Topology Optimization of Three-Wheeler Electric Vehicle Brake Pedal

Abstract

In this project a new design is proposed on the 3 wheeler vehicle brake pedal for weight reduction and it is analyzed by software named FEA. In this an electrical three-wheel vehicle brake pedal is designed for weight optimization. Brake pedals are widely used in all automotive, which acts as a linkage between occupant and brake mechanism. Existing design seems to be overdesigned as per requirement, FEA used to apply cantilever load Optistruct solver used to perform topology optimization. The model of an existing brake pedal was generated using SolidWorksV5 modeling. Furthermore, the FEA analysis is done using ANSYS workbench 21. A three-wheel vehicle brake pedal was analyzed and optimized for weight reduction in this study. Optimize design will be tested using compression loading UTM machine.

Introduction

I. INTRODUCTION

The automotive industry is constantly striving to produce lightweight vehicles to enhance energy efficiency and reduce emissions. vehicle weight plays a crucial role in determining the performance and efficiency of a car, as reducing the mass of a vehicle results in lower energy consumption. studies have shown that for every 10% reduction in vehicle weight, energy consumption can be reduced by 5-7% (cite). The brake system in a typical automobile operates by transmitting the force applied by the driver on the brake pedal, through hydraulic brake fluid, to the brakes at each wheel. The brake pedal serves as the interface between the driver's foot and the master cylinder of the brake system, allowing the driver to control the speed of the vehicle and bring it to a stop.

In recent years, there has been a growing focus on lightweight materials and their applications in automotive components. Brake pedals, traditionally made from steel, are now being considered for alternative materials to reduce weight while maintaining or improving performance. This study focuses on the optimization of the brake pedal design for weight reduction using topology optimization. The brake pedal of the Mahindra Treo is chosen as the subject for this study. The CAD model of the brake pedal is developed using SolidWorks, a 3D modeling software. The objective of the optimization design is to minimize the weight of the brake pedal while ensuring its structural integrity and performance requirements are met. This research aims to explore the use of alternative materials and design approaches for brake pedal construction, with a focus on reducing weight and cost without compromising safety or performance. The study utilizes topology optimization to achieve these objectives, aiming to contribute to the ongoing efforts in the automotive industry towards lightweight design and improved energy efficiency.

II. PROBLEM STATEMENT

Presently, automotive sedulity continues to strive for lightweight vehicles for perfecting energy effectiveness and emigration reduction. It's vital to design vehicles with an optimum weight for a better performance of the 3-wheeler. In this field, which has boundaries with fixed  morals and regulations, manufacturers continue to work on characteristics, structures, and types of material to develop new factors, which have the same safety specifications but are cheaper than current products the main model. The initial weight of the model is calculated as 437 g. When the data obtained as a result of topology optimization are examined, the maximum displacement is 0.94 mm and the maximum stress value is 103.9 MPa

III. METHODOLOGY AND OBJECTIVE

A. Objective

1. To study 3-wheeler brake pedal component factors affecting its functionality.
2. To develop a 3D CAD model using SOLIDWORKSV5 and perform FEA analysis using ANSYS Workbench on a 3-wheeler brake pedal using static loading.
3. To study Topology optimization of 3-wheeler brake pedal.
4. To perform Topology optimization analysis of the brake pedal by using FEA.
5. Experimental stress analysis of 3-wheeler brake pedal using load applied through UTM
6. Comparative analysis between FEA & Experimental results.     

Conclusion

1) The design and static structural analysis of the existing 3-wheeler electric vehicle brake pedal has been carried out. 2) The stress and displacements have been calculated using ANSYS 21 for 3 3-wheeler electric vehicle brake pedals. 3) From the static analysis results it is found that there is a maximum displacement of 0.3099 mm and Equivalent stress of 38.988 Mpa in the existing 3-wheeler electric vehicle brake pedal 4) By analyzing the design, it was found that all the stresses in the existing 3-wheeler electric vehicle brake pedal were well within the allowable limits and with a good factor of safety.

References

[1] Xiaoping Li, Junming Zhou, Wei Guan, Feng Jiang, Guangming Xie, Chunfeng Wang, Weiguang Zheng and Zhijie Fang “Optimization of Brake Feedback Efficiency for Small Pure Electric Vehicles Based on Multiple Constraints” 11 September 2023 [2] Arun J. Kulangara (Arun), “Topology optimization of lattice structure on a brake pedal” C.S.P. Rao, Jose Cherian 5 June 2021 [3] AKANCHHA R. DIXIT “CRITICAL FEA AND TOPOLOGY OPTIMIZATION OF BRAKE PEDAL WITHOUT CHANGING THE MATERIAL” NOVATEUR PUBLICATIONS ISSN: 2454-7875 VOLUME 3, ISSUE 6, Jun.-2017 [4] Wei LIU, Hongzhong QI, Xintian LIU, Yansong WANG “Evaluation of regenerative braking based on single-pedal control for electric vehicles” May 21, 2019 [5] Hongwen Hea, Chen Wanga, Hui Jia, Xing Cui “An intelligent braking system composed single-pedal and multi-objective optimization neural network braking control strategies for electric vehicle” 13 November 2019 [6] Kyoung Hyun Kwak, Yu he, Youngki Kim, Yue Ming Chen, Shihong Fan, Justin Holmer, Jason H. Lee “Desired Relative Distance Model-based Personalized Breaking Algorithm For One-padel Driving Of Electric Vehicle” 2022 10.1016/j.ifacol.2022.11.162 [7] Özlem Akçay1* , Cumali ?lk?l?ç “Structural Optimization of the Brake Pedal Using Artificial Intelligence” 24.08.2023 [8] Miss. ASHWINI N.GAWANDE, Prof.G.E.KONDHALKAR “Design Analysis and Optimization of Automotive Brake Pedal” June 2017

Copyright

Copyright © 2024 Anjali Sahu. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.