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CAD DESIGN PROJECT
MOUNTAIN BIKE DISC
BRAKING SYSTEMS
DARYN MEGAW
DAVID GORDON
GARETH EDWARDS
DAVID BELLINI
STANDARD CALIPER DESIGN
POOR - MODERATE BRAKING PERFORMANCE
POOR IN WET CONDITIONS
USES STANDARD LEVERAGE RATIO
VEE BRAKE SYSTEM
MODERATE - GOOD BRAKING PERFORMANCE
APPLY PADS TO THE WHEEL RIM
POOR PERFORMANCE IN WET CONDITIONS
USES VEE BRAKE SPECIFIC LEVERS
DISC BRAKE SYSTEMS
STRONG, EFFECTIVE BRAKING PERFORMANCE
GOOD PERFORMANCE IN WET CONDITIONS
CONSISTENT, SMOOTH APPLICATION OF BRAKING
SLIGHTLY HEAVIER THAN CALIPER OR VEE BRAKE SYSTEMS
TYPES OF DISC BRAKES
Mechanical
Design
LESS EXPENSIVE THAN
HYDRAULIC DISC BRAKE
SYSTEMS
WORKS WITH STANDARD RIM
Hydraulic
Design
COSTLY
SELF ADJUSTING
PRECISE AND POWERFUL
BRAKE LEVERS
BRAKING
SIMPLE ADJUSTMENT AND
HIGHER MAINTENANCE
MAINTENANCE
REQUIRED
NOT AS SMOOTH OR
REQUIRES HYDRAULIC
POWERFUL AS HYDRAULIC DISC
SYSTEMS
LEVERS
IMPROVEMENT GOALS
INTERCHANGABLE HYDRAULIC / MECHANICAL UNIT
VARIATIONS IN BRAKE ROTOR OPTIONS
IMPROVED BRAKING SURFACES
EASE OF ADJUSTABILITY
BETTER MODULATION
LOW UNIT COST
OVERALL DESIGN ASPECTS
RECOGNIZE INTERNATIONAL STANDARDS
MANUFACTURING CONSIDERATIONS
EASE OF SERVICABILITY
WEIGHT FACTORS
AESTHETICS
COSTS
COMPONENT BREAKDOWN
COMPLETE SYSTEM
Rotors
& Hubs
Mechanic Hydraulic
Caliper
Lever
Hydraulic
Caliper
HUB & ROTOR Design
specification
USE OF SEALED BEARINGS THROUGHOUT FOR
MAINTENANCE PURPOSES
COMPATABLE WITH STANDARD QUICK RELEASES AND
20mm THROUGH AXLE STANDARDS
TOOLESS DISSASSEMBLY OF THROUGH
AXLE FOR WHEEL CHANGES
MUST USE HAYES ROTOR
MOUNTING STANDARD
HOPE 20mm FRONT HUB
MECHANICAL CALIPER DESIGN
SPECIFICATION
LEVERAGE RATIO SUITED TO STANDARD VEE BRAKE
LEVERS
PROVIDE ADEQUATE BREAKING FORCE
REMOVABLE MECHANISM
GIVE ZERO PAD DRAG
PERFORM RELIABLY
HAYES MECHANICAL
CALIPER + ROTOR
HYDRAULIC LEVERS
ERGONOMICAL DESIGN
OPEN BATH DESIGN
ROBUST DESIGN
HOPE HYDRAULIC
LEVER
HYDRAULIC DISC
MUST USE OPEN BATH SYSTEM
PROVIDE ADEQUATE
BRAKING FORCE
USE READILY
AVAILABLE
SEALS
HAYES HYDRAULIC
UNITS
MATERIALS SELECTION
THE HUBS - 6061 Al Alloy
LIGHT WEIGHT
HIGH STRENGTH
WEAR RESISTANCE
MACHINABILITY
HYDRAULIC FITTINGS
Barrel inserts- Mild Steel
WEAR RESISTANCE
RIGIDITY
THE ROTORS - Carbon Fibre
THERMAL PROPERTIES
CORROSION RESISTANCE
COEFFICIENT OF FRICTION
WEIGHT
CALIPER HOUSING - 6061 Al Alloy
LIGHT WEIGHT
HIGH QUALITY SURFACE FINISH
HIGH RIGIDITY
MECHANICAL FITTINGS - Mild Steel
Pistons - Brass
GOOD BEARING QUALITY
HIGH STRENGTH
HIGH WEAR RESISTANCE
Rear hub assembly
Rear hub section
Rear hub explosion
Rear hub explosion
Rotor center
Rotor assembly
Rotor explosion
Bearing explosion
Front hub assembly
Front hub section
Front hub /
through axle
Front hub section
Lever front view
Lever rear view
Wireframe view
Wireframe view
Hydraulic Lever
Lever explosion
Lever section
How a hydraulic
lever works
Caliper assembly
Wireframe
views
interchangeable insert
Hydraulic insert
Mechanical insert
Caliper explosion
Caliper assembly
Full assembly
Full assembly
Full assembly
Full assembly