Brake Testing for Passenger Cars and Light Trucks
Duration: 2 Days
This data-driven and test standard-driven seminar provides details of the different elements required to successfully manage, execute, and understand brake test results related to passenger cars and light duty trucks. The course covers: US and European self-certification or type approval testing; common; overview of ISO 15484; and main test procedures for performance, NVH, wear and durability using SAE, ISO, JASO, and JIS test protocols.
To better understand brake testing, the course provides a "brake testing toolbox" with key definitions, calculations, and descriptions of typical test sections, control methods, and brake applications used in different vehicle and laboratory testing. Attendees will gain practical experience through hands-on exercises and short workshops. Each test module includes detailed explanations and examples of test setup, inertia calculations, test conditions, main test sequence, results assessment, and best testing practices.
Attendees are asked to bring an engineering calculator and laptop computer for use in classroom exercises.
Learning Objectives
By attending this seminar, you will be able to:
- Identify and utilize existing brake regulations, certification programs, and test standards for brake system development
- Identify key elements for a brake testing program regarding performance, durability, and NVH
- Specify the conditions and explain the results from different types of test sections and brake control during laboratory testing
- Calculate correctly brake test parameters and vehicle-level values
- Determine and evaluate summarized and in-stop brake test results
- Identify best testing practices to reduce test variability
Who Should Attend
The seminar is ideal for technical or engineering managers, test supervisors, test engineers, and application/product engineers involved in brake program management, test coordination and execution, product sourcing and vendor selection, quality assurance and product development.
Prerequisites
An undergraduate engineering degree or a strong technical background including basic knowledge of college algebra, physics, and familiarity with vehicle brake systems is required. Individuals should have some experience/involvement with brake products development and sourcing, testing coordination or execution, regularly preparing or reviewing test results and test programs.
Topical Outline
DAY ONE
- Brake Standards Development Organizations and Entities (regulations, type approvals, OE and tier-1, aftermarket)
- US Department of Transportation and UNECE
- OE, tier-1, and aftermarket testing
- Industry consortia and working groups
- FMVSS vs. ECE Protocols and Testing
- Self-certification vs. type approval
- FMVSS 105/135 vs. ECE R13
- Laboratory Brake Testing Process and Elements
- "Brake Testing Toolbox - Part 1"
- Vehicle dynamics applied to brake testing
- Inertia calculation (per SAE J2789) and dynamometer inertia simulation
- Friction coefficient calculation and parameters (summarized and time-based)
- Summary and in-stop test values
- Vehicle floor-checks and parameters for vehicle and dynamometer testing
- "Brake Testing Toolbox - Part 2"
- Test sections: burnish; effectiveness; baseline, fade and recovery; parking brake; and driving route or circuit simulation
- Brake applications: pressure, torque, deceleration, drags, modulated, profiles, pressure-lock, and ramp applications
- Hands-on Exercise and Test Cases Evaluation
- Performance Test Procedures and Techniques - Part I
- Dynamometer tests (SAE J2784, SAE J2522, ISO 26867, JASO C406)
- Inertia, test parameters, and setup for different test sections
- Best testing practices for improved repeatability and reproducibility
- Data review and test results evaluation
DAY TWO
- Performance Test Procedures and Techniques - Part II
- Hands-on Exercise and Test Cases Evaluation
- NVH Test Procedures and Techniques
- Dynamometer tests (SAE J2521 with optional sections and city driving simulations)
- Noise data review (waterfall, WAV files, noise indexes, noise peak finding functions, EKB noisy events) and test results evaluation
- Inertia, test parameters, and setup for different test sections
- Best testing practices for improved repeatability and reproducibility
- Data review and test results evaluation
- Hands-on Exercise and Test Cases Evaluation
- Wear Test Procedures and Techniques
- Dynamometer tests (SAE J2707 and city driving simulations)
- Inertia, test parameters, and setup for different test sections
- Best testing practices for improved repeatability and reproducibility
- Data review and test results evaluation
- Hands-on Exercise and Test Cases Evaluation
- Overview of Other Tests, Procedures and Techniques (structural integrity, crack/strength, DTV, hot judder, corrosion removal)
- Dynamometer tests (SAE, ECE, and common industry examples)
- Inertia, test parameters, and setup for different test sections
- Best testing practices for improved repeatability and reproducibility
- Data review and test results evaluation
- Hands-on Exercise and Test Cases Evaluation
- Conclusions, and Seminar Takeaways
Instructor(s): Carlos Agudelo
Carlos Agudelo is currently Chief Engineer for Laboratory Testing Services at Link Testing Laboratories. He is active on several industry, SAE, and ISO committees and task-forces. Prior to joining Link, he worked for Renault (Envigado assembly plant) and for friction material manufacturer Mafriccion in Colombia. Mr. Agudelo earned a B.S. in Production Engineering from EAFIT University (in association with Aachen University and Ruhr-Universität Bochum from Germany) and has pursued post-graduate studies in project evaluation and special courses in technical systems and systematic design in the UK.
Fees: $1225.00
; SAE Members: $980.00 - $1103.00
1.3 CEUs
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.
For additional information, contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at CustomerService@sae.org
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