Propose a power cylinder to reduce pedal

effort
Reduce heat load on oil cooler

Project Supervisor: Presented By:

Roopak Sharma Aashish Gupta
 Project Objectives
• Propose a power cylinder with external compensation to
reduce pedal effort for braking system
• Study of heat dissipation capability of current hydraulic
tank
• Suggest method to reduce heat load on oil cooler
 Existing brake system
• Rear axle disc brakes.
• Separate braking circuit for each tire operated by
separate pedals.
• Non boosted master cylinder with internal compensation
• Piston diameter: 19.05 mm
• Piston stroke: 36 mm
• Friction plates:
– 5 per brake pack
– Inside diameter: 160 mm
– Outside diameter: 220 mm
• Brake Piston
– Inside diameter: 158 mm
– Outside diameter: 176 mm
 Design methodology
• Need to calculate brake line pressure required to stop
vehicle within required distance
• Design Parameters
– Stopping parameters

– Required brake torque

– Capacity of service brakes

– Brake line pressure
– Volumetric requirements
– Required operator input effort
 Design Chart
Braking Force Mass Transfer due to Normal reaction on
deceleration front tires

Friction force on each Rear tire Total friction force on front tires
and rear tires

Torque on Rear wheel Torque on rear axle Clamp load

Brake line pressure

 Calculations
• Stopping distance less than 10.7 m
• Taken acceleration to be 3.95 m/s2
• Stopping distance will be 9.3 m
• Brake line pressure: 39.82 bars
Acceleration (MFDD) (m/s2) 3.95
WEIGHT TRANSFER(N) 9573
WEIGHT FRONT(N) 31231
WEIGHT REAR(N) 47070
FORCE ON FRONT WHEEL(N) 1093
FORCE ON REAR WHEEL (N) 32685
TORQUE ON WHEEL (Nm) 10606
TORQUE ON AXLE (Nm) 1964
PRESSURE (N/m2) 3982648
• Required pedal effort for brake line pressure 39.82 bars:
• Fpedal= 2*P*A/(r*g)
=44.6 kgf
• Maximum pedal force : 70kgf
• Pmax= 70*g*r/(2*A)
= 65.4 bars
• Volume displaced by master cylinder:
• V = A* p = 10 cm3
 Selection of master cylinder
• Hydraulic boost is better option but cost intensive
• Use a power cylinder (dual piston)
– Two pistons concentric within one housing
– Larger diameter piston for volume filling
– Smaller diameter piston for creating pressure
• Keeping same volume requirements and piston stroke
• Proposed diameter and strokes
D1(mm) P1 (mm) D2 (mm) P2 (mm)

25.4 10 15.8 26

• Pedal force required:

• F = 2*P*A2/(r*g) = 29.3 kgf
 Compensation
• Currently use internal compensation
• Increases cost of master cylinder
• Propose external compensation for use with power
cylinder
 Hydraulic tank- Heat dissipation
• Four faces effective in heat dissipation
• Static conditions:
– Oil temperature : 363K
– Ambient temperature: 323K
• Heat dissipation:
– Material steel :238W
– Material aluminum: 428.6W
 Increase heat dissipation
• Assuming surface temperature of 358K and 1 mm fin
height
• Heat dissipation by each fin : 0.12W
• Spacing : 5mm
• Number of fins : 60
• Fin height : 42 cm (for 2 kW heat dissipation)
 Conclusion
• Pedal effort reduced by 30%
• Use of fins technically feasible but economically
unfeasible