Design and Analysis of Inboard (Integrated) Braking system for an ATV. New breaking System with less weight and and effective as compare to others

Design and Analysis of Inboard (Integrated) Braking system for an ATV.

Content

•  Introduction
•  Objective
• Methodology

Introduction

An inboard braking system is an automobile technology wherein the disc brakes are mounted on the chassis of the vehicle, rather than directly on the wheel hubs.

Inboard brakes are fitted to a driven axle of the car, as they require a drive shaft to link the wheel to the brake. Most have thus been used for rear-wheel drive cars, although four-wheel drive and some front-wheel drives have also used them. A rare few rear wheel drive racing cars (e.g., the Lotus 72) have also used inboard front discs, accepting the need to provide a drive shaft to gain the unsprung weight and braking torque advantages.

Objective

• To Design an effective light weight braking system.
• To Do analysis of brake rotor and rotor hub for optimization of weight and precise design.
• To Reduce the Unspurg mass of the Vehicle.
• To Increase the stability of the Vehicle.
• To reduce the whole kerb weight of vehicle.

Methodology

Calculations

    For braking always remember –

            1)Kinetic Energy = Heat

            2)Newton is always Right

            3)F = M * A

            4)When all fails, go to point 2

Rest value needed for braking will be of –

Pedal Ratio, Front Dynamic weight, Mass of vehicle, Height of C.G., Wheel Base, Stopping Distance, Deceleration, Braking Torque, etc.

Design

    Design Phase consists of-

            1) Selection of material for brake rotor, rotor hub.

            2) Selection of MC/TMC, Caliper, Brake Lines.

            3) Design of Brake Rotor and Rotor hub in Catia V5 R20

 Analysis

   Analysis to be done is ANSYS Workbench.

            1) Thermal analysis of brake rotor.

            2) Static Analysis of rotor hub.

Design improvement based on results from analysis.

DFMEA and DVP

                                  Later a detailed Design Failure Mode and Effective analysis will be done to ensure the common mistakes and take corrective steps.

 Also a Design Validation Plan will be generated to keep quality and consistency in design and increases life of the system

Implementation for manufacturing

Calculations

• Gross Vehicle Weight = 180Kg (Assumed)
• Static Weight Distribution = 40:60 (Assumed)
• Average vehicle Velocity = 60km/hr=16.667m/s (Assumed)
• Height of CG = 24inches = 609.6mm (Assumed)
• Wheel base as per golden ratio = 64inches = 1625.6mm (Calculated)
• Tire outer Diameter = 23inches = 584.2mm (Assumed)
• Assuming Stopping Distance = 20 meters (Assumed)
• Stopping Time = 1.2sec (Calculated)
• Dynamic Weight Transfer = 95.64Kg (Calculated)
• Weight of rear portion after dynamic weight transfer = 84.36Kg (Calculated)
• Total Clamping Force = 65.4N (Calculated)
• Diameter of Brake Rotor = 220mm (Assumptions and Calculations)
• Pitch Circle Diameter = 140 mm (Assumed)
• Braking Torque Required = 17.4585 Nm (Calculated)
• Thickness of Rotor = 4mm (Calculated)

Material Selection For Braking System

 Brake Lining – Steel Braided Brake Lines

Brake Pads – Ceramic Brake Pads

Brake Caliper – Single Piston BYBRE Caliper.

TMC – Maruti 800

Rotor Hub – En19

Rotor–Grey Cast Iron

Static Thermal Analysis is to be run for checking the effectiveness of the rotor

Analysis is in progress as few input parameter’s for operation are not present in our software ANSYS 14.5