Braking Mechanism

7/28/2019 Braking Mechanism

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PREFACE

I have great satisfaction in learning about the technology of the worlds leading motor

vehicle company NISSAN and getting in depth knowledge of their new product NISSAN

EVALIA. The evaluation study was initiated by the training which a student has to for the

fulfilment of the curriculum.

The study, which has been conducted and completed within a record time of two

months, is an excellent example of cooperative endeavour among the colleagues and the

organisation.

The training taken at NISSAN gave me practical insight into the working of the

company, especially in the field of technology of motor vehicles which until now limited to

book only. But these 60 days have been special and proved to be a value addition and how

actually functions are performed in the a massive vehicle as well as in the organization.

The initial part of project report gives details of the company, like its departments,

functions, and the structure etc and the next part is related to NISSAN EVALIA and its

working.


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ACKNOWLEGEMENT

No man is an island itself rightly proclaim John Donne, the metaphysical poet to let the

world know the reality of human existence and human life.

First and foremost would like to thank the Director and teachers of PACIFIC

POLYTECHNIC COLLEGE for giving me an opportunity to develop understanding and

skills to attain quality knowledge.

I express my deep and sincere gratitude to the NISSAN for allowing me tohave my training

in this organization and my Trainer Mr. Hemendra whose valued guidance, dexterous

knowledge and unabated zeal paved my way for the completion of the work smoothly.

Finally and without being specific, I would like to thank my parents and my friends who

helped and encourage me directly or indirectly in the project and whose enthusiasm and

cheerfulness made my work on this project an enjoyable experience with a perfect balance

between pleasure and work.

DIPAL JAIN


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INTRODUCTION TO THE COMPANY

Nissan Motor Company Ltd usually shortened to Nissan, is a

Japanesemultinationalautomakerheadquartered in Japan. It was a core member of theNissan

Group, but has become more independent after its restructuring underCarlos Ghosn(CEO).

Nissan was the sixth largest automaker in the world behindGeneral Motors,Volkswagen

AG,Toyota,Hyundai Motor Group, andFordin 2011.[2]It formerly marketed vehicles under

the "Datsun" brand name. As of 2011, the company's global headquarters is located in Nishi-

ku, Yokohama. In 1999, Nissan entered a two way alliance withRenault S.A.of France,

which owns 43.4% of Nissan while Nissan holds 15% of Renault shares, as of 2008. Along

with its normal range of models, Nissan also produces a range of luxury models branded

asInfiniti.

Nissan's footprint in India has been growing steadily since its inception in

2005. Marked by an impressive rise in sales, award-winning quality from locally-built

products, an expanding range of innovative cars and a rapidly evolving dealer network the

growth underlines the strategic importance of India to Nissan.

Together with its global Alliance partnerRenault, Nissan has made a long-term and large-

scale 45 Mn INR investment commitment in a manufacturing plant at Oragadam, Chennai.

The Alliance has also invested in a state-ofthe-art global R&D center with more than 2000

engineers to support product innovation and customization. NMIPL has appointed Hover

Automotive India (HAI) as their sole distributor for India to handle sales and marketing,

dealer development, customer relationship management and after sales in India.

Guided by its global Brand commitment "Innovation and Excitement for Everyone" Nissan

delivers cutting-edge technology, Innovative design and a rewarding experience to all its

customers. In India, Nissan has been constantly expanding innovative and exciting product

offerings across hatchback, sports car, SUV and sedan segments. Today, Nissan has strongly

positioned three locally produced models premium hatchback Micra, entry level sedan

Sunny and Urban Class Utility Vehicle Evalia. Other existing range of products include the

X-Trail (SUV model), the Teana (luxury Sedan) and 370Z (iconic sports car) all three

imported from Japan as CBU (completely built units). NMIPL also commenced exports in

September 2010 to more than 100 countries including Europe, Middle East and Africa.
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In line with its global philosophy of corporate sustainability, Nissan India is demonstrating its

corporate commitment through various sustainable programs including safety campaigns and

rehabilitation projects. Nissan has constructed residential homes for relocated families from

the construction site, local Police Station and a fire service station in the Oragadam village.

Nissan has also partnered with Habitat for Humanity for providing shelter to variousfamilies by constructing homes for the socially and economically less fortunate section of the

society.

India is a key growth market for Nissan. The company continues its quest to optimize product

development and deliver highly innovative technology to the India market and its growing

customer base.

NISSAN Model 70 Phaeton, 1938


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NISSAN EVALIA

The following project consist of study of NISSANs new vehicle EVALIA

FRONT

SIDEWAYS


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VEHICLE SUMMARY

Name: Evalia

Model: XE

Car Body Type: MUV

Segment: C+ Segment

Fuel Consumption:

Highway19.30 kmpl.

Fuel Consumption:

City14.00 kmpl.

ENGINE SPECIFICATIONS

Displacement: 1461cc, Nissan K9K, BS4

Engine Type: Diesel

Maximum Power: 85 Bhp @ 3750 rpm

Maximum Torque: 200 Nm @ 2000 rpm

DIMENSIONS

Length: 4400 mm

Width: 1700 mm

Height: 1860 mm

OTHER SPECIFICATIONS

Seating Capacity: 7

Tyre Size: 165 R14
http://autos.maxabout.com/cars/bodytype/muvhttp://autos.maxabout.com/cars/bodytype/muv


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Suspension: McPherson Struts, Multi-Leaf Rigid

Turning Circle: 5.20 mtrs.

Steering: Tilt

Brakes: Front Disk, Rear Drum

Gears: 5 Manual

Ground Clearance: 180.00 mm

Kerb Weight: 1446.00 kgs.

Fuel Tank: 55.00

Body Color

Bumpers:YES

Tachometer: YES

Alloys: NO

ORVM Indicator: NO

Xenon Headlamps: NO

Trip Meter: 2

Headlamp Washer: NO

ACTIVE AND PASSIVE SAFETY

Airbag: 1

Parking Sensors: NO

Fog Lamp: NO

Traction Control: NO

EBD: YES

ABS: YES

ESP: NO


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COMFORT AND CONVENIENCE

AC:AC

without Climate Control

Power Windows: NO

Central Locking: None

Remote Boot: YES

Remote Fuel Filler: YES

Rear Wiper: YES

Rear Defogger: YES

Rear Armrest: With Cup Holder

Steering

Adjustment

(Rake/Reach):

YES/NO

Driver Seat

Adjustment:Manual

Music System: 1 DIN AM/FM/CD

Leather Seats: NO

Door Mirror: Both Side Electric

Tinted Glass: YES

Rear AC Vent: NO

Folding Rear Seats: YES

Sun Roof: NO

Buttons/Controls

on Steering:NO

Auto Viper: NO

Auto Headlamp: NO


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OVERVIEW OF NISSAN EVALIA

Multi-purpose vehicle is a segment of cars in India which is totally dominated by Innova from

Toyota. Ever since its launch its the undisputed champion of its segment. Initially this was

not a popular segment of cars in India but now consumers and manufacturers both are rushing

towards it. Recently we have seen new competitors of Innova including Ertiga from Maruti

Suzuki, face-lifted Xylo from Mahindra and nowNissan Evalia. Yes, Nissan has entered this

segment of market with their MPV known as Evalia. Till now Nissan is widely known for its

cars like Micra and Sunny in India. With Evalia, Nissan targets those looking for an

alternative of Innova for both family and commercial use.

Majority of cars in this segment faces the problem of identity crisis. Either they are given the

identity of a car which is just suitable for family or they are known as taxi which is moreappropriate for commercial usage. No owner would like his personal car to be taunted as a

taxi. Innova has managed it brilliantly. It has won hearts of many families despite being a

successful commercial vehicle. Its space, comfort with premium quality made it a huge hit in

the market. Nissan knows it perfectly as they have seen Xylo being tagged as a taxi while

only families are opting for Ertiga. It will be a tough task for Evalia to carry two successful

images with two colored number plates.

Nissan India unveiled the 'Evalia' in India at the 2012 Auto Expo in New Delhi. The Indian

version of NV200 would be more luxurious and feature-rich in comparison to the Evalias

(NV200) sold all over the world. Nissan Evalia is a proper seven-seater multi-utility vehicleand will compete against the likes of Toyota Innova, Tata Aria, Chevrolet Tavera and to some

extent with ICML Rhino. On 8th August Nissan India unveiled all the technical specifications

and features of Evalia to the online media persons. It is available in four variants: XE, XE+,

XL and top-of-the-line XV. All the variants are powered by Nissan K9K diesel engine which

is mated to five-speed manual gearbox. It generates maximum power of 85 bhp at 3750 rpm

with maximum torque of 200 nm at 2000 rpm. In terms of looks, Nissan Evalia has

commercial van-type designing with sliding doors to access the rear seats. It has to be seen

that if private owners will prefer Evalia over Innova for routine day-to-day use. Nissan has

kept the design very neat and simple.

The interiors of Nissan Evalia are very spacious with sufficient head-room and leg-room for

all seven passengers. The top-of-the-line XV variant will come fully loaded with features like

body coloured bumpers, body coloured outside rear-view mirrors, Electrically adjustable

outside rear-view mirrors, front fog lamps, alloy wheels, tachometer, trip meter, 12V power

outlet, multi-information display, 2DIN music system with 4 speakers, key-less entry, central

locking system, tilt-adjustable power steering, power windows, seat back table, rear-monitor

camera with display, air conditioner with rear AC vents, reclining seats, passenger plus driver

airbag, ABS+EBD with brake assist, immobilizer and door ajar warning.


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The Nissan Evalia is designed for perfection. Ample amount of cargo space, first-class

functionality and the latest automotive technology make it stand apart from the crowd. Nissan

exhibits a high performance on the road with its excellent diesel engine option. The interior is

a showcase of comfort and the true sporty nature of the car. They are provided with lumber

support, folding options in the passenger seats and Thermoplastic Polyolefin front rowcovering. The remote keyless entry system, central console with controls, front map lights,

Rear Glass defogger, bottle holders and passenger side rear cargo door all enhance the

comfort of the car. The Nissan Evalia is facilitated with 2-Din AM/FM/CD with four

speakers. Nissan India has launched the Evalia today (25th September, 2012) in Indian

market. The base variant of Evalia is priced at Rs. 8.49 lakhs and Rs. 9.99 lakhs for the top

model.

Nissan Evalia Exterior

One thing is for sure; Evalia looks distinctfrom its competitors. We are not sure if its goingto work in its favour or not. The car looks tall; thats it. Evalia neither looks smart or beautiful

nor its curvy or macho, its just tall. The front of the car is much more appealing than its

whole body. It has a big, broad bumper which has nice flowing lines over it along with fog

lights and air dam fitted very low. There is huge gap between headlights and fog lights which

grabs your attention instantly. It has nice angular headlights which are well mated with an

innovative front grille.

There is big Nissan logo in center with a nice finish of chrome on the last layer of grille. The

bonnet sits high above on this front grille which is not that big in size. Overall its face looks

very aerodynamic. Its side view makes it look like any other, cargo van. It has long verticalfront doors with sliding doors at the back. Yes, it has sliding doors which wont take you long

to compare it with much cheaper Marutis van like Omni or Eeco. It has body colored front

door handles and big side mirrors. It has nice wheel arches but its 14 inch alloys spoils the

party. Its side profile with small size of tyres looks very boxy and bland. Rear of the car

makes it worse. Its rear gate makes it a typical van. Its rear bumper is the most irritating thing

that you can notice. It has a tall rear gate which has extremely low fitted tail lamps. When

companies are trying to make their MPVs as stylish as possible, we wonder why Nissan has

chosen this typical van design for its car. Looking at its competitors design and style, Evalia

looks like a thing of the past.

Nissan Evalia Interior

Things get better inside Evalia. It uses beige and grey colors inside. Seats and door panels

are of beige colour which makes it look up market. The car features clear and easily readable

instrument dials. It has familiar three spoke steering wheel with a big Nissan logo over it. The

upward placement of gear knob may remind you of i10s AC vents, gear knob and center

console are surrounded with metallic colour finish. The quality of plastic material and buttons

used inside are just fine as they are not that soft to touch. If we compare it with its rivals like

Xylo than it surely has an upper hand as the total arrangement inside with fit and finish is farbetter. It also has a Multi information display which provides important information to driver.


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Comfort and Convenience

Evalia is available as a seven-seater multi-purpose vehicle. Basic function of MPVs is to

provide extra space and thats the USP of this car. Nissan has made itvery spacious and

even with full seating; luggage of a full size family can fit into its boot. Front seats are very

comfy and there is enough legroom and headroom available in the front. People who are six

feet plus may find a bit cramped knee room in the front, otherwise headroom is no issue.

There are front power windows and rear wiper and defogger. Its power steering is available

with tilt option. Driver seat is manually adjustable. Driving position will again realize you that

it is more like a van as you lack that confidence in driving position. Seating in second row is

also very comfortable.

There is ample amount of headroom and legroom. Under thigh support is just enough. It has

non sliding seats in its 2nd row. Sliding doors and almost flat floor makes it convenient to use

these rows. The tall structure of Evalia allows the passengers in third room to get fair amountof headroom. The under thigh support could have been better. There is rear AC vent for 3rd

row, we are not sure about 2nd row if it will have AC ducting or not. It also features

electrically adjustable but not retractable outside mirrors and rear parking camera with

display. The car has a smart key with function of auto lock/unlock with the help of sensors.

Dashboard and Storage

Its long dashboard uses dual tone colors. It has in-built glove box with bottle holders on either

side. Thats the only storage space this dashboard offers. The center console is fitted with

Multi information display which fits in well with the dashboard and looks sophisticated. It hasround and rectangular shaped AC vents. Overall appearance and quality of dashboard is

satisfactory. The car has no lockable storage space to keep essential or private documents. It

also has cup holder in rear center armrest. The car has first in its class tray table on the back of

front seats just like a plane. To get more storage, the rear seats folds down and allow you to

carry enormous amount of luggage.

Music system of Nissan Evalia

Nissan Evalia is equipped with double din music system fitted in center console. It has radio

andCD player coupled with four speakers. There is no audio control switches mounted on itssteering wheel. The car also lacks Bluetooth connectivity. It features a 12v power outlet at

front.

Nissan Evalia Engine and Gearbox

The familiar Renaults1.5 K9K common rail diesel engine powers this car. The maximum

power produced by this engine is of85 bhp which comes at 3750 rpm. It churns out a

maximum torque output 200 Nm available at 2000 rpm. Nissan is already using this engine in

its Micra and Sunny. This diesel unit is specially tuned for Indian Evalia. Its mated with 5-

speed manual gearbox. This engine is less powerful than most of its competitors.


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Acceleration and Performance

Those numbers seem to be very less on papers for a vehicle of this segment but drive it on

road and you will find it completely different. As per Nissan, Evalia reaches 100km/hr mark

faster than any of its competitors. Its hard to believe but yes it does. The car feels very light

and fast. Once you pass 2000 rpm mark it is fun to drive this vehicle. It suffers a major turbo

lag, especially with full seating you will continuously have to work on its gear shifting. It also

gets noisy if rev hard otherwise its a nice performer. It cant match the performance and

drivability of Innova but it is better than what we get in Xylo. Its lightweight helps it to

manage the power to weight ratio better than others. Its tall gear ratios can be irritating in city

traffic as you can avail torque only after 2000 rpm. It has smooth gear transition which is very

handy in city traffic and its gear ratios are well proportioned.

Mileage of Nissan Evalia

Nissan claims Evalia to be the most fuel efficient car in its segment. As per ARAI

certification, it manages to return 19km/ltr. When tested the car returns a mileage of around

13-15km/ltr in city conditions while on highways you can expect anything around 15-

17km/ltr. These numbers are surely better than its competitors like Innova and Xylo. There

are two reasons which undoubtedly make it the most fuel efficient car in its segment. First its

lightweight due to its monocoque design which is very lighter in comparison to its

competitors as it weighs around 1.4 tonnes and secondly its relatively taller gear ratios.

Nissan Evalia Ride and Handling

The car handles really well in traffic conditions. Its reduced turning radius along with large

door glasses on either side makes it easy while parking this car. Given its weight and usage,

its suspension has been given special treatment. It is capable of bearing heavy loads with

optimum comfort. Its strong suspension allows it to stay grounded at high speeds. Shifting

lanes quickly at high speeds is not an issue. It also digests big bumps and potholes easily and

with its high ground clearance. Its long wheelbase along with well mated suspension confirms

you a comfortable ride. It doesnt give you enough confidence to drive it fast at corners

because its suspension takes time to settle down and its small tyres are not capable to hold it

firmly on road.

Braking and Safety Features

Nissan Evalia has ventilated disk brake at its front while drum brakes are used at its back.

Brakes respond very accurately and sometime they stop this car way before than what you

expect. Top model of this car will also carry features like ABS with EBD and brake assist

which will make its braking more precise. Though it lacks ESP but you will hardly miss it.

Nissan has tried to make it a safe vehicle thats why ABS and driver side air bag is a standard

feature while the top model will also feature airbag for front passenger.


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Verdict

MPVs are known fortheir space and Evalia is surely a winner in this department. Its very

spacious and offers enough comfort what you expect from a vehicle of this segment. It

handles nicely in city traffic and on highways also it wont disappoint you.Evalia is very

economicalin terms of fuel efficiency and for that you dont even have to compromise on

power either. These are some of its qualities which will surely appeal to many buyers. We

wish if it was enough for this car to succeed as it has some major drawbacks.

Nissan Evalia looks much like a van with sliding doors which makes it look like a typical

MPV. Its competitors like Marutis Ertiga and Toyota Innova on the other hand are trying to

get rid of this image and they more look like any other city car which is more acceptable by

family buyers. It can appeal to those who are looking for a commercial MPV but again its

warranty period is an issue. Innova comes with longer warranty period which makes it worth

in comparison to Evalia. There are relatively less features in Evalia when compared to itscompetitors. It will be hard for Evalia to get the trusted buyers of Innova which is better than

it in almost every department.


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Nissan EVALIA at a glance

Manufacturer Nissan

Also called Nissan Evalia

Nissan NV200 Vanette

Mitsubishi Delica D:3

Production 2009present

Model years 2010-present

Assembly Aguascalientes,Mexico

Shnan,Kanagawa,Japan

Nissan Motor Ibrica S.A.,Spain(November 2009)Zhengzhou Nissan,China(2010)

Chennai,India(2012-)

Purwakarta,Indonesia(2012-present)

Predecessor Nissan VanetteVan (Japan)

Nissan Kubistar(Europe)

Class Light commercial vehicle

Body style 4-doorvan

Layout Front engine,front-wheel drive

Platform Nissan B platform

Engine 1.6 LHR16DEI42.0 LMR20DEI4(starting in 2013)

1.5 L K9KDieselI4(Europe)
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1.5 LHR15DE(Indonesia)

Transmission CVT

Wheelbase 2010-12: 2,860 mm (112.6 in)2013-: 115.2 in (2,926 mm)

Length 2010-12: 4,400 mm (173.2 in)2013-: 186.2 in (4,729 mm)

Width 2010-12: 1,695 mm (66.7 in)2013-: 68.1 in (1,730 mm)

Height 2010-12: 1,8501,855 mm (7373.0 in)2013-: 73.5 in (1,867 mm)
http://en.wikipedia.org/wiki/Nissan_HR_enginehttp://en.wikipedia.org/wiki/Nissan_HR_enginehttp://en.wikipedia.org/wiki/Nissan_HR_enginehttp://en.wikipedia.org/wiki/Transmission_(mechanics)http://en.wikipedia.org/wiki/Transmission_(mechanics)http://en.wikipedia.org/wiki/Continuously_variable_transmissionhttp://en.wikipedia.org/wiki/Continuously_variable_transmissionhttp://en.wikipedia.org/wiki/Wheelbasehttp://en.wikipedia.org/wiki/Wheelbasehttp://en.wikipedia.org/wiki/Wheelbasehttp://en.wikipedia.org/wiki/Continuously_variable_transmissionhttp://en.wikipedia.org/wiki/Transmission_(mechanics)http://en.wikipedia.org/wiki/Nissan_HR_engine


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SUSPENSION ASSEMBLY

Front-wheel-drive car with MacPherson-strut front suspension and strut-type independent rear suspension

Automotive suspension

The springs and related parts intermediate between the wheels and the frame, subframe, or

side rails of a unitized body. The suspension supports the weight of the upper part of a vehicle

on its axles and wheels, allows the vehicle to travel over irregular surfaces with a minimum of

up-and-down body movement, and allows the vehicle to corner with minimum roll or loss oftraction between the tires and the road. See also Automobile; Spring (machines).

In a typical suspension system for a vehicle with front-engine and front-wheel drive (see

illustration), the weight of the vehicle applies an initial compression to the coil springs. When

the tires and wheels encounter irregularities in the road, the springs further compress or

expand to absorb most of the shock. The suspension at the rear wheels is usually simpler than

for the front wheels, which require multiple-point attachments so the wheels can move up and

down while swinging from side to side for steering.

A telescoping hydraulic damper, known as a shock absorber, is mounted separately or in thestrut at each wheel to restrain spring movement and prevent prolonged spring oscillations.


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The shock absorber contains a piston that moves in a cylinder as the wheel moves up and

down with respect to the vehicle body or frame. As the piston moves, it forces a fluid through

an orifice, imposing a restraint on the spring. Spring-loaded valves open to permit quicker

flow of the fluid if fluid pressure rises high enough, as it may when rapid wheel movements

take place. Most automotive vehicles use gas-filled shock absorbers in which the air spaceabove the fluid is filled with a pressurized gas such as nitrogen. The gas pressure on the fluid

reduces the creation of air bubbles and foaming. See also Shock absorber.

Most automotive vehicles have independent front suspension, usually using coil springs as

part of either a short-arm long-arm or a MacPherson-strut suspension system. A MacPherson-

strut suspension (see illustration) combines a coil spring and shock absorber into a strut

assembly that requires only a beam-type lower control arm.

Some vehicles with short-arm long-arm front suspension use either longitudinal or transverse

torsion bars for the front springs. One end of the torsion bar is attached to the lower control

arm, and the other end is anchored to the vehicle body or frame. As the tire and wheel move

up and down, the torsion bar provides springing action by twisting about its long axis.

Turning an adjustment bolt at one end of the torsion bar raises or lowers the vehicle RIDe

height. See also Torsion bar.

Most automobiles and many light trucks have coil springs at the rear. These may mount on the

rear drive axle, on struts, or on various types of control or suspension arms in an independent

suspension system. Some rear-drive vehicles have leaf springs at the rear. Others use

transverse torsion bars.

What is Suspension?

Suspension is the term given to the system of springs, shock absorbers and linkages that

connects a vehicle to its wheels and allows relative motion between the two.[1] Suspension

systems serve a dual purpose contributing to the vehicle's roadholding/handling and

braking for good active safety and driving pleasure, and keeping vehicle occupants

comfortable and reasonably well isolated from road noise, bumps, and vibrations,etc. These

goals are generally at odds, so the tuning of suspensions involves finding the right

compromise. It is important for the suspension to keep the road wheel in contact with the road

surface as much as possible, because all the forces acting on the vehicle do so through the

contact patches of the tires. The suspension also protects the vehicle itself and any cargo or

luggage from damage and wear. The design of front and rear suspension of a car may be

different.


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BRAKING ASSEMBLY

Exploded view of the front disc brake assembly


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DETAILED BRAKING ASSEMBLY DESCRIPTION

The modern automotive brake system has been refined for over 100 years and has become

extremely dependable and efficient.

The typical brake system consists ofdisk brakesin front and eitherdiskordrum brakesin

the rear connected by a system oftubes and hosesthat link the brake at each wheel to

themaster cylinder.Other systems that are connected with the brake system includetheparking brakes,power brakeboosterand theanti-locksystem.

When you step on the brake pedal, you are

actually pushing against a plunger in the

master cylinder, which forces hydraulic oil

(brake fluid) through a series of tubes and

hoses to the braking unit at each wheel. Since

hydraulic fluid (or any fluid for that matter)

cannot be compressed, pushing fluid through a

pipe is just like pushing a steel bar through a

pipe. Unlike a steel bar, however, fluid can be

directed through many twists and turns on its

way to its destination, arriving with the exact

same motion and pressure that it started

with. It is very important that the fluid is pure liquid and that there are no air bubbles in

it. Air can compress, which causes a sponginess to the pedal and severely reduced braking

efficiency. If air is suspected, then the system must be bled to remove the air. There are

"bleeder screws" at each wheel cylinder and caliper for this purpose.
http://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Brake%20Fluidhttp://www.carparts.com/brakes.htm#Anti-Lock%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Power%20Brakeshttp://www.carparts.com/brakes.htm#Parking%20Brakeshttp://www.carparts.com/brakes.htm#Master%20Cylinderhttp://www.carparts.com/brakes.htm#Brake%20Lineshttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brake


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On adisk brake, the fluid from the master cylinder is forced

into a caliper where it presses against a piston. The piston, in-

turn, squeezes two brake pads against the disk(rotor), which

is attached to the wheel, forcing it to slow down or stop.

This process is similar to a bicycle brake where two rubber

pads rub against the wheel rim creating friction.

Withdrum brakes, fluid is forced into the wheel cylinder,

which pushes the brake shoes out so that the friction linings

are pressed against the drum, which is attached to the wheel,causing the wheel to stop.

In either case, the friction surfaces of thepadson a disk brake

system, or theshoeson a drum brake convert the forward

motion of the vehicle into heat. Heat is what causes the

friction surfaces (linings) of the pads and shoes to eventually

wear out and require replacement.

Let's take a closer look at each of the components in a brake system and see where other

problems can occur...

Master Cylinder

The master cylinder is located in the engine compartment on

the firewall, directly in front of the driver's seat. A typical

master cylinder is actually two completely separate master

cylinders in one housing, each handling two wheels. This way

if one side fails, you will still be able to stop the car. The

brake warning light on the dash will light if either side fails,

alerting you to the problem. Master cylinders have become

very reliable and rarely malfunction; however, the most

common problem that they experience is an internal leak. This will cause the brake pedal to

slowly sink to the floor when your foot applies steady pressure. Letting go of the pedal and

immediately stepping on it again brings the pedal back to normal height.

Brake Fluid

Brake fluid is a special oil that has specific properties. It is designed to withstand cold

temperatures without thickening as well as very high temperatures without boiling. (If the
http://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Disc%20Brakehttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Shoeshttp://www.carparts.com/brakes.htm#Brake%20Padshttp://www.carparts.com/brakes.htm#Drum%20Brakehttp://www.carparts.com/brakes.htm#Rotorhttp://www.carparts.com/brakes.htm#Disc%20Brake


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brake fluid should boil, it will cause you to have a spongy pedal and the car will be hard to

stop.) Brake fluid must meet standards that are set by the Department of Transportation

(DOT). The current standard is DOT-3, which has a boiling point of 460 F. But check your

owners manual to see what your vehicle manufacturer recommends.

The brake fluid reservoir is on top of the master cylinder. Most cars today have a transparent

reservoir so that you can see the level without opening the cover. The brake fluid level will

drop slightly as the brake pads wear. This is a normal condition and no cause for concern. If

the level drops noticeably over a short period of time or goes down to about two thirds full,

have your brakes checked as soon as possible. Keep the reservoir covered except for the

amount of time you need to fill it and never leave a can of brake fluid uncovered. Brake fluid

must maintain a high boiling point. Exposure to air will cause the fluid to absorb moisture,

which will lower that boiling point.

NEVER PUT ANYTHING BUT APPROVED BRAKE FLUID IN YOUR BRAKES.

ANYTHING ELSE CAN CAUSE SUDDEN BRAKE FAILURE!Any other type of oilor other fluid will react with the brake fluid and very quickly destroy the rubber seals in

the brake system causing brake failure.

Brake Lines

The brake fluid travels from the master cylinder to the wheels through a series of steel tubes

and reinforced rubber hoses. Rubber hoses are used only in places that require flexibility,

such as at the front wheels, which move up and down as well as steer. The rest of the system

uses non-corrosive seamless steel tubing with special fittings at all attachment points. If a

steel line requires a repair, the best procedure is to replace the complete line. If this is notpractical, a line can be repaired using special splice fittings that are made for brake system

repair. You must never use brass "compression" fittings or copper tubing to repair a brake

system. They are dangerous and illegal.

OTHER COMPONENTS IN THE HYDRAULIC SYSTEM

Proportioning valve or Equalizer ValveThese valves are mounted between the master cylinder and the rear wheels. They are

designed to adjust the pressure between the front and rear brakes depending on how

hard you are stopping. The shorter you stop, the more of the vehicle's weight is

transferred to the front wheels, in some cases, causing the rear to lift and the front to

dive. These valves are designed to direct more pressure to the front and less pressure

to the rear the harder you stop. This minimizes the chance of premature lockup at the

rear wheels.

Pressure Differential ValveThis valve is usually mounted just below the master cylinder and is responsible for

turning the brake warning light on when it detects a malfunction. It measures the

pressure from the two sections of the master cylinder and compares them. Since it ismounted ahead of the proportioning or equalizer valve, the two pressures it detects


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should be equal. If it detects a difference, it means that there is probably a brake fluid

leak somewhere in the system.

Combination ValveThe Combination valve is simply a

proportioning valve and a pressure

differential valve that is combined into

one unit.

Electronic Brake ForceDistribution

Newer cars use the antilock brake

hardware and the onboard computer to replace these proportioning valve systems with

a system called Electronic Brake force Distribution (EBD) in order to distribute theexact amount of pressure at each wheel to insure a balanced brake system.


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DISK BRAKES

The disk brake is the best brake we have found so far. Disk brakes are used to stop everything

from cars to locomotives and jumbo jets. Disk brakes wear longer, are less affected by water,

are self adjusting, self cleaning, less prone to grabbing or pulling and stop better than any

other system around. The main components of a disk brake are the Brake

Pads, Rotor, Caliper and Caliper Support.

Brake PadsThere are two brake pads on each caliper. They are constructed of

a metal "shoe" with the lining riveted or bonded to it. The pads

are mounted in the caliper, one on each side of the rotor. Brake

linings used to be made primarily of asbestos because of its heatabsorbing properties and quiet operation; however, due to health

risks, asbestos has been outlawed, so new materials are now being

used. Brake pads wear out with use and must be replaced

periodically. There are many types and qualities of pads available.

The differences have to do with brake life (how long the new pads

will last) and noise (how quiet they are when you step on the brake). Harder linings

tend to last longer and stop better under heavy use but they may produce an irritating

squeal when they are applied. Technicians that work on brakes usually have a favorite

pad that gives a good compromise that their customers can live with.

Brake pads should be checked for wear periodically. If the lining wears down to the

metal brake shoe, then you will have a "Metal-to-Metal" condition where the shoe

rubs directly against the rotor causing severe damage and loss of braking efficiency.

Some brake pads come with a "brake warning sensor" that will emit a squealing noise

when the pads are worn to a point where they should be changed. This noise will

usually be heard when your foot is offthe brake and disappear when you step on the

brake. If you hear this noise, have your brakes checked as soon as possible.

RotorThe disk rotor is made of iron with highly machined surfaces where the brake pads

contact it. Just as the brake pads wear out over time, the rotor also undergoes some

wear, usually in the form of ridges and groves where the brake pad rubs against

it. This wear pattern exactly matches the wear pattern of the pads as they seat

themselves to the rotor. When the pads are replaced, the rotor must be machined

smooth to allow the new pads to have an even contact surface to work with. Only a

small amount of material can be machined off of a rotor before it becomes unusable

and must be replaced. A minimum thickness measurement is stamped on every rotor

and the technician doing the brake job will measure the rotor before and aftermachining it to make sure it doesn't go below the legal minimum. If a rotor is cut


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below the minimum, it will not be able to handle the high heat that brakes normally

generate. This will cause the brakes to "fade," greatly reducing their effectiveness to a

point where you may not be able to stop!

Caliper & SupportThere are two main types of calipers: Floating calipers and fixed calipers. There are

other configurations but these are the most popular. Calipers must be rebuilt or

replaced if they show signs of leaking brake fluid.

Single Piston Floating Calipers are the most

popular and also least costly to manufacture and

service. A floating caliper "floats" or moves in a

track in its support so that it can center itself over

the rotor. As you apply brake pressure, the

hydraulic fluid pushes in two directions. It forcesthe piston against the inner pad, which in turn

pushes against the rotor. It also pushes the caliper

in the opposite direction against the outer pad,

pressing it against the other side of the rotor. Floating calipers are also available on

some vehicles with two pistons mounted on the same side. Two piston floating

calipers are found on more expensive cars and can provide an improved braking

"feel".

Four Piston Fixed Calipers are mounted rigidly to the support and are not allowed tomove. Instead, there are two pistons on each side that press the pads against the

rotor. Four piston calipers have a better feel and are more efficient, but are more

expensive to produce and cost more to service. This type of caliper is usually found

on more expensive luxury and high performance cars.


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DRUM BRAKES

So if disk brakes are so great, how come we still have cars with drum brakes? The reason is

cost. While all vehicles produced for many years have disk brakes on the front, drum brakes

are cheaper to produce for the rear wheels. The main reason is the parking brake system. On

drum brakes, adding a parking brake is the simple addition of a lever, while on disk

brakes, we need a complete mechanism, in some cases, a complete mechanical drum brake

assembly inside the disk brake rotor! Parking brakes must be a separate system that does not

use hydraulics. It must be totally mechanical, but more on parking brakes later.

Drum brakes consist of a backing plate, brake shoes, brake drum, wheel cylinder, return

springsand an automatic or self-adjusting system. When you apply the brakes, brake fluid

is forced under pressure into the wheel cylinder, which in turn pushes the brake shoes into

contact with the machined surface on the inside of the drum. When the pressure is released,

return springs pull the shoes back to their rest position. As the brake linings wear, the shoes

must travel a greater distance to reach the drum. When the distance reaches a certain point, a

self-adjusting mechanism automatically reacts by adjusting the rest position of the shoes so

that they are closer to the

drum.

Brake ShoesLike the disk pads,

brake shoes consist of a

steel shoe with the

friction material or

lining riveted or

bonded to it. Also like

disk pads, the linings

eventually wear out and

must be replaced. If

the linings are allowed

to wear through to the

bare metal shoe, they will cause severe damage to the brake drum.

Backing PlateThe backing plate is what holds everything together. It attaches to the axle and forms

a solid surface for the wheel cylinder, brake shoes and assorted hardware. It rarely

causes any problems.

Brake DrumBrake drums are made of iron and have a machined surface on the inside where the


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shoes make contact. Just as with disk rotors, brake drums will show signs of wear as

the brake linings seat themselves against the machined surface of the drum. When

new shoes are installed, the brake drum should be machined smooth. Brake drums

have a maximum diameter specification that is stamped on the outside of the drum.

When a drum is machined, it must never exceed that measurement. If the surfacecannot be machined within that limit, the drum must be replaced.

Wheel CylinderThe wheel cylinder consists of a cylinder that has two pistons, one on each side. Each

piston has a rubber seal and a shaft that connects the piston with a brake shoe. When

brake pressure is applied, the pistons are forced out pushing the shoes into contact

with the drum. Wheel cylinders must be rebuilt or replaced if they show signs of

leaking.

Return Springs Return springs pull the brake shoes back to their rest position after the pressure is

released from the wheel cylinder. If the springs are weak and do not return the shoes

all the way, it will cause premature lining wear because the linings will remain in

contact with the drum. A good technician will examine the springs during a brake job

and recommend their replacement if they show signs of fatigue. On certain vehicles,

the technician may recommend replacing them even if they look good as inexpensiveinsurance.

Self-AdjustingSystemThe parts of a self adjusting system should be clean and move freely to insure that the

brakes maintain their adjustment over the life of the linings. If the self adjusters stop

working, you will notice that you will have to step down further and further on the

brake pedal before you feel the brakes begin to engage. Disk brakes are self adjusting

by nature and do not require any type of mechanism. When a technician performs a

brake job, aside from checking the return springs, he will also clean and lubricate the

self adjusting parts where necessary.


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PARKING BRAKES

The parking brake (a.k.a. emergency brake) system controls the rear brakes through a series

of steel cables that are connected to either a hand lever or a foot pedal. The idea is that the

system is fully mechanical and completely bypasses the hydraulic system so that the vehicle

can be brought to a stop even if there is a total brake failure.

On drum brakes, the cable pulls on a lever mounted in the rear brake and is directly

connected to the brake shoes. this has the effect of bypassing the wheel cylinder and

controlling the brakes directly.

Disk brakes on the rear wheels add additional complication for parking brake systems. There

are two main designs for adding a mechanical parking brake to rear disk brakes. The first typeuses the existing rear wheel caliper and adds a lever attached to a mechanical corkscrew

device inside the caliper piston. When the parking brake cable pulls on the lever, this

corkscrew device pushes the piston against the pads, thereby bypassing the hydraulic system,

to stop the vehicle. This type of system is primarily used with single piston floating calipers,

if the caliper is of the four piston fixed type, then that type of system can't be used. The other

system uses a complete mechanical drum brake unit mounted inside the rear rotor. The brake

shoes on this system are connected to a lever that is pulled by the parking brake cable to

activate the brakes. The brake "drum" is actually the inside part of the rear brake rotor.

On cars with automatic transmissions, the parking brake is rarely used. This can cause a

couple of problems. The biggest problem is that the brake cables tend to get corroded and

eventually seize up causing the parking brake to become inoperative. By using the parking

brake from time to time, the cables stay clean and functional. Another problem comes from

the fact that the self adjusting mechanism on certain brake systems uses the parking brake

actuation to adjust the brakes. If the parking brake is never used, then the brakes never get

adjusted.


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POWER BRAKE BOOSTER

The power brake booster is mounted on the firewall directly

behind the master cylinder and, along with the master

cylinder, is directly connected with the brake pedal. Its

purpose is to amplify the available foot pressure applied to

the brake pedal so that the amount of foot pressure required

to stop even the largest vehicle is minimal. Power for the

booster comes from engine vacuum. The automobile engineproduces vacuum as a by-product of normal operation and is

freely available for use in powering accessories such as the

power brake booster. Vacuum enters the booster through a

check valve on the booster. The check valve is connected to

the engine with a rubber hose and acts as a one-way valve

that allows vacuum to enter the booster but does not let it

escape. The booster is an empty shell that is divided into two

chambers by a rubber diaphragm. There is a valve in the

diaphragm that remains open while your foot is off the brake pedal so that vacuum is allowed

to fill both chambers. When you step on the brake pedal, the valve in the diaphragm closes,

separating the two chambers and another valve opens to allow air in the chamber on the brake

pedal side. This is what provides the power assist. Power boosters are very reliable and

cause few problems of their own, however, other things can contribute to a loss of power

assist. In order to have power assist, the engine must be running. If the engine stalls or shuts

off while you are driving, you will have a small reserve of power assist for two or three pedal

applications but, after that, the brakes will be extremely hard to apply and you must put as

much pressure as you can to bring the vehicle to a stop.

Anti-Lock Brakes (ABS)

The most efficient braking pressure takes place just before each wheel locks up. When you

slam on the brakes in a panic stop and the wheels lock up, causing a screeching sound and

leaving strips of rubber on the pavement, you do not stop the vehicle nearly as short as it is

capable of stopping. Also, while the wheels are locked up, you loose all steering control so

that, if you have an opportunity to steer around the obstacle, you will not be able to do

so. Another problem occurs during an extended skid is that you will burn a patch of rubber

off the tire, which causes a "flat spot" on the tread that will produce an annoying thumping

sound as you drive.

Anti-lock brake systems solve this lockup problem by rapidly pumping the brakes whenever


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the system detects a wheel that is locked up. In most cases, only the wheel that is locked will

be pumped, while full braking pressure stays available to the other wheels. This effect allows

you to stop in the shortest amount of time while maintaining full steering control even if one

or more wheels are on ice. The system uses a computer to monitor the speed of each wheel.

When it detects that one or more wheels have stopped or are turning much slower than theremaining wheels, the computer sends a signal to momentarily remove and reapply or pulse

the pressure to the affected wheels to allow them to continue turning. This "pumping" of the

brakes occurs at ten or more times a second, far faster then a human can pump the brakes

manually. If you step on the brakes hard enough to engage the anti-lock system, you may feel

a strong vibration in the brake pedal. This is a normal condition and indicates that the system

is working, however, it can be disconcerting to some people who don't expect it. If your

vehicle has anti-lock brakes, read your owner's manual to find out more about it.

The system consists of an electronic control unit, a hydraulic actuator, and wheel speed

sensors at each wheel. If the control unit detects a malfunction in the system, it willilluminate an ABS warning light on the dash to let you know that there is a problem. If there

is a problem, the anti-lock system will not function but the brakes will otherwise function

normally.


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FINDINGS

On the completion of the training, the technical aspects that were are listed below

1. Lifting Point1.1.Safety stand point and lift up point(Front)1.2.Safety stand point and lift up point(Rear)

2. Garage Jack Point2.1.Garage Jack point(Front)2.2.Garage Jack point(Front)

3. Turbochargers3.1.Fuel3.2.Consult checking system3.3.Body control system components parts location

4. Components parts location4.1.Arrangement of combination meter

5. FRONT hydraulic piping5.1.Brake Boosters5.2.Front Disc Brake5.3.ABS actuator and electric unit5.4.Connectors5.5.Rear Drum Brakes

6. Brake piping6.1.Brake booster6.2.Master cylinder6.3.Brake tube6.4.Connector6.5.ABS(actuator and electronic unit)6.6.Lock plate6.7.Brake hose6.8.Union Bolt6.9.Copper washer6.10. 2 Front brake hose6.11. 2 Rear brake tube

7. Brake booster : The brake booster equipped with brake assist is adapted for all vehicles7.1.Master cylinder assembly7.2.Brake booster7.3.Lock Nut7.4.Clevis7.5.Gasket

8.

Brake master cylinder8.1.Sub Tank Cap


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8.2.Brake Fluid level switch8.3.Sub Tank8.4.Clamp8.5.Hose8.6.

Reservoir Tank8.7.Cylinder Body

8.8.Pin8.9.Secondary Piston Assembly8.10. Drain Plug washer8.11. Stopper Cap8.12. Seal8.13. Primary Piston Assembly

9. Front Disc Brake10.Rear Drum Brake11.Front Suspension Member12.Stabilizer13.Shock Absorber14.Rebound Spring15.High Caster Geometry


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CONCLUSION

The training was of great value which provided in depth knowledge of the subject

Mechanical Engineering. Learning the concepts with an organization like NISSAN was very

beneficial and the innovative technology used by NISSAN in Evalia was very amazing.

The topics were understood very well with their practical application and working on

them was a good job. The training was completed successfully with grasping the concepts of

Mechanical Engineering with new technologies and practically working on them.


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REFERENCES

1. The books which were followed are M. L. Mathur and F. S. Mehta Thermal Engineering R. K. Purohit

2. Websites which were followed are www.google.com www.nissanevalia.co.in autos.maxabout.com
http://www.google.com/http://www.google.com/http://www.nissanevalia.co.in/http://www.nissanevalia.co.in/http://autos.maxabout.com/http://autos.maxabout.com/http://autos.maxabout.com/http://www.nissanevalia.co.in/http://www.google.com/

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