BRAKE SYSTEMPRESENTATION

Presention by:

Muhammad ashrafAhMAD ALMADANINUR ATIRAMD NASRUDDIN

PHASE IN DESIGNING A BRAKE SYSTEM

PHASE 1 CONCEPTUAL DESIGN

PHASE 2 EMBODIMENT DESIGN

PHASE 3 DETAIL DESIGN

PHASE ONE

• BACKGROUND OF THE STUDY

• PROBLEM STATEMENT• OBJECTIVE• SCOPE OF THE PROJECT• SIGNIFICANT OF THE

PROJECT

IDENTIFY PROBLEM

• QUESTIONNAIREGATHER

INFORMATION

• FUNCTIONAL DECOMPOSITION• CONCEPT SKETCHES• MORPHLOGICAL CHART

CONCEPT GENERATION

• PUGH CONCEPT• DECISION MATRIX EVALUATION

CONCEPT EVALUATION

PH

AS

E O

NE

IDENTIFY PROBLEM(A) BACKGROUND OF THE PROJECT

Single Seater Vehicle

Usually built for racing purpose

Made up of 7 main system :1. Chassis2. Bodywork3. Safety4. Brake system5. Suspension6. Powertrain7. Steering

WOODEN BLOCK AND LEVER SYSTEM

DRUM BRAKE

HYDRAULIC BRAKE SYSTEM

IDENTIFY PROBLEM(A) BACKGROUND OF THE PROJECT

Early invention of

the brake system

IDENTIFY PROBLEM(B) PROBLEM STSTEMENT

Determine the most compatible type of braking system for the single seater

vehicle.

Determine the ability and performance of the brake system to brake within a specified time,

speed and distance frame.

IDENTIFY PROBLEM(C) OBJECTIVE

To determine the most compatible type of braking system for the single seater vehicle

To determine the ability and performance of the brake system to brake within a specified time,

speed and distance frame.

IDENTIFY PROBLEM(D) SCOPE OF THE PROJECT

Vehicle must be equipped at least one (single) independently activated braking system

The system must comprise of a single command control (pedal), command transmission (cables/hoses/lines) and activators (calipers)

The installment of the single braking system must be applied on the rear axle

The vehicle must also install a read brake light with 15 watts or more that can be seen clearly from the rear and be mounted between the wheel centerline and driver’s shoulder level vertically and approximately on vehicle centerline laterally

IDENTIFY PROBLEM(E) SIGNIFICANCE OF THE PROECT

Safety Comfort

Medium Integrate

GATHER INFORMATION

Book

Journal

ArticleQuestionnaire

Educational Video -

YouTube

QUESTIONSSCORE

Disagree Moderate Agree

1) Do u think the size and shape of the brake pedal affects your overall driving experience?2) Does placing the ergonomic brake pedal beside the throttle pedal ensures smoothness when brake is applied?3) Does applying a small or necessary amount of force on the brake pedal is the most practical way to stop (braking) ?4)Do u agree that the brake effectiveness is the most important criteria in a car? 5)Would u choose a brake system that is maintenance friendly and of less hassle to the user which bear more cost ?

6) Does the performance of the car depend on the type of brake used?

7) Are you willing to spend an appropriate sum amount of money to ensure that your car is equipped with a good braking system?

8) Is the rear brake lamp is an important aspect of any car’s braking system?

9) Does the position of the rear brake lamp affect other drivers?10) Do you think that the bright and clear brake lamp is the most important aspect in terms of safety of the car for others to see?

GATHER INFORMATION

Disagree Moderate Agree02468

10121416

0

4

16

Do you agree that the brake effectiveness is the most important criteria in a car?

Question 4

Score

Num

ber o

f Res

pond

ents

GATHER INFORMATION

Disagree Moderate Agree02468

10121416

13

16

Would you choose a brake system that is maintenance friendly and of less hassle to the user

which bear more cost ?

Question 5

Score

Num

ber o

f Res

pond

ents

GATHER INFORMATION

CONCEPT GENERATIONFU

NC

TIO

NA

L D

ECO

MPO

SITI

ON

CONCEPT GENERATION

CONCEPT GENERATIONBRAINSTORMING SKETCHES

CO

NC

EPT

1

CO

NC

EPT

2CONCEPT GENERATION

CO

NC

EPT

3CONCEPT GENERATION

Function Sub- solution

CONCEPT 1 CONCEPT 2 CONCEPT 3

1.Type of braking system

Disc Brake and Drum Break. Drum Brake Disc Brake.

2. Location of braking system

Rear :Drum Brake

Front : Disc Brake Rear Rear

3. Braking operation system Hydraulic system Cable system Hydraulic system

4.Cost Most expensive Cheap Moderate

5. Brake system effectiveness

Effective for high speed.

Effective for low to moderate

Effective for moderate to high.

6. Maintenance. Moderate to high reliability. High reliability. Moderate to high

reliability.

CONCEPT GENERATIONM

OR

PHO

LOG

ICA

L C

HA

RT

CONCEPT EVALUATIONPugh Chart Comparison Criteria and Values

Criteria CONCEPT 1 CONCEPT 2 CONCEPT 3

User Experience Most effective braking system.

Does not significantly change user experience

Effective braking system

Manufacturability Uses a mix of numerous and complex components

Has many or complex components

Uses fewer components

Safety The highest safety performance of the brake system.

The least safety performance of the brake system.

A moderate safety performance of the brake system.

Need/Market Widely used Used preferably for rear braking of a vehicle’s system

Used preferably for front braking of a vehicle’s system

Reliability Depends on the usage, as it is a mixture of both drum and disc

If appropriate usage, can withstand wear and tear. But doesn’t perform well under harsh braking conditions

A moderate amount of wear & tear period, but can withstand harsh braking conditions

Life High to moderate lifespan High lifespan Moderate lifespan.

Cost High Prototyping or Consumer cost

Low Prototyping and Consumer cost

Moderate Prototyping and Consumer cost

PUG

H C

HA

RT

DESCRIPTION Concept 1 Concept 2 Concept 3

CRITERIA WEIGHT DESIGN 1 DESIGN 2 DESIGN 3

User Experience 4 ++ + ++

Manufacturability 5 + + +

Safety 3 ++ 0 +

Need/Market 3 ++ + +

Reliability 3 ++ + +

Life 5 0 + 0

Maintenance Cost 3 - - 0

Manufacturing Cost

4 - + +

+ 28 28 26

0 0 0 0

- 0 3 0

NET SCORE 21 25 26

CONCEPT EVALUATIOND

ECIS

ION

MAT

RIX

PHASE TWO

Product Architecture

Product Architecture

• Brake Disc• Brake Calliper• Pedal• Master Cylinder• Switch• Wire• Brake Hose• Brake Lamp

Design For Human Factor

• The brake pedal (lever) should have an angle of 45 degrees.

• When the brake pedal is pushed, it should displace about another 15 degrees with a total of 60 degrees overall.

• To avoid an injury angle between 0 and 30 degrees.

• Thus the range of angle should be between 30 and 60 degrees

Modelling

Modelling of the brake disc and calliper

Modelling

Exploded view of the brake disc and calliper

Modelling

Exploded view of the brake disc and calliper

Dimensions

SIMULATION & ANALYSIS

Deformation

Von Mises Stress

Translational Displacement

Principal Stress

DETAIL CALCULATIONDeceleration rate:Assuming that the vehicle is moving at 50 km/h(13.89 m/s) and it will

be eventually in stationary in 3 seconds therefore it deceleration rate will be:

V0 = 13.89m/sV1 = 0 m/st = 3sa= = = -4.63 m/s The negative shows the deceleration.

Stopping distance:So now we are going to find the stopping distance,which could be find by using formula

which is:ds = ds= stopping distace(m)v = velocity(m/s) =Coefficient of frictiong = gravitational acceleration (m/)by taking the coefficient of friction for dry road, =0.8 Stopping distance, ds =

= = 12.29 m

 Braking time:To calculate braking time we will use this formula which isStopping time, ts = bear in mind that the stopping distance and deceleration rate have

been calculated in the previous section,therefore: =

= 2.65 seconds 

Total braking distance:To determine the total braking distance,we will use the formula as follows:total braking distance = dr + db

dr here means reaction distance which the driver needs to apply the braking force,this parameter influenced by the reaction time which can be vary with many factors such as the age of the driver,distraction during drive,condition of the road,the tendency to become very panic and etc,therefore we take the average value because it seems impossible to find the exact value for the reaction time,we take the value of treaction as 1.5 seconds, hence:

 Reaction distance: dr = (1.5 s) (13.89 m/s ) =20.835 m While db here tell us the braking distance which could be find as follows:Braking distance: db = 1/2 (V0)(ts) = 1/2(13.89 )(2.65) =18.404 m Hence our total braking distance will be:total braking distance = dr + db

=20.835 m + 14.05 m =34.885 m

Braking force:We can find the braking force by using the formula as follows:F=maF=force or in this case it should be braking force (kgm/)M=total mass (kg)a = acceleration (m/)From the requirement of this project or we called it as product design specifications,we

know that mass of the vehicle is 100 kg,and the driver’s mass is 70 kg.Therefore the total mass will be:

Total mass(kg)= mass of vehicle + driver’s mass =150 kg + 53 kg = 203 kg Therefore:F=ma =(203 ) (4.63 ) =939.89 N

 Disc Effective Radius,

The effective radius of a brake disc is calculated to find the centre of the brake pads by area. After several discussion we have decided to use inside diameter of Di = 124mm and outside diameter of D0 = 248mm. So to calculate disc effective radius we will use formula as follows:Disc effective radius, re =

= = 93mm = 0.09 m

Brake Torque:Brake torque is the moment of braking force about the center of rotation.Which

could be calculated as follows:T= F. re

Where:

T=Brake torque (N/m)F=Braking force (N)re= Disc effective radius(m)

Thus,

T= (939.89 N)( 0.093) =87.41 N.m 

Clamp Load:Clamp load is defined as force required by the calipers to stopped the brake

disc and eventually stopped the vehicle.To determine the clamp load we will use formula as follows:

Clamp load, C =

Disc effective radius,re = 0.093 mCoefficient of friction for steel alloy, µf = 0.4Friction surface contact since friction act on the 2 points in our brake disc , n = 2 Torque produce by the wheel,T = 87.41 N.m Clamp load, C =

=

= 1174.87 N 

Average Stopping Tablespeed average braking distance average driver perception-reaction time(1.5seconds) Total Stopping Distance

mph kmh feet meter feet meter feet meter

10 16.67 5 1.524 22 67.056 27 68.58

15 25.005 11 3.3528 33 100.584 44 103.9368

20 33.34 19 5.7912 44 134.112 63 139.9032

25 41.675 30 9.144 55 167.64 85 176.784

30 50.01 43 13.1064 66 201.168 109 214.2744

35 58.345 58 17.6784 77 234.696 135 252.3744

40 66.68 76 23.1648 88 268.224 164 291.3888

45 75.015 96 29.2608 99 301.752 195 331.0128

50 83.35 119 36.2712 110 335.28 229 371.5512

55 91.685 144 43.8912 121 368.808 265 412.6992

60 100.02 171 52.1208 132 402.336 303 454.4568

65 108.355 201 61.2648 143 435.864 344 497.1288

70 116.69 233 71.0184 154 469.392 387 540.4104

75 125.025 268 81.6864 165 502.92 433 584.6064

MATERIAL SELECTION

ASBESTOS

ORGANIC

SEMI-METALLIC

CERAMIC

SINTERED-METAL

BRAKE PADS

CERAMIC COMPOSITE

BRAKE DISCCARBON

CAST IRON

ALUMINUM

DESIGN FOR MANUFACTURING

BRAKE PADS

1• THE BACK PLATE IS

STAMPED DESIGNED TO FIT VEHICLE CALIPER

2• THE SURFACE IS TO BE

ROUGHEN TO INCREASED CONTACT SURFACE AREA FOR ADHESION

3• ADHENSION IS APPLIED TO

THE BACK PLATE, READY TO BOND WITH FRICTION METAL (PADS)

BACKING PLATE

MAIN PROCESS

1• THE FORMULA OF THE RAW

MATERIAL IS GATHERED

2• THE RAW MATERIAL BLENDED

TOGETHER TO GIVE OUT FINE PARTICLES

3• THE BLENDED MATERIAL GET

MOLDED INTO BRICK SHAPED UNDER HIGH PRESSURE AND TEMPERATURE

4• THE BRICK SHAPED FRICTION

METAL UNDERGOES BONDING WITH BACKING PLATE

5• THE ASSEMBLE PART IS PUT

UNDER CONSTANT HEATING TO ENSURE EVERLAST JOINING

6• THE ASSEMBLE IS PAINTED FOR

PROTECTION OF OXIDATION AND AESTHATHIC VALUE

7• THE PARTS UNDERGOES LATHE

MACHINING FOR GROOVING, CHAMFERING AND GRINDING

8• THE PARTS IS BRANDED TO

ENSURE THOSE ARE FIT TO THE CORRECT TYPE OF CAR

9

• THE SENSOR IS RIVETED TO INFORM THE DRIVERS AT WHAT MOMENT CAN THEY CHANGE THE PADS

10• THE BRAKE PADS MUST BE

INSPECTED TO ENSURE THE QUALITY OF ASSEMBLY

11• THE BRAKE PADS ARE PACKED

FOR SAFE KEEPING, TRANSPORTATION AND SALES

12

• EXCESSIVE PRODUCED BRAKE PADS ARE STORED IN WAREHOUSE FOR FURTHER ORDER AND SAFEKEEPING

BRAKE DISC

RAW MATERIAL TURNED INTO MOLTEN METAL

MOLTEN METAL UNDERGOES DIE CASTING PROCESS

THE PRODUCT IS THEN UNDERGOES SECONDARY PROCESS

EACH PRODUCED DISC IS INSPECTED TO ENSURE ITS QUALITY

THE DISC IS PACKAGED FOR TRANSPORTATION, SALES OR STORAGE

DESIGN FOR ASSEMBLY

PARTS OF BRAKES

INSERTION AND FASTENING

DESIGN FOR ROBUSTNESS

BRAKE HOSE

FAILURE MODE AND EFFECT ANALYSIS

ITEM FAILURE MODE

FAILURE

CAUSES

CURRENT

CONTROL

ACTION RECOMMENDE

D

ACTIONS

TAKEN

PHASE THREE

Bill of Material

Part Name Material QuantityBrake Disc Grey cast iron 1

Brake Disc Mount Cast iron 1

Hexagonal Bolt Stainless Steel 4

Hexagonal Nut Stainless Steel 4

Washer Stainless Steel 8

BOM for Brake Disc Assembly

Bill of Material

Part Name Material QuantityCaliper Casing Cast aluminium 2

Brake Pad Ceramic 2

Screw Pin Stainless steel 2

Piston Stainless Steel 4

Octagonal-holed bolt Stainless Steel 2

Pad Support Stainless Steel 2

BOM for Brake Caliper Assembly

Bill of Material

Part Name Material QuantityPiston Stainless Steel 1

Buffer Stainless Steel 1

Connector Stainless steel 1

Pedal Stainless Steel 1

Reservoir Plastic 1

Master Cylinder Aluminium 1

Cap Plastic 1

Base Stainless Steel 1

Hub Stainless Steel 1

BOM for Brake Pedal Assembly

COSTItem Material Quantity Price Per

Unit (RM)Total Price

(RM)Brake Pads Ceramic (1pair) 90 90

Brake Disc Cast Iron 1 110 110

Cable Polyurethane 3 meter 6 18

Caliper Mount Stainless Steel 1 46 46

Master Cylinder

Aluminium 1 193 193

Caliper Aluminium 1 120 120

Brake Pedal Zinc Plated Stainless Steel

1 17 17

Brake Lamp - 1 29 29

Total Cost 623

THANK YOU