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Objective

Design a Parking Brake for MSXV that satisfies ASC and WSC regulations

Due date

Key outcomes

Status

Status
colourYellow
titlein progress

Daily Objectives

  •  January 23, 2022: Figure out caliper suspension
  •  January 24, 2022: Come up with at least one design of caliper bracket and explain the advantages and disadvantages of each. Include sketches and screenshots of CAD models where applicable. 
  •  January 25, 2022: Come up with at least one design of suspension mount for caliper bracket and upright
  •  January 26, 2022: Finalize lever design

Overall Assembly File

Parking Brake Assembly

Problem Statement

Design MSXV’s Parking Brake, ensuring that it meets all regulations as imposed by ASC and WSC

...

Must have:

  • Rotors must have a diameter from 6.00” to 13.00”

  • Rotors must have a thickness from .25” to .81”

  • Actuating lever (to connect caliper to brake cables)

Nice to have:

  • Hang caliper on center, or very close to center of rotor(?)

  • Parking Brake Calipers should be mounted lower, (to keep center of gravity low, low c.o.g = smoother ride, reduced weight transfer)

  • Mounted at 10-11 o'clock position

  • Design caliper bracket mount

Keep in mind:

  • MSXII’s parking brake failed to meet FSGP requirements for minimum stopping distance

  • Parking cables have a minimum bending radius of 6”

Need to figure out:

  • Narrowness of car

  • How brakes (caliper portion) will be mounted

  • Do we want a stick vs center lever parking brake (center lever recommended)

  • How do brake caliper assemblies work

  • Lever forceWhat would a front suspension look like

  • Lever design

Questions for Chassis Lead (Mohamed)

  • Finalized chassis CAD file?

  • Size of occupancy cell?

  • Stick vs center lever? Possible to mount a lever in a position where it pushes out and forward from driver?

  • Two flaps on side of the driver seat, can mount there or in between the driver’s legs. If you choose to mount between the driver’s legs there will be a problem where the lever mechanism interferes with a box that will carry extra weight

Caliper Carrier (Keep in Mind)

  • Adjustable tabs

  • Caliper carrier connected to suspension mount (one part)

  • Hopefully suspension doesn’t Suspension shouldn’t interfere with caliper body (lol)

Given Parts

Parking Brake Parts

Part #

QTY

Catalogue URL

Specs

Wilwood Caliper (Parking Brake Caliper)

120-1360

2

https://www.wilwood.com/PDF/Flyers/fl13A.pdf

Brake Pad Info Sheet

https://www.wilwood.com/BrakePads/BrakePadsProd?itemno=150-13675

https://www.partsource.ca/products/c661356-dorman-first-stop-brake-cable-part-c100000-c699999

  • Single piston, floating caliper

  • Has a cam-actuated lever

  • Two settings for leverage adjustment

Dorman First Stop Brake Cable

C661356

1

  • Brake pads designed for this caliper are discontinued (no info)

Parking Brake Cable Kit

**NOT COMPATIBLE WITH CURRENT CALIPERS WILL NEEED TO BUY OTHER CALIPERS

330-9371

1

https://www.wilwood.com/PDF/DataSheets/ds1108.pdf

  • Cable’s should be routed as straight as possible, minimum bend radius of 6”

Lokar Floor Mount Emergency Brake Cables

LOK-EC-80FU

1

https://www.summitracing.com/int/parts/lok-ec-80fu?gclid=CjwKCAjw3POhBhBQEiwAqTCuBrmHMPKnEqtbtJ_nSAGLrYqbwaM0tjgGjE86dsp26-KafkHzff89oBoCCM4QAvD_BwE&retaillocation=int

Needs to be purchased

Lokar Wilwood Clevis

EC-80WC

1

https://www.shopeddies.ca/lokar-ec-80wc-wilwood-clevis-kit.html?srsltid=AfAwrE79zTWI-6fgyurX6oQ_D0oDyzZQGqQYnFp3MPiafjrWJeOYXz4j_Cs

Needs to be purchased

\uD83D\uDD17 Reference materials

Expand
titleASC Regulations

  • 10.6 Parking Brake Solar cars must be equipped with a parking brake. 

  • 10.6.A Performance The parking brake shall be able to hold the car in place without wheel chocks on dry pavement under either a forward or rearward force equal to 10% of the cars weight in fully loaded condition. 

    The parking brake should be able to hold the car in place when pushed with a force equal to 10% of the cars weight (a.k.a if car’s weight is 100N, it should be able to withstand 10N of force)

  • 10.6.B Independence This brake must operate completely independently from the main braking system and may not be used in the performance tests specified in Reg.10.9.D. 

  • 10.6.C Locking 

    • 10.6.C.1 It must be able to be locked into the “ON” position, such that the driver does not have to continue to hold it to maintain position. 

    • 10.6.C.2 The driver shall be able to set and lock the parking brake while seated in the normal driving position and seat belted in. 

    • 10.6.C.3 The driver shall be able to set and lock the parking brake in a single action or motion. 

“lockable, independent equipped with working parking brake (must hold 10% of vehicle weight in both directions), non-tire contact style”

  • 10.6.D Contact Style

    The parking brake shall not be of a tire or wheel contact style (i.e. pad on tire or pad on rim styles are not considered as acceptable designs).

...

  • 2.21.9

If the service braking system fails, the secondary braking system must be able stop the fully laden solar car within distance 0.1 v + 0.0158 v2 metres from any speed v, in km/h, that the solar car can achieve.
Expand
titleWSC Regulations

2.21.10

Solar cars must be equipped with a parking brake that can be operated by the driver from the normal driving position. The parking brake must hold the fully laden solar car on a 20% incline or decline.

Expand
titleReference Information

Parking Brake MSXII

**used ME10 mechanical disc brake

Brake Architecture -WIPParking Brake MSXIV

MathWorks Files

https://www.mathworks.com/academia/student-competitions/tutorials-videos.html#racinglounge

https://www.mathworks.com/videos/matlab-and-simulink-racing-lounge-modeling-to-understand-and-improve-your-brake-system-115872.html

Brake Calculations

https://docs.google.com/spreadsheets/d/1emCQpfTXff3dAr8s4W90xkS2jfdpFnwxZciVqpC97YI/edit#gid=401299438 Brakes Calculations

Research Collection

https://docs.google.com/document/d/17B5pEfiBy4TPqQhnZy27D2oYEcE9xzsScICu4b18Kv0/edit?usp=sharing https://docs.google.com/document/d/1XBb2xUEC58oRLKQPC8o7mxkp-MH6eaBxF3ntHLVH26s/edit?usp=sharing https://docs.google.com/document/d/1KMjVLGi9HoEhAiXVRxXvJrMTYG7MfVYD9ZGNMxHa5-s/edit?usp=sharing

All About Braking Notes

https://uwmidsun.atlassian.net/wiki/pages/viewpageattachments.action?pageId=3200122889&preview=%2F3200122889%2F3206610947%2FAll About Braking Notes[1598].pdf

Weight and Centre of Gravity Calculations
https://docs.google.com/spreadsheets/d/1xBlkRmYqN_ZggFP53P9uvoMiKzqegajE_tI0g4XiSg8/edit#gid=0 https://docs.google.com/spreadsheets/d/1SpFd0ny8D_ctzRMluiRBzaGQ-Hhy8hs_YvZh0ZNstBo/edit?usp=sharing
Helpful Parking Brake Calculations for WSC Regulations

View file
nameIOPParkingbrake.pdf

https://www.altraliterature.com/-/media/Files/Literature/Brand/twiflex-limited/Catalogs/p-1648-tf-a4-sections/p-1648-tf-a4_braking_calculations.ashx

More Resources

View file
nameAPTA-PR-M-S-006-98.pdf
View file
nameGupta_2022_Eng._Res._Express_4_025039.pdf
View file
name71_Design.pdf
View file
nameGillespie_Braking Performance.pdf
View file
nameFaunctionalityparameterstestingofPBL.pdf
View file
nameBrake_torque_analysis_of_fully_mechanical_parking_.pdf

https://www.google.com/search?q=McKinlay+A+J%2C+P+C+Brooks%2C+and+D+C+Barton.+2006+A+Study+of+Vehicle+Handbrake+Rollaway%3A+Thereotical%2C+Numerical+and+Experimental+Assessment.+in+Vehicle+Braking+Technology+IMechE).&rlz=1C1RXMK_enCA1020CA1020&oq=McKinlay+A+J%2C+P+C+Brooks%2C+and+D+C+Barton.+2006+A+Study+of+Vehicle+Handbrake+Rollaway%3A+Thereotical%2C+Numerical+and+Experimental+Assessment.+in+Vehicle+Braking+Technology+IMechE).&aqs=chrome..69i57.591j0j1&sourceid=chrome&ie=UTF-8

http://www.engineeringinspiration.co.uk/brakecalcs.html#STV

https://unacademy.com/content/gate/study-material/mechanical-engineering/brake-torque/

https://www.tolomatic.com/products/product-details/me10-mechanical-disc-brake/

https://what-when-how.com/automobile/braking-system-automobile/