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FSAE Braking System Analysis

During my time with the Formula SAE Ontario Tech Racing (OTR) team, I led the complete braking system analysis for our 2024 vehicle. Previously, the team selected components based on what other teams were using or by making "educated guesses," without conducting a detailed analysis.

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I developed a braking system calculator in MATLAB, accompanied by a simple GUI. This tool calculates key braking parameters, such as optimum and actual braking curves, based on system inputs.

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These curves provide critical information, such as:

  • The vehicle’s maximum deceleration

  • The required pedal force for the driver

  • Braking forces distribution

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Additionally, braking curves help identify vehicle behaviour during braking. If the actual braking curve exceeds the optimum curve, the car risks spinning out under hard braking, creating unsafe conditions. Conversely, if the actual curve falls below the optimum, the front brakes may lock up, leading to a safer braking event.

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As a result of the analysis I was able to increase the braking potential by over 28%

This is the GUI for the MATLAB braking calculator. The program can plot the braking curves within the window using the user-provided inputs, a log feature was also created which creates an Excel file with all the braking system inputs alongside the braking curves. 

brake curves_edited.jpg

Here are the definitions of the Optimum and actual braking curves as well as a detailed look at the plot. 

Here is the equation used to determine the optimum braking curve, this is from the textbook. Brake Design and Safety by Rudolf Limpert

Using the braking calculator, I was able to identify that above 1.14 G's of braking the car would tend to spin out which was apparent during vehicle testing. To correct this issue I added a brake proportioning valve which reduces the pressure going to the rear calipers after a set pressure value.

 

For the small cost of $60 to add a proportioning valve, I was able to:

  1. Create a safer car

  2. Increase the vehicle's max de-acceleration by over 28%

  3. Add adjustability to control the behaviour of the car

  4. Add the ability to tune further to the driver's preference 

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