Criteria for designing the Brake System

The Braking system with all its components is designed in accordance with the rule book.
Nowhere any rule is under-estimated.
The Rules are as below:-
1. The vehicle must have at least two (2) independent hydraulic braking systems. Each
hydraulic system shall have its own fluid reserve.
2. The brake system must be capable of locking ALL FOUR wheels in a static condition and
dynamically on pavement AND an unpaved surface.
3. All rigid brake pipes must be mounted securely along the roll cage / other members.
The brakes on the driven axle must operate through the final drive. Inboard braking through
universal joints is permitted

DATA USED
We have used some of the values as given below:
Royal Enfield Bullet Calliper (left) Piston Diameter=2.5cm
Hero Karizma ZMR Calliper (right) Piston Diameter=2.5cm
Number of Pistons in a Calliper=2
Disc Dia. Of Honda CBR(Dd)=22cm
Dia of Master Cylinder=2.22cm
Coefficient of Friction (u)=0.6
Max Velocity (v)=60km/hr.=16.67m/sec
Ht. of C.O.G. from ground(h)=0.524734m
Total Wt. of ATV(M)=320kg
Distance of C.O.G. from Front Axle(xf)=1010.612mm
Distance of C.O.G. from Rear Axle(xr)=539.388mm
Wheel Base(Wb)=1550mm
Wheel Diameter(D
w
)=22 inches=558.8mm
Therefore, Wheel Radius(R
w
)=279.4mm

Calculations For Designing The Brake System

Maximum Deceleration Possible at tyre(a)= u*g=0.6*9.81=5.886m/s
Braking Force(B
f
)=M*a=320*5.886=1883.5N
Stopping Distance(SD)=v/(2*u*g) =16.67/(2*0.6*9.81)=23.596m
Moment on front axle= Moment on rear axle
M
f
=M
r

W
f
*x
f
=W
r
*x
r

W
f
/W
r
=0.539388/1.010612
W
f
+W
r
=320
Front Axle Rest Load, W
f
=111.354kg
Rear Axle Rest Load, W
r
=208.646kg
Y=M
r
/M= 208.646/320= 0.652
X=h/Wb=524.734/1550=0.33854
Front Axle Dynamic Load(M
f
dy)= {(1-Y)+(X.u)}M= {(1-0.652)+(0.33854*0.6)}320=
176.36kg
Rear Axle Dynamic Load(M
r
dy)= M-M
f
dy= 320-176.36=143.64kg
%age Dynamic Load on Front Axle(%
f
dy)=M
f
dy/M=176.36/320=55.11%
%age Dynamic Load on Rear Axle(%
r
dy)=M
r
dy/M=143.64/320=44.89%
We are taking weight distribution as 50:50
Hence, Load on each wheel= 320kg/4= 80kg
Friction force between ground & wheel= 0.6*80*9.81 = 470.88N
Friction Force needed on Rotor= F
r

470.88*279.4=F
r
*110
F
r
= 1196.0352N
Coefficient of friction between pad & disc=0.8 (assumed)
Therefore, Clamping force=F
1
/.8=1495.044N
Force provided by each pad= Clamping force/2=747.522N
Pressure needed At Calliper Piston(P
c
)=Pressure needed At Master Cyllinder(P
m
)
Pressure=Force/Area
P
c
=P
m
=> (F
c
/A
c
)=(F
m
/A
m
)
(747.522/2*2.5)=(F
m
/2.22)
F
m
=294.727N
Force Applied By Foot on Pedal = 50N
=> Pedal Ratio = 294.727/50 = 5.89