The Application of an Engineering Design of Brake Calliper - Report Example

The application of an Engineering Design of Brake calliper Your name Name of Assignment 30th May, 2014 Problem identification/investigation The facilities at brake Calipers should adequately designed for safe use of Audi A4 for safety of user. Brake Calipers should be made stable before being placed in the Audi A4. If these proper specifications are not followed, it will lead to improved braking efficiency and minimized weight. Inspection of support structures, hydraulic leaks and brake systems should be periodically inspected and repaired. The aim of this paper is to design brake calipers for Audi A4 that will improve braking efficiency and minimise weight. It may be assumed that an initial production run of 10 callipers will be manufactured. For any calipers to be successful in compatibility with the Audi A4 where it is used, the design and modelling takes into account that calipers can withstand various during it use. It has been modeled using SolidWorks software focusing on appearance. The purpose was to make sure the brake calipers is able to perform their duties properly. If there is a fault in the brake caliper, the frequency will continue to be different when the caliper is rotating, therefore, it is important to simulate the signals vibrating from the caliper under different conditions so that we can come up with a well documented brake caliper which is free from fault. This will help in coming up with standards which guide in planning preventive and maintenance of the brake will caliper. The frequencies of the brake caliper does not occur uniform when there is a fault in the system when there is a problem or imbalance in the brake caliper it will produce frequencies which does not emit radial vibrations. As a way of facilitating the detection regarding the mechanical defects that are experienced in the mechanical vibrators are normally converted to strong electrical signals through the use of a sensor which is the pre-conditioned therefore converting them to digital signals. Considering the preconditioning, the signals are normally comprised of processes like of anti-alias filtering as well a pre-amplifying. Regarding the anti-alias filter, the processes operate on a frequency of about 5 kHz while the highest limit of the sensors is normally approximately 10 kHz. Ultimately, the collected information is then recorded into a known memory for future reference and can also be used for other calculations. As a matter of fact, there are present inventions that have been utilized when it comes to collection of vibration of data hence calculating particular sets of parameters regarding vibration analysis. Technical Specification Calliper ID Tooth Number Normal Modulus piston Helical Angle Wheel Centre Distance weighs Pressure Angle Y1 12 10 mm Integral piston 150 Metric calliper bolts 4.1 pounds 300 Y2 21 4.2 pounds Y3 15 12 mm Metal pistol 100 SAE caliper bolt 4.3 pounds Y4 28 4.2 pounds Y5 12 15 mm Phenolic pisto 100 Metric caliper bolts 4.0 pounds Y6 26 4.2 pounds The materials for the braking system and callipers are alloy copper, steel and cast steel respectively, and the values for the Poisson ratio and the Young’s Modulus are listed below. Through calculation, the stiffness values for the three pairs in the drive line of the brake callipers. Material Properties Item caliper ID Material Young’s Modulus Poisson Ratio Breaking system Copper and steel 0.29 callipers Cast Steel Friction Coefficient Values Static Friction Coefficient () Static Transition Velocity () Dynamic Friction Coefficient () Friction Transition Velocity () 0.05 0.5 mm/s 0.06 6 mm/s The measurements of a functioning brake Calliper will be done using sensors which will be installed in the brake and located in the paths of a moving part. They will have optical sensors for the purpose of withstanding temperatures associated with the moving part. These optical sensors will be computerized so that the signals are sending to the computer to measure against predetermined values as shown above. This will help in determining the unevenness of the brake callipers. The frequency or waves will be measured in terms of time so that proper data will be recorded. The combination of such values is generally used during the calculation of the general output values therefore characterizing a certain mechanical condition regarding the brake callipers. As such, the initial values do match up to the overall state of the calliper while the ensuing value normally corresponds to a state of the specified bearings. Considering the second value, it may be used in similar manner like detecting other mechanical problems that are characterized during impacts. They do contain the data that is supposed to be used during the analysis that does follow. In addition, they also contain particularly direct indication regarding the brake calliper that is being monitored. Development of concept designs Design Requirements- the design of brake caliper various parameters needs to be considered and they include; Dimensions – maximum length, width and height Weight – Safety Levels Safety – The sub-functions in the subsystem that rely on each other are braking and realising. The main factor which is extremely important is safety. This is because it involves human contact and if not given importance could be very risky. The second factor to be considered is the mechanism being used to braking system from one place to another. This is also important because it will determine how compact the space is, how easily it is operated etc. In the table below + means that the concept is rated better than while 0 means the same and – means it worse off. requirements efficiency Weight Oiling Brake Cells lever screw Fast & easy pad replacement 0 + + + + + 0 durability + + 0 0 + + 0 Manufacturing cost + 0 0 - - - - High performance 0 - 0 0 0 0 0 compatibility 0 0 0 0 0 + - Low drag + + 0 0 0 0 0 ABS compatible 0 - 0 - - 0 + Sum + 3 3 1 1 2 3 1 Sum 0 4 2 6 4 4 3 4 Sum - 0 2 0 2 2 1 2 Net score 3 1 1 -1 0 2 -1 rank 1 3 3 6 5 2 6 Continue yes yes yes No combine yes No From the above concept generation we can state that concepts ranked 1,2 and 3 should be developed further while concept 5 should be considered for development with some modification. The scoring were rated using the following scale Relative performance rating Much worse than 1 Worse than 2 Same as 3 Better 4 Much better than 5 Rating Efficiency Weight Safety requirements Weight (%) rating weighted score rating Weighted score rating weighted score Fast & easy pad replacement 15 4 0.6 4 0.6 3 0.45 durability 10 3 0.3 4 0.4 4 0.4 Manufacturing cost 15 2 0.3 2 0.3 3 0.45 High performance 15 3 0.45 3 0.45 4 0.6 ABS compatible 15 3 0.45 4 0.6 5 0.75 Accuracy 20 4 0.8 3 0.6 4 0.8 Low drag 10 3 0.3 3 0.3 4 0.4 Total score 3.2 3.25 3.85 rank 3 2 1 Action Develop Develop Develop All three should be develop because their total score is more than three. If it was less than three then it could have been discarded This defines the source of energy and t is distributed within the system to make the brake system operate. The following are designs available for the system to operate. The rate of movement is to be controlled by hand with the help of now extraneous booms or electronic slew rate monitors and controls. The slew rate has to be calculated in a number of ways as wind, vibration and weight all contribute to the slew rate. The system proposed above is in use in many engineering section however, the cost of manufacture and maintenance is inhibitive. It requires large space to be effective and efficient. The next power drive system under consideration is breaking system This option is one of the best in terms of maintenance, purchase, installation and usage. It is uses small space and provides effective movement and good performance compared to the other designs. The best advantage this design provides is that it has a variable speed control with the help of the calliper Motor Selection There are two motors that need to be chosen for different applications. One of them is for winch system and the other is the rack and pinion system. The rack and pinion system uses the same motors as the chain system. Hence, calculations for the winch system are done in the following section. . Design Development The final design However, the supposed vibration is normally monitored as a way of determining the relative conditions regarding other motors so as to plan well certain preventive and maintenance procedures. The supposed vibration of the motor does occur over a moderately broad frequency band as opposed to the low when compared to the higher frequencies. There are different problems that may occur in a rotating motor especially when loaded. The problems that do occur arise from the distinct vibration types. For instance, there are rotor imbalances that do produce a particular significant rise when it comes to the spectrum that does emit the radial vibrators. When the bearing problems do occur, they normally create such an increase particularly when it deals with the high frequencies. This is due to the fact that the high frequencies normally make the motors to rotate approximately twelve times more therefore the speed is much faster. There is a major concern especially when the proactive maintenance method is undertaken to detect the rolling element of bearings. In addition, there is vibration that is related and conn3cted with the worn bearings which is usually created from the numerous impacts of the numerous metal parts. Winch system This system further more uses two motors which has the force calculated divided into two equal forces From these values, the best suited motor fit for the above criteria is the Baldor AC brake motor which helps facilitate quick stops and positive hold. The motor provides manual release option with an automatic reset button and can be used when the power is off as well. Conclusion In the production, design, modelling and simulation of a callipers various procedures and testing are done to ensure that the callipers produced is going to function at the minimum without any effect. Reference Forshoffer, William. Forsthoffer's Best Practice Handbook for Rotating Machinery. Elsevier Science & Technology, Manchester: 2011. Print. Forsthoffer, William. Forsthoffer's Rotating Equipment Handbooks: Principles of rotating equipment. Manchester: Elsevier, 2006. Print. Norfield, Derek. Practical balancing of rotating machinery. Elsevier, London: 2006. Print. Overton, Caroline, Colin Davis, Lindsay McMillan and Robert Shaw. Rotating machinery: practical solutions to unbalance and misalignment. The Fairmont Press, Inc., London: 2004. Print. Robichaud, Michael. Reference Standards for Vibration Monitoring and Analysis. Saint John, NB Canada. n.d. Read More