This diploma thesis is focused on conversion of Skoda Octavia RS mark I brake system. This vehicle will be used for race use. The aim of the thesis is to design adequate components of the brake system to achieve good brake deceleration and so that the design will be correspond to hard conditions on the race track. Thesis contains complete design of hydraulic system including control and brake forces, pressures, options of brake forces management and evaluate of brake stability. Followed by the design of brake caliper adapters and the static structural analysis by FEM. The thesis contains picture and assembly drawing attachment too.

The deficient market for technically smart solutions regarding brake caliperspresents an opportunity that GETECH AB intends to explore. The task wasassigned to the students to investigate how a brake caliper adapted for the rearaxle of cars can be integrated with an electrically driven parking brake and ahydraulic handbrake adapted for motorsport. The work began with a market survey to understand what is currently offeredand what is missing. Intensive brainstorming sessions and discussions werethen initiated to create multiple concepts with solutions to the problem.Subsequently, requirements and data were gathered to be translated into aspecification. This specification became the basis for the selection criteriaused in the Pugh matrix to rank the various concepts, ultimately resulting in awinning concept that would be further developed. The winning concept underwent several iterations to contribute to functionaland design improvements, ultimately resulting in the final version. To ensurethat the final version would meet the required strength standards, multiplestrength analyses and calculations were performed to guarantee functionalityand safety. The simulations showed that the brake caliper's strengththeoretically meets the functional requirements set by Swedish inspection and the Transport Agency regarding performance. Once the concept, modeling, and strength checks were completed,manufacturing began. Detailed CAM preparations with clearly reviewed toolselections and tool paths were created, along with favorable fixtures tofacilitate clamping possibilities. All of this was to ensure a manufacturingprocess that delivers a quality result from a three-axis CNC milling machine. When the brake caliper was fully manufactured, it was assembled withstandard components. The caliper was then installed on a demonstrator whereits functions could be visualized and demonstrated. The result was a rearmulti-piston brake caliper with three braking functions in a single compactmodule. The brake caliper was made from an aluminum alloy and consisted ofa total of 53 components, four of which were manufactured in the CNCmachine. / Den bristfälliga marknaden på tekniskt smarta lösningar gällande bromsok ären möjlighet som GETECH AB har som avsikt att studera. Uppdraget tilldelades till studenterna för att utreda hur ett bromsok anpassat för bilars bakre axel kan integreras med en elektriskt driven parkeringsbroms och hydraulisk handbroms anpassad för motorsport. Arbetet inleddes med att undersöka marknaden för att skapa en förståelse för vad som erbjuds idag och vad som saknas. Därefter startades intensivabrainstorm sessioner och diskussioner för att skapa flertalet olika koncept med lösningar på problemet. Sedan samlades önskemål och data in för att översättas och föras in i en kravspecifikation. Kravspecifikationen blevgrunden till de urvalskriterier som sedan användes i Pugh-matrisen för att rangordna de olika koncepten som slutligen skulle resultera i ett vinnande koncept vilket skulle vidareutvecklas. Det vinnande konceptet genomgick flera iterationer för att bidra med funktion och designförbättringar för att till slut resultera i den slutliga versionen. För att konstatera att den slutliga versionen skulle uppnå de hållfasthetskrav som ställs utfördes flertalet hållfasthetsanalyser och beräkningar för att säkerställa funktion och säkerhet. Simuleringarna visade att bromsokets hållfasthet teoretiskt klarar de funktionskrav som svensk besiktning och Transportstyrelsen har gällande prestanda. När koncept, modellering och hållfasthetskontroller var utförda påbörjades tillverkning. Utförliga CAM beredningar med tydligt genomgångnaverktygsval och verktygsvägar skapades. Även gynnsamma fixturer för underlättandet av uppspänningsmöjligheter. Allt detta för att säkerställa en tillverkningsprocess som ger ett kvalitativt resultat från en tre-axlig CNC fräs. När bromsoket var färdigtillverkat monterades det ihop tillsammans med standardkomponenter. Därefter installerades oket på en demonstrator där bromsokets funktioner kunde visualiseras och demonstreras. Resultatet blev ett bakre flerkolvigt bromsok med tre bromsfunktioner i en enda kompakt modul. Bromsoket tillverkades ur en aluminiumlegering och bestod av totalt53 komponenter varav fyra var tillverkade i CNC-maskinen.

Design of braking system for the formula student car. Calculation of basic forces acting in the braking system. Mechanical analysis of the most important parts of the braking system. Manufacturing of brake pedal. Assembly brake components to brake system.

This thesis presents elliptical rolling contact joints as an alternative to circular rolling contact and conventional revolute joints where high quality force transmission "low friction and backlash" with variable output are desired. Parameters specific to the joint and its position are developed in terms of relative link angles and elliptical surface geometry. These parameters are used to generate the basic forward kinematics for elliptical rolling link toggle mechanisms with oscillatory motion and high mechanical advantage. As large compressive loads are characteristic of such mechanisms, stress conditions are identified and principles for joint stability with variable, precision outputs are discussed. Finally, application is made to self-adjusting passive force closures with a case study of the MUSCLE Brake (Multi-toggle Self-adjusting Connecting-Linked Electromechanical) disc brake caliper. Elliptical rolling contact joints are shown to offer several benefits over circular rolling contact, including: reduced Hertz contact stresses and flexure bending stresses, variable output velocity, maximum use of contact interface by distributing small rotations across surfaces of small curvature, reduced forces on stabilizing members, increased mechanical advantage due to eccentricity, and no-slip pure rolling provided exclusively by connecting links (or flexures) without the need for gear teeth or friction.