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CAD D ESIGN P ROJECT. M OUNTAIN B IKE D ISC B RAKING S YSTEMS. D ARYN M EGAW D AVID G ORDON G ARETH E DWARDS D AVID B ELLINI. S TANDARD C ALIPER D ESIGN. POOR - MODERATE BRAKING PERFORMANCE POOR IN WET CONDITIONS USES STANDARD LEVERAGE RATIO. V EE B RAKE S YSTEM.
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CADDESIGNPROJECT 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 DISCBRAKES Mechanical Design Hydraulic Design • LESS EXPENSIVE THAN HYDRAULIC DISC BRAKE SYSTEMS • WORKS WITH STANDARD RIM BRAKE LEVERS • SIMPLE ADJUSTMENT AND MAINTENANCE • NOT AS SMOOTH OR POWERFUL AS HYDRAULIC DISC SYSTEMS • COSTLY • SELF ADJUSTING • PRECISE AND POWERFUL BRAKING • HIGHER MAINTENANCE REQUIRED • REQUIRES HYDRAULIC LEVERS
IMPROVEMENT GOALS • INTERCHANGABLE HYDRAULIC / MECHANICAL UNIT • VARIATIONS INBRAKE ROTOR OPTIONS • IMPROVED BRAKING SURFACES • EASE OF ADJUSTABILITY • BETTERMODULATION • LOW UNIT COST
OVERALL DESIGN ASPECTS • RECOGNIZE INTERNATIONAL STANDARDS • MANUFACTURINGCONSIDERATIONS • EASEOFSERVICABILITY • WEIGHTFACTORS • AESTHETICS • COSTS
COMPONENT BREAKDOWN COMPLETESYSTEM Rotors & Hubs Mechanic Caliper Hydraulic 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 DISSASSEMBLYOF THROUGH AXLE FOR WHEEL CHANGES • MUST USE HAYESROTOR MOUNTING STANDARD HOPE 20mm FRONT HUB
MECHANICALCALIPER DESIGN SPECIFICATION • LEVERAGE RATIO SUITED TO STANDARD VEE BRAKE LEVERS • PROVIDEADEQUATE BREAKING FORCE • REMOVABLEMECHANISM • 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 • USEREADILY AVAILABLE SEALS HAYES HYDRAULIC UNITS
THE HUBS - 6061 Al Alloy LIGHT WEIGHT HIGH STRENGTH WEAR RESISTANCE MACHINABILITY THE ROTORS - Carbon Fibre THERMAL PROPERTIES CORROSION RESISTANCE COEFFICIENT OF FRICTION WEIGHT MATERIALS SELECTION CALIPER HOUSING - 6061 Al Alloy • LIGHT WEIGHT • HIGH QUALITY SURFACE FINISH • HIGH RIGIDITY HYDRAULIC FITTINGS Barrel inserts- Mild Steel • WEAR RESISTANCE • RIGIDITY Pistons - Brass • GOOD BEARING QUALITY MECHANICAL FITTINGS - Mild Steel • HIGH STRENGTH • HIGH WEAR RESISTANCE
