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BRAKE REPORT

BRAKING DEPT.
NED FORMULA RACING

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RULES

T7.1 Brake System - General The car must be equipped with a braking system that acts
on all four wheels and is operated by a single control.

T7.1.1 It must have two (2) independent hydraulic circuits such that in the case of a leak or
failure at any point in the system, effective braking power is maintained on at least two (2)
wheels. Each hydraulic circuit must have its own fluid reserve, either by the use of separate
reservoirs or by the use of a dammed, OEM-style reservoir.

T7.1.2 A single brake acting on a limited-slip differential is acceptable.

T7.1.3 The brake system must be capable of locking all four (4) wheels during the test
specified below.

T7.1.4 “Brake-by-wire” systems are prohibited.

T7.1.5 Unarmored plastic brake lines are prohibited.

T7.1.6 The braking systems must be protected with scatter shields from failure of the drive
train (see T8.4) or from minor collisions.

T7.1.7 In side view no portion of the brake system that is mounted on the sprung part of
the car must project below the lower surface of the frame or the monocoque, whichever is
applicable.

T7.1.8 The brake pedal must be designed to withstand a force of 2000 N without any failure
of the brake system or pedal box. This may be tested by pressing the pedal with the
maximum force that can be exerted by any official when seated normally.

T7.1.9 The brake pedal must be fabricated from steel or aluminum or machined from steel,
aluminum or titanium.

T7.1.10 EV ONLY: The first 90% of the brake pedal travel may be used to regenerate
brake energy without actuating the hydraulic brake system. The remaining brake pedal

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travel must directly actuate the hydraulic brake system, but brake energy regeneration
may remain active. Any strategy to regenerate energy whilst coasting or whilst braking
must be covered by the FMEA T7.2 Brake Test T7.2.1 The brake system will be
dynamically tested and must demonstrate the capability of locking all four (4) wheels and
stopping the vehicle in a straight line at the end of an acceleration run specified by the
brake inspectors.

T7.2.2 EV ONLY: After accelerating the tractive system has to be switched off by the
driver and the driver has to lock all four wheels of the vehicle by braking. The brake test is
passed if all four wheels lock while the tractive system is shut down.

NOTE: It is acceptable for the Tractive System Active Light to switch off shortly after the
vehicle has come to a complete stop as the reduction of the system voltage may take up to 5
seconds.

T7.3 Brake Over-Travel Switch T7.3.1 A brake pedal over-travel switch must be installed
on the car as part of the shutdown system and wired in series with the shutdown buttons.
This switch must be installed so that in the event of brake system failure such that the
brake pedal over travels it will result in the shutdown system being activated and
controlling the systems as defined in Part IC Article 4 (IC vehicles) or EV5.4 (electric
vehicles).

T7.3.2 Repeated actuation of the switch must not restore power to these components, and it
must be designed so that the driver cannot reset it.

T7.3.3 The switch must be implemented with analog components, and not through recourse
to programmable logic controllers, engine control units, or similar functioning digital
controllers.

T7.4 Brake Light T7.4.1 The car must be equipped with a red brake light. The brake light
itself has to have a black background and a rectangular, triangular or near round shape
with a minimum shining surface of at least 15cm². The brake light must be clearly visible
from the rear in very bright sunlight. When LED lights are used without a diffuser, they
may not be more than 20mm apart. If a single line of LEDs is used, the minimum length is
150mm.

T7.4.2 This light must be mounted between the wheel centerline and driver’s shoulder level
vertically and approximately on vehicle centerline laterally.

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BRAKING FUNCTION
The function of the brakes in the car is to stop or to reduce the motion of the car.

MECHANISM
The mechanism of the brakes is to convert the kinetic energy of the moving car into heat energy
then this heat energy will be dissipated.

COMPONENTS
 Wilwood Brake/Clutch/Throttle Pedal. (Main Component)
 Three individual fabricated steel pedals.
 Non-slip pedal pads.
 Aluminium frame.
 Steel pedal arms.
 Mounting studs.
 Clevises.
 Balance bar assembly.
 Master and Slave cylinders.
 Braking Fluid.
 Callipers.
 Brake Pads.
 Nuts and Bolts.

INFORMATION ABOUT COMPONENTS


Wilwood’s new floor mount pedal assembly has a brake / clutch / throttle triple pedal design.
There are three individual fabricated steel pedals with non-slip pedal pads to control brake,
clutch and throttle. Pedal assembly part number 340-12410 is for rear engine cars and does not
include a throttle bell crank and linkage. This unit features an aluminium frame with strong
lightweight fabricated steel pedal arms. The frame and the pedal arms have a black e-coat finish
for protection and an attractive appearance. Also included with the pedal assembly are mounting
studs, clevises, and balance bar assembly that is designed to provide smooth and accurate
settings of the brake pedal bias. The balance bar can be set and locked down with the jam nut, or
attached to a remote cable for quick on-track adjustments. The pedal assembly provides a 5.25 to
1 nominal ratio.

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PROCEDURE
The brake pedal assembly is set and after adjusting the brake biasing/balance bar to neutral (i.e.
50/50 or any other desired value) and then connect the master cylinders and slave cylinders to
brake pads and callipers. When the driver applies the force on the pedal in order to lock the four
wheels, the piston moves and pushes the braking fluid to the braking lines and through braking
lines, it will reach to the callipers which would grasp the moving rotor and the wheels will be
locked.

DATA

Mass of the Car (M)= 350kg


Mass distribution= 60/40 (i.e. 60% on rear and 40% on front)
Centre of gravity (CG)= 990mm (behind front axle) 305mm (above the ground)
Wheel base=1650mm
Nominal Pedal Ratio=5.25 to 1.
Driver’s applied assumed force on pedal=312N to 800N and can be >800N in panic situations.
Braking Force (Bf)
Coefficient of friction (u)= 1.5
Acceleration due to gravity (a)= 9.81m/s^2
Dia of master cylinder=19.05mm
Braking Heat Energy (K.E)
Velocity at test= 65km/hr=18.05m/s
Time taken after applying brakes (t)=-V/a=18.05/9.81=1.84sec

Calculations

a) Required Braking Force (Bf)= Ma


=(350)(1.0)(9.81)
=3433.5N as a=ug
Let assume driver applies 660N which is multiplied by Pedal’s nominal ration i.e.
(660)(5.25)=3465N
The average Vaccum pressure inside master cylinder is 8psi (55.16 kpa), So additional force on
it would be (55.16e3)(3.142/4 (19.05e-3)^2)=15.72N.
So total generated force would be 3465+15.72=3480.72N
As (3480.72 > 3433.5), All four wheels will be locked.

b) Braking heat energy= 1/2Mv^2


=1/2(350)(18.05)^2

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=57.05KJ

c) Braking Power= Braking energy/time (t)


=57.05e3/1.84
=31005.434Kwatts

Circuit Diagram

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Note: In this figure, drum attached to rear wheels but we are going to use rotors (i.e. Disc
Braking System) on the rear wheels too as like on the front wheels

REFERENCES
1. http://www.engineeringinspiration.co.uk/brakecalcs.html
2. http://www.wilwood.com/MasterCylinders/MasterCylinderProd.aspx?itemno=260-3374
3. http://www.wilwood.com/Pedals/PedalProd.aspx?itemno=340-12410
4. http://iracing.wikidot.com/components:brake-bias
5. http://www.formula1-dictionary.net/brake_balance.html
6. https://www.youtube.com/watch?v=bMg_j5_AGMg&index=3&list=PLAxMIGy7kz5dgl
AG5K7KiA7t5wMHoxH01&t=17s
7. https://www.youtube.com/watch?v=ZkFkLuSma5g&index=6&list=PLAxMIGy7kz5dgl
AG5K7KiA7t5wMHoxH01&t=22s
8. https://www.youtube.com/watch?v=ISLqGf0sMX0&index=7&list=PLAxMIGy7kz5dgl
AG5K7KiA7t5wMHoxH01

IMPORTANT NOTE

There are some calculations and dimensions which are not yet done. They will be done
after arrival of the car. There may be the chance of changing calculations and dimensions
after testing to improve the braking system.

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