spring brake cylinder and released by compressed air via a hand control valve. The trailer brake consists of a direct two line system: the supply line (marked red) and the separate control or service line (marked blue). The supply line receives air from the prime mover park brake air tank via a park brake relay valve and the control line is regulated via the trailer brake relay valve. The operating signals for the relay are provided by the prime mover brake pedal air valve, trailer service brake hand control (subject to local heavy vehicle legislation) and the prime mover park brake hand control.
Advantages.
Air brakes are used as an alternative to hydraulic brakes which are used on lighter vehicles such as automobiles. Hydraulic brakes use a liquid (hydraulic fluid) to transfer pressure from the brake pedal to the brake shoe to stop the vehicle. Air brakes are used in heavy commercial vehicles due to their reliability. They have several advantages for large multi-trailer vehicles:
Disadvantages.
Although air brakes are considered the superior braking system for heavy vehicles (gross weight ~26,000 to 33,000 pounds or more) which would over load hydraulic brakes, they also have the following disadvantages when compared to hydraulic braking systems: