重型卡车制动系统-中英文版2015-10解析.ppt

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1、0Chassis Department of C&C Trucks Co., Ltd. Research Institute 2015年年9月月 September, 2015 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系统主要部件功用及工作原理 Chapter

2、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 Troubleshooting1目录目录 Contents1、制动系的功用：、制动系的功用：Functions of Brake Sy

3、stem: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).2、制动系的类型：、制动系的类型

4、： 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: Combining with

5、 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 device: such as

6、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 brake2一、概述一、概述 Chapter 1 Overview3驻车手阀驻车手

7、阀+挂车手阀挂车手阀Parking Brake + Trailer Parking Brake 前盘式制动器前盘式制动器+气室气室Front Disc Brake + Air Chamber 挂车连接头及管路挂车连接头及管路Trailer Connector and Pipeline制动大管束及散管制动大管束及散管 Big Brake Pipe Bundle and Separate Pipes后后ABS电磁阀电磁阀 Rear ABS Solenoid Valve前前ABS电磁阀电磁阀Front ABS Solenoid Valve挂车阀挂车阀Trailer Valve空压机空压机Air Co

8、mpressor制动踏板制动踏板+脚阀脚阀Brake Pedal + Service Brake制动硬管制动硬管Brake Hard Pipe限压阀限压阀Relief Valve四回路四回路Four-circuit干燥器干燥器 Dryer差动阀差动阀Differential Valve继动阀继动阀Relay Valve后桥盘式制动器及制动气室后桥盘式制动器及制动气室 Rear Axle Disc Brake and Brake Chamber储气筒模块储气筒模块Air Reservoir Module排气制动蝶阀排气制动蝶阀Exhaust Brake Butterfly Valve二、制动系统

9、构造二、制动系统构造 Chapter 2 Brake System Construction多通接头多通接头Multi-way Connector前继动阀前继动阀Front Relay Valve储气筒储气筒Air Reservoir适配阀适配阀Adaptation Valve挂车挂车ABS电磁阀电磁阀ABS For Trailer变速箱变速箱+缓速缓速器器Transmission and Retarder储气筒储气筒Air Reservoir 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 Sy

10、stem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,

11、dryer, four-circuit, air reservoir and other related components 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

12、;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 components are the brakes at the end of the air circuits and the relevant executive air circuits.4执行元件部分执行元件部分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 Part 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

13、）牵引车为例）1. See the following drawing for the operating principle 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 ai

14、r circuit is roughly divided into: service brake, parking brake, supplemental brake, other auxiliary air and ect. Next, the operating principles of these braking methods will be described in detail.5三、制动系统工作原理三、制动系统工作原理 Chapter 3 Operating Principle of Brake System6a.行车制动：行车制动：Service Brake:联合卡车行车制动

15、采用双回路气压制动系统。即前行车制动回路和后行车制动回路，二者彼此独立。见下图线条加粗联合卡车行车制动采用双回路气压制动系统。即前行车制动回路和后行车制动回路，二者彼此独立。见下图线条加粗部分，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

16、circuit, which are independent. As shown by the bold lines in the drawing, the red represents the front service brake circuit, the green represents the rear service brake circuit.脚阀脚阀 Service Brake踏板踏板Pedal制动气室制动气室 Brake Chamber制动器制动器 Brake行车制动操纵装置行车制动操纵装置 Service Brake Operating Device行车制动执行装置行车制动执

17、行装置 Service Brake Execution Device7当需要车辆减速或遇红绿灯等其余路况需要临时停车时，驾驶员踩下制动踏板，顶杆下移，推动制动总阀当需要车辆减速或遇红绿灯等其余路况需要临时停车时，驾驶员踩下制动踏板，顶杆下移，推动制动总阀8的顶杆座下移的顶杆座下移，消除排气间隙，制动总阀排气阀门关闭，进气阀门被打开，这时由后桥储气筒，消除排气间隙，制动总阀排气阀门关闭，进气阀门被打开，这时由后桥储气筒4过来的控制气流经制动总阀上腔流向后过来的控制气流经制动总阀上腔流向后继动阀继动阀10的控制口，通过气流压力打开继动阀进气阀门，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

18、后的控制口，通过气流压力打开继动阀进气阀门，这时由后桥储气筒过来的供能气流便经继动阀进出气口，到后桥行车气室桥行车气室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 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 ro

19、d seat of the brake valve 8 is pushed downward to eliminate the exhaust clearance, the exhaust valve 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

20、 the control port of the rear relay valve 10, the intake valve of the relay valve is opened by the air flow 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

21、 the service braking of the center rear axle.与此同时，由前桥储气筒与此同时，由前桥储气筒5过来的控制气流经制动总阀下腔流向前继动阀过来的控制气流经制动总阀下腔流向前继动阀10的控制口，通过气流压力打开继动阀进气阀门的控制口，通过气流压力打开继动阀进气阀门，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

22、air reservoir 5 passes through the lower chamber on the brake valve, flowing into the control port of the front relay 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 o

23、f the relay valve , flowing into the front axle brake chamber 13, achieving the service braking of the front axle.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

24、 of the trailer valve 17 to control the trailer brake.8b.驻车制动：驻车制动：Parking Brake:驻车制动用于使驻车制动用于使已停驶的汽车在原地（包括在斜坡上）驻留不动。已停驶的汽车在原地（包括在斜坡上）驻留不动。联合卡车驻车制动采用手控阀弹簧储能制动。见下图联合卡车驻车制动采用手控阀弹簧储能制动。见下图线条加粗部分，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 veh

25、icle in original location (including on the slope). The C&C truck parking brake uses the energy stored in the parking brake spring 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 co

26、ntrol air circuit.驻车手阀驻车手阀Parking Brake 驻车制动操纵装置驻车制动操纵装置 Parking Brake Operating Device弹簧制动气室弹簧制动气室 Spring Brake Cylinder 制动器制动器 Brake驻车制动执行装置驻车制动执行装置 Parking Brake Execution Device9当需要车辆停驻时，驾驶员拉动驻车手阀手柄当需要车辆停驻时，驾驶员拉动驻车手阀手柄12 ，手阀进气阀门关闭，排气阀门打开，这时由驻车手阀到差动式继动阀，手阀进气阀门关闭，排气阀门打开，这时由驻车手阀到差动式继动阀11的控制气流便经驻车手阀

27、排气口排出，施加在差动式继动阀控制口上的气压解除，差动式继动阀进气阀门关闭，排气阀门的控制气流便经驻车手阀排气口排出，施加在差动式继动阀控制口上的气压解除，差动式继动阀进气阀门关闭，排气阀门打开，这时中后桥弹簧制动气室打开，这时中后桥弹簧制动气室14的压缩空气便由制动软管流向差动式继动阀，经差动式继动阀排气口排出，弹簧释放，的压缩空气便由制动软管流向差动式继动阀，经差动式继动阀排气口排出，弹簧释放，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 hand

28、le 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 relay valve 11 is discharged from the exhaust port of the parking brake, the air pressure applied to the control port of the differential relay

29、 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 spring brake chamber 14 flows to the differential relay valve through brake hoses, and is discharged from the exhaust port of the differe

30、ntial relay valve, the spring is released, achieving the parking brake.对于牵引车，由驻车手阀到挂车手阀对于牵引车，由驻车手阀到挂车手阀18的控制气流同时经驻车手阀排气口排出，挂车手阀排气阀门打开，由挂车手阀到挂的控制气流同时经驻车手阀排气口排出，挂车手阀排气阀门打开，由挂车手阀到挂车阀车阀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

31、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 controlled air flow from the trailer parking brake to the trailer valve 17 is discharged from the exhaust port of the trailer park

32、ing brake to control the trailer parking brake. c.辅助制动：辅助制动：Supplemental Brake:辅助制动是主要用于汽车下长坡时，持续的减速或保持车速稳定，并减轻或解除行车制动装置的负荷，从而提高辅助制动是主要用于汽车下长坡时，持续的减速或保持车速稳定，并减轻或解除行车制动装置的负荷，从而提高坡道行车安全，提高制动器使用寿命。坡道行车安全，提高制动器使用寿命。The supplemental brake is operating when the vehicle runs on a long downhill, it reduces

33、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 service life.联合卡车辅助制动分为：压缩释放制动联合卡车辅助制动分为：压缩释放制动+排气制动排气制动(YC6K12)、压缩释放制动（、压缩释放制动（ISME）、泄气制动）、泄气制动+排气制动排气制动(YC6K10)、排气制动（、排气制动（YC

34、6MK）。）。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 brake (YC6MK).10COMPRESSION RELEASE BRAKE(ENGINNE BRAKE)压缩释放制动器压缩释放制动器(发动机制动器发动机制动器)BLEEDER BRAKE泄气制动器泄气制动器EX

35、HAUST BRAKE排气制动器排气制动器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 恒压压缩释放制动：压缩释放制动：Compression Release Brake:压缩释放制动是在发动机压缩冲程上止点，打开排气门，使高压气体经排气门排出，使得做功冲程中无能量返回活塞，压缩释放制动是在发动机压缩冲程上止点，打开排气门，使高压气体经排气门排出，使得做功冲程中无能量返回活塞，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

36、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 the exhaust valve and no energy returns to the piston during the power stroke, resulting in the n

37、et 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. 11Intake 进气进气Compression 压缩压缩Release 释放释放Expansion膨胀膨胀Exhaust排气排气 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，在膨胀泄气制动是在

38、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，使发动机降速，从而实现整车缓速。阻力，使发动机降速，从而实现整车缓速。Bleeder brake opens the exhaust valve during the four engine strokes. The compressed air is discharged from the exhaust v

39、alve 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 to form the exhaust back pressure and provide the resistance to the exhaust stroke

40、, then the engine speed is reduced, achieving the goal of slowing down the complete vehicles speed.12Intake 进气进气Compression 压缩压缩Expansion膨胀膨胀Exhaust排气排气排气制动：排气制动： Exhaust Brake:排气制动是通过关闭安装在排气管上的蝶形阀门，阻止发动机排气冲程中的气流流出，增加排气背压，在发动机排气制动是通过关闭安装在排气管上的蝶形阀门，阻止发动机排气冲程中的气流流出，增加排气背压，在发动机排气冲程提供阻力，使发动机降速，实现制动。排气冲程

41、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 resistance during the engine exhaust stroke, reduces the engine speed,

42、 and achieves the braking.13 d.应急制动：应急制动：d.Emergency Brake:应急制动用于主制动供能装置出现压力过低等故障时，通过应急制动装置实现汽车制动。联合卡车应急制动与驻应急制动用于主制动供能装置出现压力过低等故障时，通过应急制动装置实现汽车制动。联合卡车应急制动与驻车制动相结合，控制及执行装置同驻车制动。车制动相结合，控制及执行装置同驻车制动。When the main brake supply device has problems such as low pressure, the emergency brake uses the emerg

43、ency 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 Butterfly Valve继动阀继动阀Relay Valve 差动阀差动阀Differential Valve 挂车阀挂车阀Trai

44、ler 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 15四、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 Operating Principle of Main Brake System Components驻车手阀驻车手阀Parking

45、Brake1. 空压机空压机 1. Air Compressor a.功用：空压机作为发动机附件装与发动机上，由发动机驱动，向制动系统及其它功用：空压机作为发动机附件装与发动机上，由发动机驱动，向制动系统及其它辅助用气系统提供能量。辅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 supplies energy to the brake system and other auxiliary g

46、as 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曲柄连杆机构。The air compressor has a crank link me

47、chanism just like that of the engine.发动机运转时，空压机随之运转。当活塞下行时发动机运转时，空压机随之运转。当活塞下行时，外界空气经进气歧管（增压进气）外界空气经进气歧管（增压进气）或空滤后（自然吸气）被吸人气缸；活塞上行时，缸内空气即被压缩，压力升高、或空滤后（自然吸气）被吸人气缸；活塞上行时，缸内空气即被压缩，压力升高、克服排气阀弹簧的顶紧力使排气门开启，压缩空气便经出气克服排气阀弹簧的顶紧力使排气门开启，压缩空气便经出气口流向干燥器及后续制口流向干燥器及后续制动气路，从而实现向制动气路供气动气路，从而实现向制动气路供气。When the engine

48、 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 is compressed, the pressur

49、e 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.功用：对来自空压机的压缩空气进行吸附干燥，防止管路及系

50、统内其他金属件功用：对来自空压机的压缩空气进行吸附干燥，防止管路及系统内其他金属件锈蚀、橡胶件龟裂、润滑脂分解、管路堵塞等故障，增加制动系统的可靠性。集锈蚀、橡胶件龟裂、润滑脂分解、管路堵塞等故障，增加制动系统的可靠性。集成的调压阀能自动调节系统压力，集成的安全阀可防止气路过压，集成的加热装成的调压阀能自动调节系统压力，集成的安全阀可防止气路过压，集成的加热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 pipeline