Design and Fabrication of Test Rig for Disc Brakes

The brakes are one of the most important aspects of a vehicle since it fulfills all the stopping functions and requirements. Automobiles are subject to many forces using operation. Vibrations from the engine or the road-surface transmit through the vehicle?s chassis and suspension to the most essent

Project Title

Design and Fabrication of Test Rig for Disc Brakes

Project Area of Specialization

Mechanical Engineering

Project Summary

The brakes are one of the most important aspects of a vehicle since it fulfills all the stopping functions and requirements. Automobiles are subject to many forces using operation. Vibrations from the engine or the road-surface transmit through the vehicle’s chassis and suspension to the most essential mechanical component of the vehicle, the brake system.

Our FYDP project is based on “The Design and Fabrication of Test Rig for Disc Brakes “for Vibrational Testing. It is solution to the problem of increasing costs of product production in industry. Our project is to design a cost-efficient and accurate device to measure the vibrations produced in different disc brakes. Our design includes a Test stand on which the motor will be mounted to rotate the disc brake. Sensors will be mounted to measure the vibrations produced and DAS (Data acquisition System) will be used to record and process the information.

Firstly, detailed literature review was carried out to study already existing similar projects and find their limitations and how they can be improved in various aspects. Using suitable mathematical equations maximum load, Torque and other design parameters were calculated. Suitable choice of Motor was made keeping in view these requirements. Suitable Dimensions for Test stand were finalized and then 3D model of test stand was built in CREO and ANSYS analysis was performed to verify the results. Different types of sensors are also being studied for optimal performance.

Initial Phase of Market survey was carried out to find the availability of desired motor and check for the types of sensors locally available. Specimen of different materials were also collected to select suitable one to build test bench.

Project Objectives

Disc brakes are important vehicle part so there is need of an effective, accurate, economical, and compact device which can measure vibration produced in them.

The goal of our FYDP project is provide solution to the problem of increasing costs of product production in industry and design a cost-efficient and accurate device to measure the vibrations produced in disc brakes. Our design includes a Test stand on which the motor will be mounted to rotate the disc brake. Sensors will be mounted to measure the Page 10 of 25 vibrations produced and DAS (Data acquisition System) will be used to record and process the information.

Project Implementation Method

The Test Bench will consist of three subsystems, namely driving unit, braking unit and measurement facilities. The driving unit consists of a motor that rotates the driving shaft at different rotating speeds. This is achieved with the help of a VFD controller. The main goals of this subsystem to provide the adequate rotational speed of the disc brake. The braking unit comprises the front disc brake assembly of a passenger car. It is composed of the brake ventilating disc with its floating caliper. The measurement facilities including suitable instruments to measure Rotating speed and acceleration/vibrations.

• • Drive motor
• • Drive shaft 4. Support bearing with stands
• • Drive motor on/Off switch
• • VFD controller
• • Disc/Rotor for testing
• • Sensors

Benefits of the Project

This Test Rig is

• Cost effective
• Small and compact
• Multipurpose

This Test Rig can be used in

• Small industries
• • Auto Repair Shops
• • Educational Purposes

Technical Details of Final Deliverable

900-2000 variable RPM

ADXL Average Accelerometer to Measure VIbrations

1 hp AC Motor with VFD Controller

Arduino to Process DATA

Final Deliverable of the Project

Hardware System

Core Industry

Manufacturing

Other Industries

Education

Core Technology

Others

Other Technologies

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com