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Optimized Caliper Design for Low Drag Using DFSS Method
ISSN: 1946-3995, e-ISSN: 1946-4002
Published September 17, 2012 by SAE International in United States
Citation: Kim, J., Ryu, N., and Kim, Y., "Optimized Caliper Design for Low Drag Using DFSS Method," SAE Int. J. Passeng. Cars - Mech. Syst. 5(4):1259-1265, 2012, https://doi.org/10.4271/2012-01-1835.
Limiting residual drag torque and fluid displacement is a major requirement of a caliper brake as they are related to the fuel efficiency and the safety of a vehicle. However, it is difficult to simultaneously reduce both the drag torque and the fluid displacement since improving one tends to degrade the other.
This paper investigates a caliper with a high residual drag torque. DFSS (Design for Six Sigma) method was implemented to identify all major factors and the design optimization was performed to achieve a low drag caliper. The prototype was created with the desirable design factors identified in the study and the dynamometer tests confirmed that it is possible to achieve a low drag caliper without sacrificing the fluid displacement.