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brake layout
brake layout
Vehicle calculation
Vehicle calculation
Brake Proportioning
Choose Brake Proportioning at 0.8 (Rear brake force/Front Brake force) to operate the front brake lock before the rear brake to avoid loss of stability
Braking Force
Required Braking Torque
Front
Required torque 257 N
Rear
Required torque 230 N
Braking system calculation and characteristics of selected and design components
Braking system calculation and characteristics of selected and design components
Pedal Box
Brake Pedal ratio X:Y = 6:1
Brake Peadl Ratio
Because the formula student competition does not permit the use of booster brakes, the human power has been increased by the pedal leverage ratio and applied to the master cylinder. The pedal ratio that best suited the design and computation was determined to be 6:1 (Typical non-boosted ratios range from 6:1 to 7:1, with booster pedals using 4.5:1 to 5:1)
Balance Bar
Due to the dual master cylinder configuration, a balancing bar is required to convert the force to the master cylinders; one master cylinder feeds the front brakes while the other provides the rear brakes.
Setting the Balance Bar ratio at (Front/Rear) 1:0.8 to distribute brake force from the pedal to the front and rear master cylinders
Bearing SKF GE10
Master Cylinders
the master cylinder converts the mechanical force to high hydraulic pressure and transfer it to the brake caliper.
the master cylinder chosen is the GS Compact Remote Master Cylinder type from willwood, which meets the specifications listed in Table
GS Compact Remote Master Cylinder
Force Applied by the driver at 350 N
Pressure at front is 5.55 MPa
Pressure at rear is 4.95 MPa
Master Cylinders Mounting
Customized for the dimension of the mounting of the dual master cylinder and the position of the pedal ratio to connect with the balance bar.
Material: Aluminium Alloy
Weight: 0.24 kg
Brake Caliper
Willwood GP200
Front
Clamping force is 8808 N
Friction force is 1762 N(each pad)
Rear
Clamping force is 7856 N
Friction force is 1571 N(each pad)
Brake Rotor
The disc is typically made of cast iron due to its adequate material properties such as (hardness, wear resistance, stiffness, and thermal expansion).
Produced Torque
Front
Produced torque 268 N
Rear
Produced torque 239 N
Calculation results and comparison
The Force applied by the driver = 350 N
It is essential that the produced braking force exceeds the required braking force. According to the table, the applied torque from the braking system is higher than the required torque for both the front and rear axles. This suggests that the vehicle will meet the FSAE test requirements and achieve a four-wheel lock.
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