International Journal of Management, Technology And Engineering ISSN NO : 2249-7455
Design of Braking System for Go-Kart
Raj Kumar Prasad, Harwinder Singh
Department of Mechanical Engineering, Chandigarh University,
Gharuan, Mohali
kumarraj9957@[Link]
Abstract
This paper aims to design for the Braking system of Go-Kart Vehicle. There are
involvement of many system in manufacturing of Go-Kart, but the most important
requirement is braking system. Without braking system every vehicle is incomplete, and
the vehicle cannot function properly. It is righteous to say that without the braking system
in vehicle the passenger's life is in danger. Therefore Braking system plays the major role
in the manufacturing of vehicle. Not surprisingly, braking is an exciting area for
development within the automobile industry with a number of technologies competing to
improve safety and overall efficiency.
Keywords: Go-Kart, Disc Brakes, Caliper, Master Cylinder.
Introduction
In selection of braking system , Hydraulic Disc brake we have used in our Go-Kart
vehicle to decelerate or decrease the speed of a vehicle. By stepping on the brake
pedal, the brake pads compress against the rotor attached to the wheel, which then
forces the vehicle to slow down due to friction. Mostly all of go-kart have disc
brake on only rear axle because disc brake mechanism is simple than other brake
and moderate weight and easier mechanism . All of these components need to be in
good shape and working properly for the vehicle to have 100% brake system
effectiveness while driving.
Braking System
1. Purpose:
I. To decrease the speed of a vehicle using kinetic friction and keep it from
rolling when stopped using static friction.
II. To design a braking system which take least time to bring the vehicle to
stop.
III. To ensures safety of the driver.
2. Selection of Brakes:
We had used a Hydraulic Disc Brake considering the following advantages,
availability, and their limitations .
For selection of best braking system in go-kart you have to kept
some points in your mind:
a) Hydraulic system
b) Disc brake - appache RTR rear 200mm
c) Master cylinder- appache RTR rear master cylinder
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International Journal of Management, Technology And Engineering ISSN NO : 2249-7455
d) Brake lines- appache RTR front
e) Caliper- appache front double piston caliper
f) T-joint- for transferring fluid and pressure valve (brake
light).
3. Parts and Specifications:
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International Journal of Management, Technology And Engineering ISSN NO : 2249-7455
Calculations:
Every racing vehicle requires good brakes to have control over the speed and stop the
vehicle at any point of time within shortest time period and stopping distance. In order to
achieve maximum performance from the braking system, the brakes have been designed
to lock up rear wheels, while minimizing the cost and weight. To achieve best braking
parameters in our Go Kart all the static and dynamic loads were calculated at the rear and
front wheels.
Type - Hydraulic, disc
Brakes Calliper- Both rear wheels TVS Apache rear calliper
Master cylinder -Maruti 800 TMC
Retardation of the body at any given time is: (co-eff of adhesion)*(acc. Due to gravity)
= K*g
K: 0.7 for dry roads
Therefore retardation (a): 0.7*9.81 =6.867 m/s2
Front axle dynamic load is given as (Wf):
Wf = w1 + (a/g) ×W× (h/L)
Rear axle dynamic load is given as (Wr):
Wr = w2 - (a/g) ×W× (h/L)
Where,
w1 = Static load on the front wheels = 74 kg
w2 = Static load on the rear wheels = 111 kg
a = retardation of the vehicle
W = Weight of the vehicle = 185kg
h = Distance of C.G from ground = 0.29 m
L = Wheel Base = 47inch= 1.19m
Now,
Braking Force(Fb)
Fb=(W*a/g)=1269.1N
Braking Efficiency
(Fb/W)*100=69.2%
Stopping distance d = v^2 /2 a
v = 40 km /h = 11.1 m/s (as per rulebook)
d = 12 m (maximum)
Now the dynamic loads,
Wf = 105.52kg
Wr = 79.47kg
Therefore weight transfer of 26kg takes place from rear axle to front axle.
Now we calculate the forces applied by the driver on the brakes and the final force
available at the calliper.
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International Journal of Management, Technology And Engineering ISSN NO : 2249-7455
Force applied by driver (Fd) - 100N (assumed)
Leverage- 5:1
No. of pistons per calliper- 1
calliper:
Bore of calliper piston - 32mm
Bore of TMC- 19.08mm
Co-eff of friction of brake pads (μ) -0.4
Effective disc diameter- 190mm
Net force applied at the master cylinder: 50*leverage = 100*5 = 500N
Area of master cylinder (Am) : π*(19.08/2)2
= 2.86x10-4 m2
Pressure developed in the system (P):force / Am
500/2.86x10-4
= 1748251.75 N/m2
Since the pressure in the system is entirely same so the brake force at the calliper can be
calculated as follows:
Area of the calliper piston (Ac) : π*(32/2)2
= 8.04x10-4 m2
Therefore,
The force on calliper (Fc): P*Ac
(1748251.75)*(8.04x10-4)
= 1405.6N
This is the force acting on one rotor but we are using 2 rotors (one on each rear wheels),
so the total force:
2* Fc = 2*1405.6 = 2811.2N
Total frictional force = Fc*μ = 2811.2*0.4
=1124.8N
Braking torque produced: (frictional force)*(effective disc radius)
1124.8*0.09 = 105Nm
Braking torque - 105Nm
Stopping distance: 12m
Stopping time :1.8s
References
1) [Link]
2) [Link]
[Link]
3) [Link]
4) [Link]
brake-technology-the-fu
5) [Link]
6) [Link]
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