Use of load cells for reliable brake tests
The Automotive Industry Safety is of fundamental importance - from design to monitoring performance in operation. Every vehicle component must undergo rigorous testing to ensure it functions reliably and safely under a variety of conditions.
The braking system is one of the most important components for preventing accidents and ensuring passenger safety. Accurate and reliable braking tests are essential, and Load cells are important tools. Interface has long been a supplier of force measurement solutions to vehicle manufacturers and test laboratories.
The basic principle of braking, which uses friction to slow or stop motion, dates back to the days when wheels were attached to carts to move heavy objects. Imagine pulling a stone behind a cart or using a stick to create friction against a wheel. Early designs were made of planes and blocks of wood. Over time, brakes evolved from mechanical and hydraulic systems to the disc brakes and modern systems common today.
brake test today
Modern brake testing includes a variety of procedures. These tests are performed on all types of vehicles, from private cars to race cars, motorcycles and off-road vehicles. Load cells enable more precise and objective brake testing. Force measurement solutions allow engineers to thoroughly analyze the performance of braking systems and ensure compliance with safety standards. Advanced braking technologies such as anti-lock braking systems (ABS) and electronic stability control (ESC) have further increased the importance of accurate brake testing with precision measurements. Types of testing include:
- Dynamometer tests simulate real driving conditions in a controlled environment.
- Road tests are crucial for evaluating braking performance under different road conditions.
- The testing of the components focuses on the individual parts of the braking system, such as brake pads, brake discs and brake calipers.
force measurement-based brake testing
Brakes are responsible for slowing and stopping a vehicle, and their effectiveness has a direct impact on safety. The four main use cases for using precise force measurement in brake testing are validation, regulatory compliance, fault detection, and performance.
- Braking testing is essential for design and performance validation to ensure that the braking system meets specifications and performs as expected under various loads, speeds and environmental conditions.
- Compliance is essential in the automotive industry. This includes adhering to strict safety standards and regulations set by organizations such as NHTSA (National Highway Traffic Safety Administration) and ECE (Economic Commission for Europe).
- Identify potential defects and material problems by detecting defects, weak points or inconsistencies in the braking system early in the development or production phase.
- Improving reliability and durability by evaluating the long-term performance and wear resistance of brake components.
How load cells improve brake testing
Load cells are force transducers that convert mechanical force into an electrical signal. In brake testing, they provide precise measurements of the forces acting on various braking components, such as brake pedal force, brake caliper force and brake disc force.
The specially developed for braking tests BPL Pedal Load Cell Pedal Force from Interface has capacities from 50 lbf to 500 lbf (250 N to 2,5 kN). The Model BPL is a LowProfile® load cell for measuring brake pedal force. The Model BPL has the lowest sensitivity to off-center loading, outperforming all competing models.
Features and Benefits of the Interface Brake Pedal Load Cell
- Lowest nonlinearity and hysteresis of all brake pedal load cells – < 0,05%
- Ultra-low altitude
- Low sensitivity to off-center loads
- Attaches directly to the pedal with the included strap
- Replaceable mounting plates
- For use with accelerator, brake or clutch pedal
- Including storage case
Brake pedal force and braking distance test – application
The precise measurement of force and distance is a common application in brake tests. While the pedal is being operated, the Interface BPL Pedal Load Cell the force and an LVDT sensor calculates the distance. The results are compared with the 4 channel USB4 USB interface module graphically represented, logged and displayed. Check out the test of braking force and braking distance
Brake Caliper Testing – Application
A brake caliper is a component in a disc brake system that holds the brake pads and applies pressure to them so that they conform to the brake disc or rotor. Over time, the brake caliper changes due to factors such as aging, temperature changes and environmental conditions. Therefore, it is important to continually calibrate and test the brake calipers to ensure optimal braking performance and vehicle safety. The LW General Purpose Load Washer load cell is placed between the piston and the brake pad of the vehicle's brake caliper and subjected to a brake pad test. The brake pad test is carried out. The force data collected by the LW is displayed, graphed and logged on the customer's PC or laptop when it is sent to the 4 channel USB4 USB interface module For more information, see brake caliper inspection.
Wireless brake pedal force test
Pedal force testing is critical to establishing vehicle safety protocols. To quantify the effectiveness of the braking system, the relationship between the pedal force and the braking force at the axle must be determined during a braking test on the road or in a simulated indoor environment using a dynamometer where the pedal force can be evaluated. The Model BPL Pedal Load Cell Load is mounted on the pedal in such a way that the output cable to the transmitter is not pinched during the entire pedal application cycle. Mount the transmitter WTS-AM-1E secure so that the cable has enough slack for a full pedal pumping cycle. The module transmits wirelessly to the WTS Toolkit App. If you use the WTS Wireless System with the receiver (WTS-BS-6), the force measurements from the load cell can be displayed, logged and graphed directly on a computer.
It is also possible to use Bluetooth technology for brake tests with load cells. In this application report Interface describes how it helps a customer measure the brake pedal force with its new Bluetooth Telemetry System (BTS) and a BPL-300-C brake pedal force sensor.
Advantages of using load cells in brake testing
- High accuracy: The load cells provide exceptional accuracy in force measurement and ensure reliable and consistent test results.
- Real-time data: They enable real-time data collection so that engineers can dynamically analyze the performance of the braking system.
- Versatility: Load cells can be integrated into various brake test setups and are suitable for different brake types and test scenarios.
- Durability: They are robust and can withstand the demanding conditions of brake testing.
The Evolution of Brake Testing: From Street to Race and Beyond
The principles of precise force measurement with load cells have found applications that go far beyond traditional automotive testing. The demand for realism in gaming and esports has led to the introduction of load cell technology in racing simulators. Gamers are looking for the most realistic experience possible, and load cell-based pedal systems offer a far more realistic feel than traditional distance-based pedals.
A pedal system for their racing simulation game. Force sensing pedals are more advanced and offer greater accuracy than standard racing simulation pedals. They want a wireless system that measures the amount of pressure applied to the pedals and determines the optimal braking force for future players. Here's how it works.
The BPL Pedal Load Cell from Interface can be installed on the brake pedal of a game to measure the force exerted when a person presses the pedal. The forces are measured with the WTS-AM-1E Wireless Strain Bridge Transmitter Modules measured and recorded, with the data being sent to the WTS-BS-6 Dongle Base Station when connected to a laptop. Interface's BPL Pedal Load Cell measures and records the forces applied to the brake pedals of racing games. Unlike traditional simulation pedals that measure the distance traveled when pressed, Interface's load cell pedal system provides a more realistic experience for players.
Braking testing is critical to ensuring safety and reliability. Load cells are vital in this process as they provide accurate and reliable force measurement for various braking components, whether it is a bicycle or a Formula racing car. Furthermore, the application of load cell technology has expanded beyond traditional automotive testing and is finding its place in gaming and esports, demonstrating the versatility and importance of precise force measurement in various fields.
As technology advances and the demand for safety and realism increases, the role of load cells in brake testing and other force measurement applications will continue to grow. Contact our application engineers to learn more about load cells, gauges and wireless solutions for brake testing.