A REPORT ON Design of Brake calliper assembly unit for Bicycles BY

Name of Student Sodisetty V N B Prasad P.N.Uday

ID No. 2010H141033G 2010H141029G

M.E (Design)

Prepared in partial fulfilment of the course Product Design BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI

November 2011

Table of contents
1. Introduction 2. Mission statement 3. Technical questionnaire 4. Customers need by questionnaire 5. Grouping of customers needs 6. List of metrics 7. Black box model 8. Activity diagram 9. Design drivers 10. FAST method 11. SOP Procedure 12. Function tree 13. Technology road map 14. Cost scenario 15. Product life cycle 16. Concept generation 17. Concept screening 18. Conclusion 19. References

Introduction
A bicycle brake is used to slow down or stop a bicycle. The three main types of brakes are: rim brakes, disc brakes, and drum brakes. Most bicycle brake systems consist of three main components: a mechanism for the rider to apply the brakes, such as brake levers or pedals; a mechanism for transmitting that signal, such as Bowden cables, hydraulic hoses, rods, or the bicycle chain; and the brake mechanism itself, a calliper or drum, to press two or more surfaces together in order to convert, via friction, kinetic energy of the bike and rider into thermal energy to be dissipated. Spoon Brake The spoon brake consists of a pad (often leather) or metal shoe (rubber faced), which is pressed onto the top of the front tyre. These were always rod-operated by a right-hand lever. It consists of a spring-loaded flap attached to the back of the fork crown. This is depressed against the front tyre by the rider's foot. Advantages and disadvantages of spoon brake Perhaps more so than any other form of bicycle brake, the spoon brake is sensitive to road conditions and increases tyre wear dramatically. Duck Brake The duck brake or Duck Roller Brake used a rod operated by a lever on the handlebar to pull twin friction rollers (wood or rubber) against the front tyre.Mounted on axles secured by friction washers and set at an angle to conform to the shape of the tyre, the rollers were forced against their friction washers upon contacting the tyre, thus braking the front wheel.A tension spring held the rollers away from the tyre except when braking.Braking power was enhanced by an extra-long brake lever mounted in parallel with and behind the handlebar, which provided additional leverage when braking (two hands could be used to pull the lever if necessary. Rim brakes In this type of brakes, Braking force is applied by friction pads to the rim of the rotating wheel, thus slowing it and the bicycle. Brake pads can be made of leather, rubber or cork and are mounted in metal "shoes". Rim brakes are typically actuated by the rider squeezing a lever mounted on the handlebar. Types of Rim brakes 1) Rod-actuated brakes The rod brakes also called as stirrup brakes uses a series of rods and pivots, rather than Bowden cables, to transmit force applied to a hand lever to pull friction pads upwards against the inner surface, which faces the hub, of the wheel rim. Rod brakes are used with a rim profile known as the Westwood rim, which has a slightly concave area on the braking surface and lacks the flat outer surface required by brakes that apply the pads on opposite sides of the rim. The rear linkage mechanism is complicated by the need to allow rotation where the fork and handlebars attach to the frame.

2) The calliper brakes The calliper brake is a class of cable-actuated brake in which the brake mounts to a single point above the wheel, theoretically allowing the arms to auto-centre on the rim. Arms extend around the tyre and end in brake shoes that press against the rim. While some designs incorporate dual pivot points, the arms pivot on a subframe and the entire assembly still mounts to a single point. 3) Disc Brake A disc brake consists of a metal disc attached to the wheel hub that rotates with the wheel. Callipers are attached to the frame or fork along with pads that squeeze together on the disc. As the pads drag against the disc, the wheel - and thus the bicycle - is slowed as kinetic energy (motion) is transformed into thermal energy (heat). (In basic operation, disc brakes are identical to rim brakes.) A bicycle disc brake may be mechanically actuated, as with a Bowden cable, or hydraulically actuated, or a combination of the two. Types Of Disk Brakes There are two main types of disc brake: mechanical (cable-actuated) and hydraulic.. Advantage of Hydraulic Brake Modern hydraulic disc brakes generate more stopping power than mechanically actuated disc brakes. Advantages Of Mechanical Brakes The advantages of mechanically actuated disc brakes are in their lower cost, lower maintenance, and lighter system weight. Additionally, mechanically actuated disc brakes can be used with drop handlebars. Advantages of disc Brakes Disc brakes tend to perform equally well in all conditions including water, mud, and snow due to several factors: 1. The braking surface is farther from the ground and possible contaminants like mud which can coat or freeze

on the rim and pads.

2.

Disc brake pads when fully retracted ride much closer to the braking surface than rim brake pads.This better

prevents a build-up of water or debris under the pad. 3. There are holes in the rotor, providing a path for water and debris to get out from under the pads. Drum brakes Bicycle drum brakes operate like those of a car, although the bicycle variety use mechanical rather than hydraulic actuation. Two pads are pressed outward against the braking surface on the inside of the hub shell. Shell inside diameters on a bicycle drum brake are typically 70 120 mm. Drum brakes have been used on front hubs and hubs with both internal and external freewheels. Both cable- and rod-operated drum brake systems have been widely produced.

Mission statement:

Bicycle brake calliper product

Product Description:Stops a bicycle in the quickest time and also is economically feasible. Key business or humanitarian goals: 2 months design and development of prototype. Primary market: General usage for students and common people Secondary market: Ardent Bikers Assumptions:Operating cost will be minimal. Quick in action. Long Life, less wear of pads, Less Mechanical force required. Avenues for creative design:Ergonomic structure. Different materials for brake pads. Scope limitations: Reuse of worn out parts. Interchange ability of brake wires.

Technical questioning for the bicycle brake calliper

1) What is the problem really about? Existing brake callipers wear down quickly and sometimes do not act properly. Replacing worn down parts are at times higher. 2) What implicit expectation and desires we want? It should be noiseless, easy to setup and should have quick action. 3) Are stated customer needs, functional requirements and constraints truly appropriate? The original concept is developed considering the problems faced by the students and customers based on their interviews. The replacement sometimes becomes a costly affair, 4) What avenues are open for creative design? Different materials can be used for brake pads and processes can be used to reuse the rubber from the worn out pads. 5) What avenues are limited or not open for creative design? Limitations and scope: No reuse of worn out parts. No electrical power 6) What characteristic/ properties must the product have? It should be easy to install, durable, and have adjustable straddle wire. 7) What aspects of the design task can and should be quantified now? Customer Needs analysis, development costs to be covered by profits, research estimates should be carried out to understand competition. 8) What are the technical and technological conflicts inherent in the design task? Compact size vs. balancing surface area and larger mechanical advantage.

Like/dislike method of data collection form

Customer Data: Brake callipers Customer: Siva sai Kodali Address: V.I.T Willing to do follow up? Y Type of user: College student Question Costumer need Typical uses Stopping a bicycle Likes

Interviewer(s): S V N B Prasad & P.N. Uday Date: 27-10-2011 Currently uses : Rim brakes Interpreted need Importance

Dislikes

Suggested improvements

Pad wear should be minimal Setup should be made easy Parts should be interchangeable alignment shoes Stops quickly when wet Long life and strength Aesthetically pleasing Noise produced during braking Poor performance when rim is wet Prone to clogging with mud Heavier structure Brake lever is tight Slippage of brakes when centre pivot is not correctly placed Disc brake Hydraulic braking system Less wear off Make effective braking area more

Less Pad wear Easy to set up Interchange ability is required Easy to toe shoes Great stopping power Durable and rigid Aesthetic pleasing Squealing of brakes to be avoided Strong braking conditions Clearance between ground and callipers Light weight Effective force transmission Adjustment and proper alignment

Good Should Good Good Should Should Good Should Good Good Good Should Good

Customer needs collected by conducting questionnaires and interviews

Grouping of Customer needs

Customer Need Interviewer : P N Uday & S V N B Prasad Sample size : 12 customers Average customer : Male/Female, age 20-30 Students
1. Usage/Manipulation a) Ease of Setup b) Adjustment & proper alignment c) Interchangeability Aesthetics a) Aesthetically pleasing

Weight

4 3 2 3

2.

3.

Stability a) Long life & strength b) Resistance to corrosion Size a) Light Weight b) Compact Proper Working a) Less Pad wear b) Strong Braking c) Effective force transmission d) Good response e) Easy replacements of worn out parts Cleaning a) Mud should not clog on calipers Cost a) Installation Cost b) Maintenance Cost Temperature a) Less heat to be generated

4 3

4.

3 4

5.

4 3 3 3 2 2

6.

7.

3 4

8.

List of metrics for brake callipers

Black box model

Activity diagram

Purchase /Get With Bicycle

Install in the cycle

Disposal

Prepare to Brake

Prepare to wash & clean

Home position

Braking

Clean The brake

Wash

Return From Braking

Return from washing/cleaning

Design drivers

Sales Profit

Ease of setup

Profitable Operating Condition

Manufacturing Cost

Bowden Cables

Callipers

Effort Braking Condition

Weight

Braking

FAST METHOD

Support structure

Reduce noise

Ergonomic system

Create aesthetic appeal

Stop Bicycle

Apply brakes

Convert mechanical force to friction

Actual force

Apply force

Hold Pads in position

Actuate tension in brake wire

Hand force

Press pads

Generate friction

Generate friction

Reduce friction

Reduce friction

Subtract and Operate applied to Brake callipers

Calliper

Brake pad

Adjusting barrel

Brake lever

Anchor bolt

No provision for holding brake pads

No defined way of stopping

No provision for lengthening and shortening of cable wire

Mechanical squeezing is not converted to tension

No way to hold the cable wire in place

No way of transmitting force to rim Toe-in will not be achieved

No way of holding against the rim

No way of adjusting slack when brake shoes wear down.

No way of pulling the callipers

No provision for reducing impact noise

Indexing not possible on geared shifting cables

Slow forward motion of bicycle can be achieved Safety issues will be failed Aesthetic appearance reduced Difficult to clean undefined body

No prevention of squeaking

Function tree for brake callipers

Stopping Of Bicycle

Input Force

Input Signal

Hold

Apply Brakes

Provide Stoppage

Accept Force Control Force

Support Assembly

Contain vibrations

Hold rim

Adjust position Support assembly Dampen vibrations Control rotation Secure Assembly Transmit force

Hold force

Adjust assembly

Accept Signal

Convert Force To friction

Apply Brakes

Hold signal

Apply Friction

On pads
Control signal Generate noise

Control tension in cable

Drag lever

Transmit Signal

Reduce noise

Release lever

Technology road map

Functional elements

Technologies

Actuation mechanisms

Mechanical

Hydraulic

Dual type

Pivot Config.

Single pivot

Dual pivot

Operation type

Rod actuated

Bowden cable actuated

Brake levers

Standard pull levers

Long pull levers

Rim brake type

Side pull

Centre pull

V brakes

Delta
Time brakes

Brake type

Spoon brakes

Duck brakes

Rim brakes

Drum brakes

Disc brakes

Drag brakes

Time

Cost scenario

Category Labour costs Large calliper: Assembly Handling Total Fabrication costs Large calliper: Materials Parts Tooling Total Installation costs Large calliper: Installation cost Engineering costs Avg. 10 weeks per product Maintenance cost Avg.1 time per week

Projected cost($)

Cost per product($/clipper)

$300,000 $225,000 $525,000

$9 $6 $15 (avg. calliper)

$390,400 $250,300 $10,000 $650,700

$20 $9 $5 $34 (avg.calliper) $6 (avg. calliper) $12 (avg. calliper) $3 (avg. calliper) $70 (avg.calliper)

$10,000 $115,000 $5,000 $1305,700

Total cost

Product life cycle S-curve

Concept generation

Convert Mechanical Force To Friction

Accumulate Energy

Apply Braking Force to Wheel

Liquid/oil Liquid/oil

Piston Piston

Single Impact Single sImp

Water/Oil Water/oil

Piston Multiple Impact

Bowden Cables Bowden Cable

Electrical Load

Electro Magnet

Cables

Convert Mechanical Force To Friction

Accumulate Energy

Apply Braking Force to Wheel

Liquid/oil Liquid/Oil

Piston

Water/Oil Water/oil

Piston

Push Brake

Bowden Cables Bowden Cable

Cables

Electro Magnet

Electrical

Multiple Impact

Concept Screening(Pughs Method) )

Selection Criteria

Rim Brakes

Electro -Magnetic Brakes

Pneumatic Disc Brakes 0 + 0 1 3 3 -2 4 No

Hydraulic BrakesBrakes 0 + + 2 1 3 -1 3 Combine 0 0 + + 0 + 3 1 0 3 1 Yes

Ease of Setup Light Weight Strong Braking Good Response Compact Effective Force Transmission Sum +s Sum 0`s Sum s Net Score Rank Continue?

0 0 0 0 0 0 0 6 0 0 2 Yes

0 + 0 + 2 1 2 0 2 Revise

Conclusion
We have done design of brake callipers for bicycles using product design techniques. The customers needs, cost scenario, constraints, specifications are taken into consideration. Through this study we found that Electromagnetic brakes are good prospect, more study is required in this field to implement them on a full-fledged basis. More experimentation needs to be done to make them more compact.

References
1) Design Websites 2) Text book on Machine design by V.B.Bhandari. 3) Bicycle brake callipers Wikipedia 4) Manufacturers catalogue of Dawson India Pvt ltd 5) http://engin1000.pbworks.com/w/page/18942694/ElectromagneticBicycleBrake