REVOLUTIONARY BRAKE SYSTEM: ENHANCING PERFORMANCE IN FORMULA

ELECTRIC VEHICLE DESIGN

Muhammad Faiz Bin Jansar

Department of Mechanical Enginering, Polytechnic Muadzam Shah, PAHANG
faiz.jansar@pms.edu.my

Sıtı Hanıs-Syazana Bıntı Mohamad

Department of Mechanical Enginering, Polytechnic Muadzam Shah, PAHANG
hanisyazana@pms.edu.my

Jamadeel Izwan bin Ibrahim

Department of Mechanical Enginering, Polytechnic Muadzam Shah, PAHANG
jama@pms.edu.my

ABSTRACT
This research focuses on meticulous design to develop the braking system for the
Formula Electric Vehicle (FEV) to enhance performance and race strategy. The challenge
involves optimizing braking efficiency, minimizing stopping distance, and aligning with the
characteristics of electric vehicles (EVs). The specific vehicle in focus is a high-performance
racing car powered by an electric motor. Therefore, reducing its weight is paramount for
improving speed and energy efficiency. The strategy involves trimming the weight of brake
components through material replacement without compromising braking effectiveness. The
achieved result demonstrates a remarkable weight reduction of over 70%, and the vehicle
successfully passed the brake test during the competition, ensuring safety.
The rotor typically consists of stainless steel, and occasionally grey cast iron or carbon-
carbon composite in premium automobiles or motorcycles. It is essential to investigate stress
distribution and heat generation to enhance braking efficiency. The rotor design is crafted
using SolidWorks and then imported into ANSYS for further analysis. Hence, the primary
objective is to create a system where the driver can exert substantial force on the brake without
exceeding the limit that would lead to the complete locking of the car tires. The system is
specifically engineered to accommodate a foot capacity of around 2500N.
In conclusion, this research advances FEV braking system design development and
other optimization methods should be carried out in the future to achieve better braking
performance.
Keywords: FEV, braking system, braking effectiveness, SolidWorks, Ansys