International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 07 Issue: 08 | Aug 2020 www.irjet.net p-ISSN: 2395-0072

Design of Electronic Wedge Braking System for Go-Kart

Sanket Sudhir Patil1, Rajiv Sadanand Gangatirkar2, Neeraj Ajaykumar Inamdar3,

Prajwal Pravin Bhosale4

1-4Student, Dept. of Mechanical Engineering, Padmabhooshan Vasantraodada Patil Institute of Technology,
budhgaon, Sangli, Maharashtra, India.
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Abstract – This paper present the design of EWB braking 1.1 COMPONENTS OF EWB SYSTEM
system for Go-Kart. It is new way braking system i.e. braking
without hydraulics like the conventional bakes .It can The EWB is newly raised braking system. The EWB will
dramatically reduce stopping distance of Go-kart compared be far superior to any brake system in present for go kart.
with conventional hydraulic braking system. EWB is based on The EWB system decreases stopping distance .EWB system
wedge principle to provide a self-reinforcement mechanism, mainly contains calliper, E-pedal, battery and main brake
resulting in reduce current to the actuation motor. The controller .The detailed information of this components is as
clamping force and braking time of the proposed EWB are follows.
shown to satisfactory with respect to the required braking (1) BRAKE CALIPER-
deceleration. A new design of electronic wedge brake system is
presented to replace and to overcome the shortcomings of
hydraulic brake system.

Key Words: Electronic wedge brake, Go-kart brake system,

Wedge mechanism.

1. INTRODUCTION

The main concept behind this paper is that to give a efficient

and reliable EWB braking technology for go karts.

Brake system is one of the most important mechanical

components in any moving vehicles. This system must be
able to provide sufficient stopping effort in order to control BRAKE CALLIPER
longitudinal motion of the vehicles. Braking system of EWB calliper contains brake pad, two DC motors, wedge
vehicles are always given the priority when the safety issues shaped system and rollers .In EWB calliper piston and the
are addressed. Generally in Go-kart hydraulic braking fluid ducts are replaced by a double plate, slick on one side
system is used, but this type of braking system may leads to and the featuring wedge-shaped “teeth” on the other .The two
leakage and vaporization of hydraulic fluid at high teethed plates face each other and lodged between the teeth
temperature which will cause major problems such as are small cylindrical rollers .In the calliper, as with a regular
hydraulic brake failure. For increasing performance of brake, the rubbing pad is set against the floating plate of the
braking system we can use Electric Wedge Braking system calliper. Two small electrical motors also located in the
(EWB). calliper move the wedge against one another. As a result
when the brake pedal depressed, the wedge are activated;
The EWB is a pure electronically actuator that typically they push back both plates and force the pads against the
comprises of an electric motor driving the wedge mechanism disc. Here the wedge effect automatically increases the brake
to clamp and release the brake rotor. In Go-kart while doing force that is applied. In reality; it’s the kinetic energy of the
drift and skid sometimes brake issues arise so we need moving vehicle that helps to slow it down. In other words, the
assured braking system. In that case we can use EWB faster the vehicle goes, the harder the brake reacts.
braking system rather than other conventional braking
system. Other conventional brake takes between 140 and
170 milliseconds to generate full braking power, the EWB
needs only about 100 milliseconds and therefore shorten the
braking distance. The wedge uses a Go-kart‘s kinetic energy
converting it into braking energy. By reinforcing itself this
way, the EWB needs only one tenth of the actuating energy
required by today’s hydraulic braking system.
© 2020, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 4177
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 08 | Aug 2020 www.irjet.net p-ISSN: 2395-0072

(2) E-PEDAL (4) BATTERY-

E-PEDAL

The brake pedal is pedal that you press with your foot in
order to make a vehicle go slower or stop. E-pedal is the
connecter between battery and main brake controller. When
the driver engages the brake pedal, the EWB system
BATTERY
electronically transmits the activation sign to the
interconnected brake modules. E-pedal is connected with The battery is the main source of electrical energy in go kart
battery and main brake controller. or any other automotive. It only stores chemicals not
electricity.
(3)MAIN CONTROLLER or ELECTRONIC CONTROL
The typical 12-volts wet cell type battery is used in go kart
UNIT (ECU) which is mostly used in automotive. Battery is six cell units
and is made of plastic enclosures with each cell having a set
of positive and negative plates immersed in an electrolyte.
Each cell has a voltage of around 2.1 volts when fully
charged, leading to combined battery voltage of about 12.6
volts.

The main purpose of the battery used in go kart Or any

automotive is to operate the starter motor and to provide
sufficient current for the ignition system during engine
cranking. But in this EWB braking system battery used for
one more purpose that is to provide a sufficient current to a
caliper through e-pedal. By which caliper does further
MAIN CONTROLLER working .Battery plays vital role in this EWB braking system.

Electronic control unit is the main system to operate the DC 1.2 THE EWB
motor by controlling the EWB actuator. The interior design
of ECU is based on minimum system of microcontroller unit The prototype of EWB system has been developed through
(MCU) and motor driver circuit17. The MCU is installed the modification of conventional brake calliper taken from
based on the microcontroller minimum system (minsys) an existing automotive brake system. The model showing the
circuit. The minsys refers to the minimum circuit internal components of the EWB actuator can be seen fig. 1
configuration in order to operate MCU properly. The
minimum circuit system provides necessary input or output
(I/O) port to support the MCU. The output port from MCU
will provide signal to drive the motor. However, the signal
obtained from MCU alone cannot directly control the motor
because the current is very low. Hence, motor driver circuit
will act as current buffer for the MCU to drive the DC motor.

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 08 | Aug 2020 www.irjet.net p-ISSN: 2395-0072

braking system playing important role.The efficient braking

system like EWB is very useful for in events like drifting,
skidding and always very useful for long racing events.

The components that are used in EWB braking system are

attached in go kart at comfortable position. E-pedal is placed
at as same as normal pedal position. EWB brake controller is
the important part of this braking system and this is placed
in front of sheet and on the chassis. Battery is attached
backside of the sheet. Caliper is imposed on the disk which is
connected to the shaft. The systematic arrangement of EWB
braking system for go kart is as shown in following
computer aided design (CAD) model:

INTERNAL COMPONENTS OF EWB ACTUTOR

The DC motor drives the input through worm pinion in MODEL OF GO KART
rotational displacement. The worm pinion rotation is then
redirected as clamping motion by means of worm gear 2.1 CALCULATIONS –
reducer coupled with thrust ball bearing to reduce Tooth
friction. Backlash between gears can be ignored since the We consider -
motion is one way although involving both left and right
rotational movement. This is due to the fact that Clamping (1)Kart-weight=200kg.
force only occurs on worm gear at its first tooth face. The (2) Disc diameter=200mm.
worm gear reducer is mounted along with the first wedge (3) Mean effective radius (re)=100-10=90
mechanism where wedge mechanism is designed with slider (4) Speed of kart=45 kmph=12.5
shape inner cylinder so that it can maintain its alignment (5) Coefficient of friction between pad and disc= (µ) =0.4
with the second wedge mechanism. (6) Force generated by roller=Froller=11255.55 N
(7) Wedge angle=β=30°
The second wedge mechanism is mounted along the piston
and located in between a cavity boundary. The cavity As per above consideration we calculate,
boundary located at the centre of calliper casing has been
Designed square shaped so that the second wedge (1) Force generated by caliper pad on disk-
mechanism could slide linearly without rotation during
countering the rotational motion of the first wedge. Studs are FN = F roller × cos β
added to the piston aligned with the cavity boundary to
reduce shear friction between cavity wall and wedge = 11255.55 × cos 30°
mechanism. Compression springs are installed around studs
to provide spring back motion at the piston. By acting FN = 9747.5922 N
against cavity boundary, the compression spring act to
retract back the piston to avoid the piston from jammed on (2) Clamping Force (FCL)
brake pads and also to reduce noise between brake pad and
first wedge mechanism due to floating nature. FCL= 2 × FN

2. DESIGN OF EWB SYSTEM ON GO KART = 2 × 9747.5922

A go kart is a simple small open wheel vehicle used for basic FCL = 19495.1845 N
motorsport events. Because of these types of events efficient

© 2020, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 4179
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 08 | Aug 2020 www.irjet.net p-ISSN: 2395-0072

(3) Braking Force (FB) t = 0.32 sec

FB = µ × FCL ∴ Braking time of Go-kart is 0.32 sec.

= 0.4 × 19495.1845 ADVANTAGES USING EWB SYSTEM IN GO KART-

FB = 7798.0738 N (1) It is a very efficient braking system.

(2) It responds faster compare to other conventional braking
(4) Braking Torque (TB) system and having faster reaction time.
(3) There is no need for brake lines, vacuum boosters, servo
TB = FB × Effective radius units and because of these elements are eliminates some
amount of weight is also reduces.
= 7798.0738 × 0.09 (4) It requires one tenth of the energy compare to other
conventional braking system.
TB = 701.8266 N/m
DISADVANTAGES USING EWB SYSTEM IN GO KART-
(5) Max Deceleration -
After some time battery get discharged due to continues
Braking Force supply to caliper or other electronic elements, hence Battery
Max Deceleration = discharging is main disadvantage of this system in go kart.
Weight
3. CONCLUSION
7798.0738
= As per above discussion, the design of EWB braking system
200 in go kart have a faster reaction time which make the
braking system more efficient. It reduces the stopping
Max Deceleration = 38.99 m/s2 distance by 15% as compare to hydraulic braking system.
The results show that this system using in go kart make
(6) Stopping Distance – braking system more effective and effectual. The braking
system is more reliable.
By using kinematic equation
V2 –u2 REFERENCES
S =
2a [1] Wedge braking system by Technical word
(latesttechnology-world.com)
0 - (12.5)2 [2] Roberts, R., Schautt, M., Hartmann, H., and Gombert,
=
B. Modelling and validation of the mechatronic
2× 38.99 Wedge brake. Paper 2003-01-3331, 2003. (SAE Paper).
S = 2.0037 m [3] Hartmann, H., Schautt, M., Pascucci, A., and
Gombert, B. eBrakeH: the mechatronic wedge brake.
paper 2002-01-2582, 2002. (SAE Paper).
∴ Stopping distance of Go-kart running at a speed of 45
[4] “Theory of Machine” by “R, S Khurmi and J.K.Gupta
kmph is 2.0037 m.
[5] Wedge brake EWB by Siemens-electronic (paultn.org) .
(7) Stopping Time [6] Vimal Rau Aparow, Khisbullah Hudha, Fauzi Ahmadb,
Hishamuddin Jamaluddin journal paper on modeling
By using kinematic equation and validation of electronic wedge brake mechanism for
Vehicle safety system.JURNAL TEKNOLOGI Paper).
S = 1/2 (u+v) t

We have S = 2.0037 m

2.0037 = 1/2 (12.5+0) t

2.0037 × 2
t=
12.5

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