In October, the Alcon staff invited a handful of Speedhunters to go to its UK headquarters and analysis and improvement services. We had a collection of technical braking questions that have been introduced to us within the feedback part. So we requested them to the Alcon staff. Listed here are the solutions …
Nerd Mode is On …
Why don’t we now have "uncooked" aluminum brakes with the model emblem / title machined on the floor as an alternative of painted calipers? Does portray have any benefits?
Alcon: All our stirrups are "exhausting anodized"; This gives a tough floor (inside bores). Nonetheless, the colour may be very restricted and it is extremely troublesome to keep up consistency, so the paint is utilized to offer an aesthetically interesting and environmentally resistant end.
When upgrading aftermarket brake techniques, is it vital to keep up the braking bias of the brand new system as shut as doable to the entrance / rear polarization of the producer? origin or no matter and let solely the digital parts (eg, EBD) do the sorting?
Alcon: We all the time suggest that the distribution of the brake bias between the entrance and rear be as shut as doable to the OEM configuration.
When upgrading to an Alcon braking system, ie calipers, rotors and bells, does the unsprung weight change have a serious impression on braking? Is it one thing that’s usually missed?
Alcon: One of many nice benefits of lighter brakes is the discount of unsprung mass – it’s a key efficiency goal for any automobile race and in addition advantages all highway autos.
I’m curious to know if there’s a critical dialogue about staggered rotor sizes or if the rear discs are a couple of millimeters bigger than the entrance, with four-way entrance pistons and rear pistons. This can be a commercially obtainable possibility for my automobile obtainable from StopTech, they usually point out that it’s okay to trip on observe. What are the benefits or disadvantages?
Alcon: We calculate a protected steadiness for braking torque from the entrance to the again by combining the disc dimension (from efficient radii), the diameter of the pistons and friction pads. We additionally keep in mind the thermal capability of the discs and the working price of the pads for each axles. If the house obtainable for a disc signifies that we now have an even bigger rear disc than earlier than, we compensate by the friction and the scale of the caliper pistons. Due to this fact, the connection between the diameter of the entrance and rear rotors isn’t an issue so long as the remainder of the system is specified accordingly.
Two-piece rotors (or floating rotors) are thought of higher. Nonetheless, this would go away the disc in tremendous warmth and wouldn’t be dissipated. How can we optimize that? Simply use a rotor in a single piece?
Alcon: The 2-piece rotors are designed in order that the rotor serves as a warmth reserve and the bell is the assist, we carry out predictive calculations of the thermal brake to make sure that the rotor is sized appropriately for the appliance. , this permits us to design the bell in lighter supplies decreasing the rotating mass. Our two-piece assemblies are assembled utilizing "coils" that enable totally different thermal enlargement charges between the bell and the rotor because of the usage of totally different supplies.
Some folks use titanium shims between calipers, pistons and pads to stop warmth from boiling the brake fluid. How would this be optimized to stop the buffer from coming into the tremendous warmth cycle? There are concepts for letting different parts act as a warmth sink, however how far will we isolate warmth?
Alcon: This can be a extra frequent use in motorsports functions, the place the temperatures of calipers, brake fluid, discs and pads might be managed and balanced. in consequence, typically permitting to maintain the warmth contained in the pads in order to remain inside. their optimum temperature vary might be a bonus.
How do you calculate the scale of the grasp cylinder upon getting changed the calipers with bigger piston dimension or extra pistons?
Alcon: We now have our personal inside calculation software program which permits us (on the premise of the car knowledge) to make exact suggestions on the design of the grasp cylinder. For the aftermarket, our kits are designed with nice care to make use of the actuation tools already put in on the car.
How do you calculate the grasp cylinder dimension to account for brake booster removing? (This one is for all LS change guys!)
Alcon: We now have focused pedal efforts and specify grasp cylinder sizes to focus on what’s protected and, if used on the highway, authorized. We should keep in mind the pedal ratio and the wheel brakes. An entire system calculation is required and have to be carried out by a professional brake techniques engineer.
The drilled, grooved and grooved rotors truly appear to hold the pads quicker, with marginal and even negligible efficiency positive factors. How can we differentiate actual performers from devices?
Alcon: Grooved rotors have turn out to be the norm within the aftermarket and motorsport functions, as they’ve a cleansing benefit for bearings, the power to disperse gassing by the pads, higher preliminary grip and moist climate extra constant efficiency. Drilled rotors provide the identical advantages, however endure extra cracks from holes – therefore, drilled rotors at the moment are extra restricted to carbon ceramic choices the place disc cracking isn’t an issue.
I lately upgraded the brakes on my 2006 Honda Accord from inventory to rotor. After a tough cease, the pedal begins to melt. Do I overheat my brake fluid? What’s one of the best ways to decide on an improve for my wants that matches my rotor improve?
Alcon: The issue might certainly be brought on by the truth that boiled brake fluid has brought on the formation of gasoline bubbles within the fluid itself, which is way more compressible and gives flip a gentle and spongy pedal sensation. If the one change made is to fit rotors, this is not going to give any further warmth capability and the braking efficiency achieve shall be minimal. Relying on the rise in braking efficiency required, we suggest bigger discs with improved thermal capability, excessive efficiency pads, and improved caliper.
Does the scale of the disc play a serious position in stopping energy?
Alcon: The scale of the disc might be divided into two points. the diameter of the disc, which will increase the braking energy by rising the torque (leverage), and the mass of the disc, which may retailer extra warmth, which permits the pads and compasses to function extra effectively.
There are a lot of corporations providing "large" brake kits, however how do you filter those who work correctly and those who work as effectively (if not higher) than these of OEMs?
Alcon: The market has certainly been flooded by quite a few corporations promoting "large" brake kits. Our recommendation would all the time be to decide on an organization that’s inherited and well-known for designing excessive efficiency brakes. We’re positive it’s not a shock if our suggestion could be Alcon!
Why do some corporations suppose that the larger it’s, the higher it’s with regard to caliper pistons, is there any fact to that?
Alcon: The caliper piston sizes are calculated from an entire system calculation. What we wish is for the driving force to have pedaling feeling when he stops the car safely. For this, we specify essentially the most acceptable piston sizes, giant or small. Rising the scale of the pistons might be very harmful for disc and rotor brake kits solely, as this may have an effect on the car's steadiness (make it unstable), make the underside of the grasp cylinder much less fluid and trigger issues. issues with stability management techniques.
Does the climate (particularly rain) affect some discs? Is there a design that’s higher within the moist or does it make no distinction?
Alcon: Early carbon ceramic techniques had moist issues. We now have advanced significantly during the last ten years and the distinction between the disc supplies for the moist highway race is minimal.
Why do some folks go for the removing of brake brakes – what are the benefits and drawbacks?
Alcon: The amplifier reduces the pedal effort. Trendy vehicles have boosters that may have ratios between 5: 1 and 11: 1, relying on the unit. Due to this fact, suppressing the booster will improve pedal effort. It’s extremely possible that on some autos, the removing of the booster will increase efforts past the authorized restrict of highway use.
The benefit of suppressing the booster is that there could be a robust acceleration, giving a a lot lighter feeling on the backside of the pace and that the booster can add losses of effectivity to the system. Any removing of a servomotor shouldn’t be carried out on a highway software with out the discover of a accountable and certified brake engineer.
What’s the most temperature that your carbon ceramic brakes can face up to?
Alcon: It relies on how the temperature was generated and the design of the disk geometry. Typically, it’s not the discs that trigger issues, however the pads (with progressive attenuation) and the brake fluid (with boiling).
Does the place of the brake caliper contribute to the braking effectivity?
Alcon: The publish is not going to enhance efficiency, however will facilitate upkeep and safety. Calipers are often positioned as shut as doable to 3 hours or 9 hours, so that they bleed simply. In a motor sport software, corresponding to Components 1, they greatest place the thickness to decrease the middle of gravity, however that is extra prone to collapse if the hub design isn’t strong. The commonest apply in motorsport is to function the entrance and rear leakage calipers to carry the load nearer to the middle of the automobile.
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