BRAKING SYSTEM

Introduction: The safe and reliable use of a vehicle necessitates the continual adjustment of its
speed and distance with the help of braking system in response to change in road and traffic
conditions. So the main objective of the braking system is to absorb the kinetic energy of the vehicle
in order to decrease its speed and also to stop the vehicle in considerable distance. It is desired from
a quad bike that it should have effective braking capability to negotiate rigid terrains.

Methodology: As per our design we choose disc brakes over drum brakes because it contains good
anti fade characteristics and better heat dissipation than drum brakes. The vehicle is equipped with
two independent hydraulic circuits with T joint on front and at rear there are two master cylinders
(single piston) which are placed on single rod and each having their own fluid reservoir

Selection criteria:

Components Specifications Quantity

1. Rotors Front and rear Dia-170mm(front) 4

Dia = 190mm(rear)

2. CBR 250cc front brake Bore dia- 10mm 1

master cylinder

3. Rear master cylinders Bore dia- 14mm 2

4. BYBRE single piston calipers Floating caliper of dia-1” 2

for left two wheels

5. BYBRE single piston calipers Floating caliper of dia-1” 2

for right two wheels

Initial data for Front:

Effort applied 7kg

Pedal ratio 8.6:1

𝜇 between disc pad and rotor 0.4

Calculations:
F=7kg=68.67N
Amc=78.5𝑚𝑚2
Fmc=F*(lever ratio) = 590.562N
Pmc=𝐹𝑚𝑐/𝐴𝑚𝑐 = 7.52𝑁𝑚𝑚−2
Acp=506.45𝑚𝑚2
Fcp=Acp*Pmc = 3808.5N
Fd=𝜇*Fcp=1525.77N
T=Fd*112=N-mm
Braking force on each wheel (Fb) =𝑇/ [𝑡𝑦𝑟𝑒 r𝑎𝑑𝑖𝑢𝑠 (11∗25.4)] =611.82N
Total braking force on front wheels = 2*Fb=1223.24N
Initial Data for Rear:

Effort applied 25kg

Pedal ratio 6:1

𝜇 between disc pad and rotor 0.4

For rear two wheels we are using two master cylinder (single piston) which are connected on single
rod for applied on pedal is 25kgs where for distributed on single master cylinder is 12.5kgs

Calculations:
F=12.5kg=122.625N
Amc=153.86mm2
Fmc=F*(leverage)=735.75N
Pmc=𝐹𝑚𝑐/𝐴𝑚𝑐 = 4.75N/mm-2
Acp=506.45𝑚𝑚2
Fcp=Acp*Pmc = 2405.63N
Fd=𝜇*Fcp=968.72N
T=Fd*90=131746.93N-mm
Braking force on each wheel(Fb) = 𝑇/ [𝑡𝑦𝑟𝑒 𝑟𝑎𝑑𝑖𝑢𝑠 (11∗25.4)] =471.53N
Total braking force on front wheels = 2*Fb=943.07N
Total braking force on four wheels(Ft)=21666.31N
Deceleration (a)= 𝐹𝑡 /𝑚 (210) = 10.31𝑚𝑠-2=1.05g
Braking distance(S)= 𝑣2 /2∗𝑎 = (9.72)2 /2∗10.5= 4.49m
Thinking distance=𝑣 ∗ 0.5=9.72*0.5=4.86m
Stopping distance= thinking distance + stopping distance=9.35
stopping time =𝑢/a= 1.07𝑠𝑒c

Weight distribution:

Vehicle weight (W) = 210kg

CG height (h) = 300mm
Wheel base (b) = 1100
Weight distribution at static condition-:
% of weight on front wheels=40% (84 kg)
% of weight on rear wheels= 60% (126kg)
Weight distribution after braking-:
Weight transfer= (W*a*h)/b = (210*10.9*300)/1100=589.90N
Weight on front wheels after weight transfer=1413.94N=68.63%
Weight on rear wheels after weight transfer= 866.32N=31.41%

Braking system layout

Pedal travel:
Distance between a pad and disc is 1.5mm
Change in volume of master cylinder = change in volume of caliper
a*(14)2=3*(10)2
a=1.52mm
b=6*1.52=9.18mm
Pedal travel=9.18mm

Conclusion:

Dynamic force f= ma=1728.3N

Therefore a= acceleration

Braking force = 21666.31N

Since braking force is greater than the dynamic force of the vehicle. Hence the braking force is
enough to stop the vehicle in motion.

References:

1. The Physics of Braking Systems by James Walker, Jr. of scR motorsports.

2. Brake design and Safety by Rudolf limpert (second edition).
3. Brake Handbook - Fred Puhn.