Kinematic analysis on concurrent brake actuator design for dynamically modelled motorcycle / Mahamad Hisyam Mahamad Basri

The simultaneous application of front and rear brake are required to obtain a betterbraking performance on the motorcycle. The proper amount of braking force on bothwheels is needed to optimize the braking performance and stability of the motorcycle.The braking effectiveness can be maximized by keeping the ideal nonlinear brakeforce distribution during braking. The objective of this work is to develop a newconcurrent brake actuator (CBA) with nonlinear force distribution to improve thebraking capability and stability control on the motorcycle system. The analysis of theCBA conceptual design was carried out to identify the best actuation mechanism. Theintegration of Design Failure Mode and Effect Analysis (DFMEA) andSOLIDWORKS Motion Analysis have been utilized in this analysis. The optimalbrake force distribution was obtained based on the Altair HyperStudy framework andbecome a design target for CBA. The CBA model was developed based on theconcept of the passive compliant actuator to exhibit the required design target. Then,the kinematic analysis of the CBA model was carried out using the multibodydynamic (MBD) platform offered by Altair MotionView. The validation of theexperiment results possessed an excellent correlation with the CBA performance. Italso found that the simulation results had correctly predicted the overall forcedistribution produced by the CBA. However, spring stiffness and mass of the CBA main body are identified as the significant factors that influenced the CBA performance. Therefore, the optimization analysis was carried out to obtained theoptimum configuration of CBA. Design exploration analysis offered by the AltairHyperStudy-MotionView framework has been used in this study. The range of springstiffness was set between 9.00 N/ram to 20 N/mm. The range of mass for the CBA main body is 0.2 kg up to 0.3 kg. Global Response Surface Method (GRSM) was usedto identify the optimum configuration. Based on this analysis, the spring stiffness of15.30 N/mm with the mass of the CBA main body is 0.255 kg has been selected for CBA configuration. The optimum CBA configuration possessed the best correlation compared to other spring stiffness conditions. The prediction obtained by this optimum configuration had correctly predicted as the design target. Therefore, a new CBA has been successfully developed to distribute nonlinear brake force with CBAmain body mass is 0.255 kg and spring stiffness of 15.30 N/mm. Thus, the braking performance of the motorcycle can be enhanced with this final configuration of the CBA. Therefore, the riders of motorcycles will receive the safety benefit from this CBA design regardless of their skill level and riding experiences.