Aircraft Brakes

Very early aircraft have no brake system to slow and stop the aircraft while it is on the ground. Instead, they rely on slow speeds, soft airfield surfaces, and the friction developed by the tail skid to reduce speed during ground operation. Brake systems designed for aircraft became common after World War I as the speed and complexity of aircraft increased, and the use of smooth, paved runway surfaces proliferated. All modern aircraft are equipped with brakes. Their proper functioning is relied upon for safe operation of the aircraft on the ground. The brakes slow the aircraft and stop it in a reasonable amount of time. They hold the aircraft stationary during engine run-up and, in many cases, steer the aircraft during taxi. On most aircraft, each of the main wheels is equipped with a brake unit. The nose wheel or tail wheel does not have a brake.

In the typical brake system, mechanical and/or hydraulic linkages to the rudder pedals allow the pilot to control the brakes. Pushing on the top of the right rudder pedal activates the brake on the right main wheel(s) and pushing on the top of the left rudder pedal operates the brake on the left main wheel(s). The basic operation of brakes involves converting the kinetic energy of motion into heat energy through the creation of friction. A great amount of heat is developed and forces on the brake system components are demanding. Proper adjustment, inspection, and maintenance of the brakes is essential for effective operation.

Types and Construction of Aircraft Brakes 

Modern aircraft typically use disc brakes. The disc rotates with the turning wheel assembly while a stationary caliper resists the rotation by causing friction against the disc when the brakes are applied. The size, weight, and landing speed of the aircraft influence the design and complexity of the disc brake system. Single, dual, and multiple disc brakes are common types of brakes. Segmented rotor brakes are used on large aircraft. Expander tube brakes are found on older large aircraft. The use of carbon discs is increasing in the modern aviation fleet.  

Single Disc Brakes 

Small, light aircraft typically achieve effective braking using a single disc keyed or bolted to each wheel. As the wheel turns, so does the disc. Braking is accomplished by applying friction to both sides of the disc from a non-rotating caliper bolted to the landing gear axle flange. Pistons in the caliper housing under hydraulic pressure force wearable brake pads or linings against the disc when the brakes are applied. Hydraulic master cylinders connected to the rudder pedals supply the pressure when the upper halves of the rudder pedals are pressed.

Dual-Disc Brakes 

Dual-disc brakes are used on aircraft where a single disc on each wheel does not supply sufficient braking friction. Two discs are keyed to the wheel instead of one. A center carrier is located between the two discs. It contains linings on each side that contact each of the discs when the brakes are applied. The caliper mounting bolts are long and mount through the center carrier, as well as the backplate which bolts to the housing assembly.

Multiple-Disc Brakes 

Large, heavy aircraft require the use of multiple-disc brakes. Multiple-disc brakes are heavy duty brakes designed for use with power brake control valves or power boost master cylinders, which is discussed later in this chapter. The brake assembly consists of an extended bearing carrier similar to a torque tube type unit that bolts to the axle flange. It supports the various brake parts, including an annular cylinder and piston, a series of steel discs alternating with copper or bronze-plated discs, a backplate, and a backplate retainer. The steel stators are keyed to the bearing carrier, and the copper or bronze plated rotors are keyed to the rotating wheel. Hydraulic pressure applied to the piston causes the entire stack of stators and rotors to be compressed. This creates enormous friction and heat and slows the rotation of the wheel.

Segmented Rotor-Disc Brakes 

The large amount of heat generated while slowing the rotation of the wheels on large and high-performance aircraft is problematic. To better dissipate this heat, segmented rotordisc brakes have been developed. Segmented rotor-disc brakes are multiple-disc brakes but of more modern design than the type discussed earlier. There are many variations. Most feature numerous elements that aid in the control and dissipation of heat. Segmented rotor-disc brakes are heavy-duty brakes especially adapted for use with the high pressure hydraulic systems of power brake systems. Braking is accomplished by means of several sets of stationary, high friction type brake linings that make contact with rotating segments. The rotors are constructed with slots or in sections with space between them, which helps dissipate heat and give the brake its name. Segmented rotor multiple-disc brakes are the standard brake used on high performance and air carrier aircraft.

Carbon Brakes 

The segmented multiple-disc brake has given many years of reliable service to the aviation industry. It has evolved through time in an effort to make it lightweight and to dissipate the frictional heat of braking in a quick, safe manner. The latest iteration of the multiple-disc brake is the carbon-disc brake. It is currently found on high performance and air carrier aircraft. Carbon brakes are so named because carbon fiber materials are used to construct the brake rotors.

Expander Tube Brakes 

An expander tube brake is a different approach to braking that is used on aircraft of all sizes produced in the 1930s–1950s. It is a lightweight, low pressure brake bolted to the axle flange that fits inside an iron brake drum. A flat, fabric-reinforced neoprene tube is fitted around the circumference of a wheellike torque flange. The exposed flat surface of the expander tube is lined with brake blocks similar to brake lining material. Two flat frames bolt to the sides of the torque flange. Tabs on the frames contain the tube and allow evenly spaced torque bars to be bolted in place across the tube between each brake block. These prevent circumferential movement of the tube on the flange.

Brake Actuating Systems 

The various brake assemblies, described in the previous section, all use hydraulic power to operate. Different means of delivering the required hydraulic fluid pressure to brake assemblies are discussed in this section. There are three basic actuating systems: 

1. An independent system not part of the aircraft main hydraulic system;

2. A booster system that uses the aircraft hydraulic system intermittently when needed; and 

3. A power brake system that only uses the aircraft main hydraulic system(s) as a source of pressure. 

Independent Master Cylinders 

In general, small, light aircraft and aircraft without hydraulic systems use independent braking systems. An independent brake system is not connected in any way to the aircraft hydraulic system. Master cylinders are used to develop the necessary hydraulic pressure to operate the brakes. This is similar to the brake system of an automobile.

In most brake actuating systems, the pilot pushes on the tops of the rudder pedals to apply the brakes. A master cylinder for each brake is mechanically connected to the corresponding rudder pedal (i.e., right main brake to the right rudder pedal, left main brake to the left rudder pedal). When the pedal is depressed, a piston inside a sealed fluidfilled chamber in the master cylinder forces hydraulic fluid through a line to the piston(s) in the brake assembly. The brake piston(s) push the brake linings against the brake rotor to create the friction that slows the wheel rotation. Pressure is increased throughout the entire brake systems and against the rotor as the pedal is pushed harder.

Boosted Brakes 

In an independent braking system, the pressure applied to the brakes is only as great as the foot pressure applied to the top of the rudder pedal. Boosted brake actuating systems augment the force developed by the pilot with hydraulic system pressure when needed. The boost is only during heavy braking. It results in greater pressure applied to the brakes than the pilot alone can provide. Boosted brakes are used on medium and larger aircraft that do not require a full power brake actuating system.

Power Brakes 

Large and high-performance aircraft are equipped with power brakes to slow, stop, and hold the aircraft. Power brake actuating systems use the aircraft hydraulic system as the source of power to apply the brakes. The pilot presses on the top of the rudder pedal for braking as with the other actuating systems. The volume and pressure of hydraulic fluid required cannot be produced by a master cylinder. Instead, a power brake control valve or brake metering valve receives the brake pedal input either directly or through linkages. The valve meters hydraulic fluid to the corresponding brake assembly in direct relation to the pressure applied to the pedal.

Brake Control Valve/Brake Metering Valve 

The key element in a power brake system is the brake control valve, sometimes called a brake metering valve. It responds to brake pedal input by directing aircraft system hydraulic fluid to the brakes. As pressure is increased on the brake pedal, more fluid is directed to the brake causing a higher pressure and greater braking action. 

Emergency Brake Systems 

As can be seen in Figure, the brake metering valves not only receive hydraulic pressure from two separate hydraulic systems, they also feed two separate brake assemblies. Each main wheel assembly has two wheels. The inboard wheel brake and the outboard wheel brake, located in their respective wheel rims, are independent from each other. In case of hydraulic system failure or brake failure, each is independently supplied to adequately slow and stop the aircraft without the other. More complicated aircraft may involve another hydraulic system for back-up or use a similar alternation of sources and brake assemblies to maintain braking in case of hydraulic system or brake failure. 

NOTE: In the segmented rotor brake section above, a brake assembly was described that had alternating pistons supplied by independent hydraulic sources. This is another method of redundancy particularly suitable on, but not limited to, single main wheel aircraft.

Parking Brake 

The parking brake system function is a combined operation. The brakes are applied with the rudder pedals and a ratcheting system holds them in place when the parking brake lever on the flight deck is pulled. 

At the same time, a shut-off valve is closed in the common return line from the brakes to the hydraulic system. This traps the fluid in the brakes holding the rotors stationary. Depressing the pedals further releases the pedal ratchet and opens the return line valve.

Brake Deboosters 

Some aircraft brake assemblies that operate on aircraft hydraulic system pressure are not designed for such high pressure. They provide effective braking through a power brake system but require less than maximum hydraulic system pressure. To supply the lower pressure, a brake debooster cylinder is installed downstream of the control valve and anti-skid valve. The debooster reduces all pressure from the control valve to within the working range of the brake assembly.

Anti-Skid 

Large aircraft with power brakes require anti-skid systems. It is not possible to immediately ascertain in the flight deck when a wheel stops rotating and begins to skid, especially in aircraft with multiple-wheel main landing gear assemblies. A skid not corrected can quickly lead to a tire blowout, possible damage to the aircraft, and control of the aircraft may be lost.

The anti-skid system not only detects wheel skid, it also detects when wheel skid is imminent. It automatically relieves pressure to the brake pistons of the wheel in question by momentarily connecting the pressurized brake fluid area to the hydraulic system return line. This allows the wheel to rotate and avoid a skid. Lower pressure is then maintained to the brake at a level that slows the wheel without causing it to skid.

Maximum braking efficiency exists when the wheels are decelerating at a maximum rate but are not skidding. If a wheel decelerates too fast, it is an indication that the brakes are about to lock and cause a skid. To ensure that this does not happen, each wheel is monitored for a deceleration rate faster than a preset rate. When excessive deceleration is detected, hydraulic pressure is reduced to the brake on that wheel. To operate the anti-skid system, flight deck switches must be placed in the ON position. After the aircraft touches down, the pilot applies and holds full pressure to the rudder brake pedals. The anti-skid system then functions automatically until the speed of the aircraft has dropped to approximately 20 mph. The system returns to manual braking mode for slow taxi and ground maneuvering. 

There are various designs of anti-skid systems. Most contain three main types of components: wheel speed sensors, antiskid control valves, and a control unit. These units work together without human interference. Some anti-skid systems provide complete automatic braking. The pilot needs only to turn on the auto brake system, and the anti-skid components slow the aircraft without pedal input. Ground safety switches are wired into the circuitry for anti-skid and auto brake systems. Wheel speed sensors are located on each wheel equipped with a brake assembly. Each brake also has its own anti-skid control valve. Typically, a single control box contains the anti-skid comparative circuitry for all of the brakes on the aircraft.

Anti-Skid Control Valves 

Anti-skid control valves are fast-acting, electrically controlled hydraulic valves that respond to the input from the anti-skid control unit. There is one control valve for each brake assembly. A torque motor uses the input from the valve driver to adjust the position of a flapper between two nozzles. By moving the flapper closer to one nozzle or the other, pressures are developed in the second stage of the valve. These pressures act on a spool that is positioned to build or reduce pressure to the brake by opening and blocking fluid ports.

Touchdown and Lock Wheel Protection 

It is essential that the brakes are not applied when the aircraft contacts the runway upon landing. This could cause immediate tire blowout. A touchdown protection mode is built into most aircraft anti-skid systems to prevent this. It typically functions in conjunction with the wheel speed sensor and the air/ground safety switch on the landing gear strut (squat switch). Until the aircraft has weight on wheels, the detector circuitry signals the anti-skid control valve to open the passage between the brakes and the hydraulic system return, thus preventing pressure build-up and application of the brakes. Once the squat switch is open, the anti-skid control unit sends a signal to the control valve to close and permit brake pressure build-up. As a back-up and when the aircraft is on the ground with the strut not compressed enough to open the squat switch, a minimum wheel speed sensor signal can override and allow braking. Wheels are often grouped with one relying on the squat switch and the other on wheel speed sensor output to ensure braking when the aircraft is on the ground, but not before then.

Auto Brakes 

Aircraft equipped with auto brakes typically bypass the brake control valves or brake metering valves and use a separate auto brake control valve to provide this function. In addition to the redundancy provided, auto brakes rely on the anti-skid system to adjust pressure to the brakes if required due to an impending skid. Figure shows a simplified diagram of the Boeing 757 brake system with the auto brake valve in relation to the main metering valve and anti-skid valves in this eight-main wheel system.

Brake Inspection and Service 

Brake inspection and service is important to keep these critical aircraft components fully functional at all times. There are many different brake systems on aircraft. Brake system maintenance is performed both while the brakes are installed on the aircraft and when the brakes are removed. The manufacturer’s instructions must always be followed to ensure proper maintenance. 

Inspection and servicing of aircraft brakes while installed on the aircraft is required. The entire brake system must be inspected in accordance with manufacturer’s instructions. Some common inspection items include: brake lining wear, air in the brake system, fluid quantity level, leaks, and proper bolt torque.

Lining Wear. Brake lining material is made to wear as it causes friction during application of the brakes. This wear must be monitored to ensure it is not worn beyond limits and sufficient lining is available for effective braking. The aircraft manufacturer gives specifications for lining wear in its maintenance information. The amount of wear can be checked while the brakes are installed on the aircraft.   

Air in the Brake System 

The presence of air in the brake system fluid causes the brake pedal to feel spongy. The air can be removed by bleeding to restore firm brake pedal feel. Brake systems must be bled according to manufacturers’ instructions. The method used is matched to the type of brake system. Brakes are bled by one of two methods: top down, gravity bleeding or bottom up pressure bleeding. Brakes are bled when the pedals feel spongy or whenever the brake system has been opened. 

Bleeding Master Cylinder Brake Systems 

Brake systems with master cylinders may be bled by gravity or pressure bleeding methods. Follow the instructions in the aircraft maintenance manual. To pressure bleed a brake system from the bottom up, a pressure pot is used. This is a portable tank that contains a supply of brake fluid under pressure. When dispersing fluid from the tank, pure air-free fluid is forced from near the bottom of the tank by the air pressure above it. The outlet hose that attaches the bleed port on the brake assembly contains a shutoff valve. Note that a similar source of pure, pressurized fluid can be substituted for a pressure tank, such as a hand-pump type unit found in some hangars.

Bleeding Power Brake Systems 

Top down brake bleeding is used in power brake systems. Power brakes are supplied with fluid from the aircraft hydraulic system. The hydraulic system should operate without air in the fluid as should the brake system. Therefore, bottom up pressure bleeding is not an option for power brakes. The trapped air in the brake system would be forced into the main hydraulic system, which is not acceptable. 

Brake Malfunctions and Damage 

Aircraft brakes operate under extreme stress and varied conditions. They are susceptible to malfunction and damage. A few common brake problems are discussed in this section. 

Overheating. While aircraft brakes slow the aircraft by changing kinetic energy into heat energy, overheating of the brakes is not desirable. Excessive heat can damage and distort brake parts weakening them to the point of failure. Protocol for brake usage is designed to prevent overheating. When a brake shows signs of overheating, it must be removed from the aircraft and inspected for damage. When an aircraft is involved in an aborted takeoff, the brakes must be removed and inspected to ensure they withstood this high level of use. 

The typical post-overheat brake inspection involves removal of the brake from the aircraft and disassembly of the brakes. All of the seals must be replaced. The brake housing must be checked for cracks, warping, and hardness per the maintenance manual. Any weakness or loss of heat treatment could cause the brake to fail under high-pressure braking. The brake discs must also be inspected. They must not be warped, and the surface treatment must not be damaged or transferred to an adjacent disc. Once reassembled, the brake should be bench tested for leaks and pressure tested for operation before being installed on the aircraft.

Dragging. Brake drag is a condition caused by the linings not retracting from the brake disc when the brakes are no longer being applied. It can be caused by several different factors. Brakes that drag are essentially partially on at all times. This can cause excessive lining wear and overheating leading to damage to the disc(s). 

A brake may drag when the return mechanism is not functioning properly. This could be due to a weak return spring, the return pin slipping in the auto adjuster pin grip, or similar malfunction. Inspect the auto adjuster(s) and return units on the brake when dragging is reported. An overheated brake that has warped the disc also causes brake drag. Remove the brake and perform a complete inspection as discussed in the previous section. Air in the brake fluid line can also cause brake drag. Heat causes the air to expand, which pushes the brake linings against the disc prematurely. If no damage has been caused when reported, bleed the brakes to remove the air from the system to eliminate the drag.

At all times, the technician should perform inspections to ensure the proper parts are used in the brake assembly. Improper parts, especially in the retraction/adjuster assemblies, can cause the brakes to drag.

Chattering or Squealing. Brakes may chatter or squeal when the linings do not ride smoothly and evenly along the disc. A warped disc(s) in a multiple brake disc stack produces a condition wherein the brake is actually applied and removed many times per minute. This causes chattering and, at high frequency, it causes squealing. Any misalignment of the disc stack out of parallel causes the same phenomenon. Discs that have been overheated may have damage to the surface layer of the disc. Some of this mix may be transferred to the adjacent disc resulting in uneven disc surfaces that also leads to chatter or squeal. In addition to the noise produced by brake chattering and squealing, vibration is caused that may lead to further damage of the brake and the landing gear system. The technician must investigate all reports of brake chattering and squealing.