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2005-26-037 3W Brakes by TVS
2005-26-037 3W Brakes by TVS
of any segment of vehicle viz. moped, motorcycle, conducted in controlled environment as a complete
scooter, three wheeler, can be mounted for evaluation. system. Test results obtained should be repeatable and
Quick change over time from one system to another accurate. All the above said issues are addressed during
was also addressed during design. The test bench has design and development of this custom-built test facility.
inbuilt system to measure various parameters like
stopping distance, stopping time, brake input force, brake METHODOLOGY ADOPTED
torque, Mean Fully Developed Deceleration (MFDD),
temperature at different locations, etc under controlled Following steps were considered to develop the custom-
test conditions. In addition to that, the system is built test facility and evolve methodology for evaluation
interfaced with an user friendly software which is capable of brakes as a complete system.
of formulating the various test cycles viz. performance, l Conceptual design
fade test, water recovery test, constant downhill mode,
l Adoption of components
various endurance test cycles etc. In addition to that,
drive cycle can be created from road data collected from l Force actuation
different city driving conditions, to simulate actual l Torque measurement
customer usage conditions. l Software development
l Experimentation
This paper also describes about the usage of this
l Correlation of test results with field data
custom-built test facility, which resulted in effective
optimisation of brake system and drastic reduction in l Safety considerations
development time. The system was used for design
optimisation of several parameters like lever ratio, brake CONCEPTUAL DESIGN : Inertia simulation, force
cam geometry, pedal design etc. Performance actuation, torque measurement, adoption of brake system
characteristics at different speeds with various input components are the key parameters for brake testing.
forces, friction coefficient of brake liner material and liner In basic design consideration, structural components and
wear characteristics can be studied much faster. The inertia simulation is taken up.
effect of brake performance at different temperature,
speed, payload, input force, presence of water etc can The test facility was designed with a rigid base structure
be assessed. The test facility was helpful in delivering made out of steel where the inertia simulation system,
good quality in design, reducing development and testing chucking mechanism etc are mounted. The rigid base
time in new products and value engineering components. was isolated from floor with rubber mounts to reduce
Dynamic behavior of each component can be studied machine vibration during operation at higher speed.
very closely with this custom-built test facility.
In order to attain maximum accuracy in inertia simulation,
an electrical prime mover was employed for this
NEED FOR DEVELOPING CUSTOM-BUILT TEST application. The electrical prime mover will act as
FACILITY dynamometer during braking and prime mover during
acceleration. Thereby it absorbs predetermined vehicle
Accelerated durability evaluation with good accuracy inertia. The inertia simulation system is controlled by an
under actual customer usage condition will enrich interfacing module interlinked with a computer aided
product reliability. Exhaustive evaluation for safety related Programmable Logic Control (PLC) unit, which is shown
components need to be done to avoid catastrophic as block diagram in Fig. 1.
failures at customer end. Traditional inertia brake
dynamometers used for durability evaluation of brake
system are generally equipped with mechanical flywheels
at the end for inertia simulation. Accuracy of this inertia
simulation technique is not precise. Also the whole mass
to be accelerated during the test run cycle, results in
additional time for testing. In the emerging competition
it is necessary to deliver reliable products at par with
customer expectations.
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Symposium on International Automotive Technology 2005
Fail-safe mechanism was provided in the mounting FORCE ACTUATING MECHANISM : Force application
arrangement to avoid catastrophic failure in the system. is one of the important factors in both performance and
The above said arrangements were provided to test durability evaluation of brakes. Accuracy of test result
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Symposium on International Automotive Technology 2005
SOFTWARE DEVELOPMENT
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Symposium on International Automotive Technology 2005
In this case the acceleration can be calculated. Lever Deflection Characteristics : This test helps in
validation of brake lever movement to the input force
Equating the friction loss : applied i.e. sponginess, excess free play, transmission
Floss_dec - Roller friction loss during deceleration (N) loss in linkages etc can be determined. Input parameter
for this test is maximum force to be applied on hand
Floss_acc - roller friction loss during acceleration (N) lever. The system automatically performs the test as per
the test script and gives output in graphical form with
F SG_dec = F loss_dec + m roller x a dec(50km/h) (9)
deflection in abscissa, and Force in ordinate. A typical
F SG_acc = F loss_acc + m roller x a acc(50km/h) (10) output graph is shown in Fig. 10. The deflection
characteristics can be determined both static and
F loss_acc = F loss_dec (11) dynamic conditions. The increase in deflection of brake
lever during endurance test will give the wear and
F SG_acc- m roller x a acc(50km/h) = F SG_dec- m roller x a dec(50km/h) transmission loss (due to elongation of cable in case of
(12) cable operated brakes) of the system.
FSG_dec - FSG_acc
m roller =
a dec(50km/h) - a acc(50km/h) (13)
The dynamometer is accelerated to the test speed and Figure 10 : Typical Test Run Cycle–Lever Force Vs.
switched to road load simulation. All road load Deflection
coefficients are set to zero. As a result depending on
the corrected torque, the speed of the dynamometer Burnishing Test : Burnishing test for any new brake
should be constant. Over a period of 30 s the difference liner is conducted to ensure effective contact area of liner
in speed is recorded and the excessive or inadequate to the brake drum. Generally burnishing test is
power calculated that the dynamometer applied. conducted at lower deceleration. During burnishing test,
distance between every successive braking is kept
(15) minimum of 1000 m and the typical cycle time
distribution is shown in Fig. 11. Effective burnishing
depends on the machining accuracy of brake shoe as
EXPERIMENTATION : In order to utilise the developed complete assembly. Generally 80% of contact area is
test facility, experiments were carried out in motorcycle ensured before starting performance evaluation. Number
disc brake, drum brake, Scooter type brakes and in three of cycles taken to achieve 80% of contact area will give
wheeler brakes. Sample disc brake experimentation was the burnishing effectiveness.
discussed in this paper.
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Symposium on International Automotive Technology 2005
Table - III : Correlation of Road and Lab Test. l Rider fatigue and unsafe condition eliminated by
(*Not Tested Due to Unsafe Riding. **Not avoiding on-road endurance of brake testing
Tested Due to Linkage Design Constraint)
ACKNOWLEDGMENTS
In addition to that one disc brake pad was subjected to The authors would like to thank Mr. Vinay Harne, Vice
road test and compared the life with similar samples President (R&D), TVS Motor Co. Ltd., for his continued
tested in lab under accelerated condition. This study was support to the present study. The authors also express
resulted in direct correlation of road and lab testing. From their gratitude towards the management of TVS Motor
the liner wear data it was able to formulate a correlation Co. Ltd. for allowing them to publish this work. The
that one cycle in lab testing equals to 1.4 km on road. authors also appreciate the timely help and assistance
Time compression of 1:30 times achieved in lab testing extended by their colleagues Mr. S.Mohan, Mr. Rajput
through this inertia simulation technique. Brijesh.
SAFETY CONSIDERATIONS : Since the brake parts like
brake drum, disc etc are rotating at high speed during REFERENCES
test, there are more likely chances of causing accident
in case of any failure in the rotating component. Also 1. IS 13453:1994, “Automotive Vehicles-Braking
the force gauge, torque-metering flange, non-contact Systems Method of Test on Brake Dynamometer for
temperature sensor are expensive. In order to avoid Two and Three Wheelers”
damages to test bench and other external damage, 2. Pawar, P. R., “Effect of Disc and Drum Brake on
necessary steps are taken care in the design of test the Durability of Front Shock Absorber Tube of a
bench. Protective cover was provided in the system to Motorcycle”, SAE paper 2003-26-0031
avoid accidents during testing and water splash during 3. HBM Torque Metering System - Manual
water recovery test is represented in Fig. 20. 4. Katsuhiro Shibata, “Development of Brake Friction
Material”, SAE paper 930806
5. Lewis, Richard l., “Stopping- Distance Analysis”, SAE
paper 730193
6. Brake Test Bench – Manual
CONTACT
R. Govindarajan
TVS Motor Company Ltd., Hosur, India
Tel.: +91 04344 276780
E-mail : R.govindrajan@tvsmotor.co.in