Professional Documents
Culture Documents
PRESENTATION
Presention by:
Muhammad ashraf
AhMAD ALMADANI
NUR ATIRA
MD NASRUDDIN
PHASE 3
DETAIL DESIGN
PHASE 2
EMBODIMENT DESIGN
PHASE 1
CONCEPTUAL DESIGN
PHASE ONE
PHASE ONE
IDENTIFY
PROBLEM
BACKGROUND OF THE
STUDY
PROBLEM STATEMENT
OBJECTIVE
SCOPE OF THE PROJECT
SIGNIFICANT OF THE
PROJECT
GATHER
INFORMATION
QUESTIONNAIRE
CONCEPT
GENERATION
FUNCTIONAL DECOMPOSITION
CONCEPT SKETCHES
MORPHLOGICAL CHART
CONCEPT
EVALUATION
PUGH CONCEPT
DECISION MATRIX EVALUATION
IDENTIFY PROBLEM
(A) BACKGROUND OF THE PROJECT
Single Seater
Vehicle
IDENTIFY PROBLEM
(A) BACKGROUND OF THE PROJECT
Early
invention of
the brake
system
IDENTIFY PROBLEM
(B) PROBLEM STSTEMENT
IDENTIFY PROBLEM
(C) OBJECTIVE
IDENTIFY PROBLEM
(D) SCOPE OF THE PROJECT
Vehicle must be equipped at least one (single) independently activated
braking system
The installment of the single braking system must be applied on the rear
axle
The vehicle must also install a read brake light with 15 watts or more that
can be seen clearly from the rear and be mounted between the wheel
centerline and drivers shoulder level vertically and approximately on
vehicle centerline laterally
IDENTIFY PROBLEM
(E) SIGNIFICANCE OF THE PROECT
Safety
Comfort
Medium
Integrate
GATHER INFORMATION
Book
Educational
Video
-YouTube
Questionnaire
Journal
Article
GATHER INFORMATION
QUESTIONS
1) Do u think the size and shape of the brake pedal
affects your overall driving experience?
2) Does placing the ergonomic brake pedal beside the
throttle pedal ensures smoothness when brake is
applied?
3) Does applying a small or necessary amount of force
on the brake pedal is the most practical way to stop
(braking) ?
4)Do u agree that the brake effectiveness is the most
important criteria in a car?
5)Would u choose a brake system that is maintenance
friendly and of less hassle to the user which bear more
cost ?
6) Does the performance of the car depend on the type
of brake used?
7) Are you willing to spend an appropriate sum amount
of money to ensure that your car is equipped with a
good braking system?
8) Is the rear brake lamp is an important aspect of any
cars braking system?
9) Does the position of the rear brake lamp affect other
SCORE
Disagr Moderat
ee
e
Agree
GATHER INFORMATION
Do you agree that the brake effectiveness is the most important criteria in a car?
16
16
14
12
10
Number of8Respondents
6
4
2
0
0
Disagree
Question 4
Moderate
Score
Agree
GATHER INFORMATION
Would you choose a brake system that is maintenance friendly and of less hassle to the user which bear more cost ?
16
16
14
12
10
Number of8 Respondents
6
1
4
2
0
Disagree
Question 5
Moderate
Score
Agree
FUNCTIONAL DECOMPOSITION
CONCEPT GENERATION
CONCEPT GENERATION
CONCEPT GENERATION
CONCEPT 1
BRAINSTORMING SKETCHES
CONCEPT 2
CONCEPT GENERATION
CONCEPT 3
CONCEPT GENERATION
CONCEPT GENERATION
MORPHOLOGICAL CHART
Function
1.Type of braking
system
CONCEPT 1
Disc Brake and Drum
Break.
Sub- solution
CONCEPT 2
CONCEPT 3
Drum Brake
Disc Brake.
Rear
Rear
3. Braking operation
system
Hydraulic system
Cable system
Hydraulic system
4.Cost
Most expensive
Cheap
Moderate
5. Brake system
effectiveness
6. Maintenance.
Moderate to high
reliability.
Moderate to high
reliability.
CONCEPT EVALUATION
PUGH CHART
CONCEPT 1
CONCEPT 2
CONCEPT 3
User Experience
Manufacturability
Safety
A moderate safety
performance of the brake
system.
Used preferably for front
braking of a vehicles
system
Need/Market
Reliability
Life
Cost
A moderate amount of
wear & tear period, but can
withstand harsh braking
conditions
High Prototyping or
Consumer cost
Moderate lifespan.
CONCEPT EVALUATION
DESCRIPTION
DECISION MATRIX
CRITERIA
WEIGHT
Concept 1
Concept 2
Concept 3
DESIGN 1
DESIGN 2
DESIGN 3
User Experience
++
++
Manufacturability
Safety
++
Need/Market
++
Reliability
++
Life
Maintenance Cost
Manufacturing
Cost
+
28
28
26
NET SCORE
21
25
26
PHASE TWO
Product Architecture
Product Architecture
Brake Disc
Brake Calliper
Pedal
Master Cylinder
Switch
Wire
Brake Hose
Brake Lamp
Modelling
Modelling
Modelling
Dimensions
Deformation
Translational Displacement
Principal Stress
DETAIL CALCULATION
Deceleration rate:
Assuming that the vehicle is moving at 50 km/h(13.89 m/s) and it will
be eventually in stationary in 3 seconds therefore it deceleration rate
will be:
V0 = 13.89m/s
V1 = 0 m/s
t = 3s
a=
=
= -4.63 m/s
The negative shows the deceleration.
Stopping distance:
So now we are going to find the stopping distance,which could be find by using formula
which is:
ds =
ds= stopping distace(m)
v = velocity(m/s)
=Coefficient of friction
g = gravitational acceleration (m/)
by taking the coefficient of friction for dry road, =0.8
Stopping distance, ds =
=
= 12.29 m
Braking time:
To calculate braking time we will use this formula which is
Stopping time, ts =
bear in mind that the stopping distance and deceleration rate have
been calculated in the previous section,therefore:
=
= 2.65 seconds
Braking force:
We can find the braking force by using the formula as follows:
F=ma
F=force or in this case it should be braking force (kgm/)
M=total mass (kg)
a = acceleration (m/)
From the requirement of this project or we called it as product design specifications,we
know that mass of the vehicle is 100 kg,and the drivers mass is 70 kg.Therefore the
total mass will be:
Total mass(kg)= mass of vehicle + drivers mass
=150 kg + 53 kg
= 203 kg
Therefore:
F=ma
=(203 ) (4.63 )
=939.89 N
Brake Torque:
Brake torque is the moment of braking force about the center of rotation.Which
could be calculated as follows:
T= F. re
Where:
T=Brake torque (N/m)
F=Braking force (N)
re= Disc effective radius(m)
Thus,
T= (939.89 N)( 0.093)
=87.41 N.m
Clamp Load:
Clamp load is defined as force required by the calipers to stopped the brake
disc and eventually stopped the vehicle.To determine the clamp load we will
use formula as follows:
Clamp load, C =
Disc effective radius,re = 0.093 m
Coefficient of friction for steel alloy, f = 0.4
Friction surface contact since friction act on the 2 points in our brake disc ,
n=2
Torque produce by the wheel,T = 87.41 N.m
Clamp load, C
=
= 1174.87 N
kmh
average braking
distance
feet
meter
meter
Total Stopping
Distance
feet
meter
10
16.67
1.524
22
67.056
27
68.58
15
25.005
11
3.3528
33
100.584
44
103.9368
20
33.34
19
5.7912
44
134.112
63
139.9032
25
41.675
30
9.144
55
167.64
85
176.784
30
50.01
43
13.1064
66
201.168
109
214.2744
35
58.345
58
17.6784
77
234.696
135
252.3744
40
66.68
76
23.1648
88
268.224
164
291.3888
45
75.015
96
29.2608
99
301.752
195
331.0128
50
83.35
119
36.2712
110
335.28
229
371.5512
55
91.685
144
43.8912
121
368.808
265
412.6992
60
100.02
171
52.1208
132
402.336
303
454.4568
65 108.355
201
61.2648
143
435.864
344
497.1288
70
116.69
233
71.0184
154
469.392
387
540.4104
75 125.025
268
81.6864
165
502.92
433
584.6064
MATERIAL SELECTION
BRAKE
PADS
BRAKE DISC
CARBON
DESIGN FOR
MANUFACTURING
BRAKE PADS
BACKING PLATE
1
MAIN PROCESS
1
BRAKE DISC
PARTS OF BRAKES
DESIGN FOR
ROBUSTNESS
BRAKE HOSE
PHASE THREE
Bill of Material
BOM for Brake Disc Assembly
Part Name
Material
Quantity
Brake Disc
Cast iron
Hexagonal Bolt
Stainless Steel
Hexagonal Nut
Stainless Steel
Washer
Stainless Steel
Bill of Material
BOM for Brake Caliper Assembly
Part Name
Material
Quantity
Caliper Casing
Cast aluminium
Brake Pad
Ceramic
Screw Pin
Stainless steel
Piston
Stainless Steel
Octagonal-holed bolt
Stainless Steel
Pad Support
Stainless Steel
Bill of Material
BOM for Brake Pedal Assembly
Part Name
Material
Quantity
Piston
Stainless Steel
Buffer
Stainless Steel
Connector
Stainless steel
Pedal
Stainless Steel
Reservoir
Plastic
Master Cylinder
Aluminium
Cap
Plastic
Base
Stainless Steel
Hub
Stainless Steel
COST
Item
Material
Quantity
Brake Pads
Ceramic
(1pair)
Brake Disc
Cast Iron
Price Per
Unit (RM)
Total Price
(RM)
90
90
110
110
18
Cable
Polyurethane
3 meter
Caliper Mount
Stainless Steel
46
46
Master
Cylinder
Aluminium
193
193
Caliper
Aluminium
120
120
Brake Pedal
Zinc Plated
Stainless Steel
17
17
Brake Lamp
29
29
Total Cost
623
THANK YOU