Rotor Design Version 1

The Mitsuba motors being used require a specific type of rotor that does not fit the conventional design. Unfortunately, there is only one option available for this type of rotor, and it is not capable of handling the breaking load required for the application. As a result, we had to develop special rotors.

Finite Element Analysis

Test Conditions

The loads acting on the rotor are the normal force and the torque applied from the brake caliper. The force calculation can be viewed here:

Calculations

Fixtures were added in all the bolt holes.

Result

As with all our design, we aim for a FOS of at least 1.4. This FEA study shows a that the minimum FOS of the design is ~4.6. These are great results. The design passes!!!

Manufacturing

Design failed. Reasoning can be found here:

Bolt Failure

We decided to redesign the rotor.

Version 2