In view of this, refinement at the sub system level is becoming far more critical. On the same lines, the present work discusses a refined brake system for Light Commercial Vehicles where the conventional pneumatic system is replaced with Dual Air Over Hydraulic (DAOH) to achieve cost and weight advantages without compromising on its performance. However, during the development process, a lot of issues were observed with respect to the braking performance and the brake pedal feel. The proposed work focuses specifically on analyzing the cause of such problems and suggesting a solution by optimization of this alternate braking system to achieve better overall performance Vis-à-Vis current system with significant reduction in weight by almost 20% and cost by 5%.
'DAOH' (Dual Air Over Hydraulic) with foundation brake configuration of front - disc and rear - drum is being developed for 7 ton - 9.6 ton gross vehicle weight vehicles. Particularly optimization of pedal ergonomics and pedal characteristics (utilization of pedal travel) is carried out to achieve enhanced performance in terms of: Stopping distance, Deceleration, Brake pedal feel and driving confidence.