Comprehensive Analysis and Development of a Solar Electric Vehicle Brake Disc

Effective braking systems are critical for ensuring safe and controlled deceleration in any vehicle. The advancements in the brake systems over the years have seen a surge in the utilization of disc brakes. This study outlines the complete design, analysis, validation, and fabrication of a custom brake disc developed for a student-built solar car competing in the ESVC 3000. Based on vehicle dynamics and brake design fundamentals, key parameters like braking force, torque, disc size, and heat transfer were calculated. Among three proposed designs, AB-3 was chosen for its superior thermal and mechanical performance. The disc (with AB-3 design) was then fabricated using a vertical machining centre and tested on the car under different braking conditions, including sudden stops, gradient holding, and repeated braking to simulate heat buildup. The brakes performed reliably without any signs of failure and maintained consistent performance throughout. The final system performed reliably during the ESVC3000 competition, contributing to the car’s recognition in braking and acceleration events.