Swinburne University of Technology's F-SAE car brakes system creativity journey of concept design.

1. ts_17 Brake Package Upgrade

2. Aim
• Design a minimum15% lighter brake system
• Comply with FSAE regulations
• More compact system
• Increase performance
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3. The Problem
Existing System:
• Too Heavy
• Too Large
Update:
• Lighter material
• Smaller size for better packaging
• Lighter manufacturing
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4. Knowledge
• Performance calculations/system modelling
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5. Existing Knowledge
• Knowledge transfer from ts_14 to ts_17
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6. New Knowledge
• Caliper design and manufacture technique
• 5-axis CNC
• Braking balance
• Car setup
• FEA/FMEA
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7. Brainstorming
A mindmap was drawn
to identify the
components and
requirements that
would need our
attention during this
project.
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8. Concept 1: 2 piston lightweight
caliper
Pros
• Lightweight
• Neatly packaged
Cons
• Not rigid enough (poor pedal
feel)
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9. Concept 2: 4 piston caliper
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Pros
• Even pad wear
• Greater clamp force
Cons
• Heavy
• Large

10. Final concept: Rigid 2 piston caliper
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• Final design is a 2 piston caliper
• Machined from billet aluminium
• Held together with 2 steel bolts
• Made to fit Bendix pad that is
currently used in TS_16
• Non-handed (symmetrical)
• Compatible with TS_16 disc rotor

11. Forward Looking
• Interfacing with other vehicle components
• Communication with other groups
• Reverse compatibility
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12. Questions?
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