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 draws up a basic overview of the current groups pedal cars. It focuses on creating a computer model of the pedal group with the help of the mathematical model and simulation stress of individual components and proposed relief.

No / Braking system characteristics, brake system performance and brake system component design parameters that influence brake pedal ‘feel’ in a passenger car have been studied using the simulation modelling package AMESim, in particular to model the linear and nonlinear characteristics of internal components. A passenger car hydraulic brake system simulation model incorporating the brake pedal, booster, master cylinder, brake lines and calipers has been developed to predict brake system response to assist in the design of braking systems with the desired brake pedal force / travel characteristic characteristics to create good brake pedal ‘feel’. This has highlighted the importance of system components, in particular the master cylinder and caliper seal deformation, and the operating characteristics of the booster in determining the brake pedal force / travel characteristic. The potential contribution of these 3 components to brake pedal ‘feel’ improvement has been investigated, and the results of the AMESim model have been verified using experimental measurement data. The model can be used in the future to provide an accurate prediction of brake system response at the design stage thereby saving time and cost.

I denna rapport redovisas fyra koncept för utveckling av en bromspedal, med målet att reducera godstjockleken från den befintliga pedalen som är 2mm till 1,5mm, men samtidigt behålla hållfastheten som den befintliga bromspedalen erhåller. Det ställs höga belastningskrav på bromspedaler, och att minska godstjockleken innebär högre påfrestningar på materialet.För att utveckla en ny konstruktion som skall leva upp till dessa krav har programvaran PTC Creo 3.0 använts, och för analysering av dessa koncept har verktyget Simulate använts.I resultatdelen simuleras och redovisas fyra koncept i 1,5mm plåt som jämförs i total förskjutning med originalpedalen i 2mm plåt. Slutsatsen är att de inte når upp till lika bra resultat som originalpedalen. Däremot med 1,9mm plåt når det resultatmässigt bästa konceptet (koncept 3) upp till ett bättre resultat än originalpedalen, och detta leder till en viss förbättring i minskning av material, med bibehållen hållfasthet. / This report describes four prototypes for the development of a brake pedal, with the goal of reducing material thickness from the the existing pedal from 2mm to 1.5mm, while maintaining the strength of the existing brake pedal. There are high load demands on the brake pedals, and to reduce the thickness means higher strain on the material.To develop a new design that will live up to these requirements, the design tool software PTC Creo 3.0 has been used, and the analysis of these structures has been performed using the tool Simulate in PTC Creo parametric.The result show four concepts presented and simulated in 1.5mm plate thickness, and the results are compared with the original pedal results in 2mm plate thickness regarding total displacement. The conclusion is that the concepts do not fulfill the load requirements.However with 1.9mm plate thickness, our best concept (concept 3) is fulfilling the loading requirements even better than the existing pedal, and that leads to an improvement regarding reducement of material, with retained strength.

This thesis is concerned with design of pedal box for Formula Student vehicle. Summary of design solutions is presented in introductory chapter, especially those used in Formula Student competition. Designed assembly is divided into parts of single pedals and base plate. The proposed design is supported by stress analysis of loaded parts in pedal box. In conclusion, design is reviewed in terms of the results, as well as compared with current pedal box.