Ts 17 brakes creative journey

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ts_17 Brake Package Upgrade

Aim

Design a minimum15% lighter brake system Comply with FSAE regulationsMore compact systemIncrease performance20/03/2017

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The Problem Existing System:Too HeavyToo Large Update:Lighter materialSmaller size for better packagingLighter manufacturing20/03/2017

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KnowledgePerformance calculations/system modelling20/03/2017

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Existing KnowledgeKnowledge transfer from ts_14 to ts_1720/03/2017

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New KnowledgeCaliper design and manufacture technique5-axis CNC Braking balance Car setupFEA/FMEA20/03/2017

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Brainstorming

A mindmap was drawn to identify the components and requirements that would need our attention during this project.20/03/2017

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Concept 1: 2 piston lightweight caliper

ProsLightweightNeatly packaged

ConsNot rigid enough (poor pedal feel)20/03/2017

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Concept 2: 4 piston caliper

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8ProsEven pad wearGreater clamp force

ConsHeavyLarge

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Final concept: Rigid 2 piston caliper

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Final design is a 2 piston caliperMachined from billet aluminiumHeld together with 2 steel boltsMade to fit Bendix pad that is currently used in TS_16Non-handed (symmetrical)Compatible with TS_16 disc rotor

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Forward LookingInterfacing with other vehicle componentsCommunication with other groupsReverse compatibility

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Questions?

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