The objective of this project is to prototype an automation code that can simulate the dynamic response of a drum brake assembly given a force and pressure input.
Sponsored by: Volvo
Team Members
Garrison Scoulos Ian Smith Eric Pham Haoran Yang
Instructor: Asok Ray
Project Poster
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Project Video
Project Summary
Overview
The objective of this project is to prototype an automation code that can simulate the dynamic response of a drum brake assembly given a force and pressure input. This code can be used to predict the motion of the push rod that actuates the braking assembly, as a function of force at a specific chamber pressure. Volvo currently has to manually test and obtain this data at their wheel rigs, which takes time, and is cost and labor intensive.
Objectives
1.) Produce an algorithm that has 95% accuracy or greater at all pressures, when compared to the test data.
2.) Obtain values for unknown parameters
3.) Produce an accurate mass-spring-damper system, that can be utilized, along with the code for further analysis by future engineering teams.
Approach
We gathered and weighed each Customer Need using an AHP Matrix.
The group generated and selected concepts based through mentor and sponsor feedback, which guided us in our approach to solving the problem.
We reviewed the Patent on Volvo’s drum brake system, and its functionality, in order to perform our engineering system analysis.
We received data from the sponsor in the form of excel spreadsheets and cad measurements.
The group utilized MATLAB ODE solver, and Simulink to perform calculations for the project.
The group physically tested some parameters, such as the springs, to determine the values of unknown constants.
Multiple code prototypes were used to sequentially add more sophistication to the system in order account for all of the mechanical features.
We validated our model’s by running them through our sponsor and comparing the data to the physical test data previously performed and measured.
We generated results from our models that were reasonably accurate at certain chamber pressures. These results generally fit the loading and unloading phases of the test curve.
Outcomes
The sponsor will save time and costs by applying this model instead of manually testing at the rigs.
This project sets the stage for further analysis and simulation.
The model prototype creates a foundation for different wheel end configurations as well.
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