ts_17 Brake Package Upgrade

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Aim

• Design a minimum15% lighter brake system • Comply with FSAE regulations• More compact system• Increase performance

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The Problem Existing System:• Too Heavy• Too Large Update:• Lighter material• Smaller size for better packaging• Lighter manufacturing

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Knowledge• Performance calculations/system modelling 

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Existing Knowledge• Knowledge transfer from ts_14 to ts_17

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New Knowledge• Caliper design and manufacture technique• 5-axis CNC • Braking balance • Car setup• FEA/FMEA

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Brainstorming

A mindmap was drawn to identify the components and requirements that would need our attention during this project.

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Concept 1: 2 piston lightweight caliper

Pros• Lightweight• Neatly packaged

Cons• Not rigid enough (poor

pedal feel)

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Concept 2: 4 piston caliper

Pros• Even pad wear• Greater clamp force

Cons• Heavy• Large

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Final concept: Rigid 2 piston caliper

• Final design is a 2 piston caliper• Machined from billet aluminium• Held together with 2 steel bolts• Made to fit Bendix pad that is

currently used in TS_16• Non-handed (symmetrical)• Compatible with TS_16 disc rotor

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Forward Looking• Interfacing with other vehicle components• Communication with other groups• Reverse compatibility

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Questions?