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Brake system is one of the most important safety related sub systems for any automobile. This requires all auto majors to put more effort in design optimization of brake system and exhaustive evaluation for the same. On-road evaluation of brakes is time consuming process and has other shortfalls like unsafe riding conditions, less repeatability, limitation of brake input force, speed, less control in test conditions, requirement of special track etc. Normal lab testing for brake system has several drawbacks like imprecise inertia simulation, more testing time, uncontrolled test environment, partial system level evaluation, huge rotating mass which may lead to unsafe operating conditions, frequent maintenance, etc. This paper describes about the methodology adopted, efforts involved and results obtained by developing an accelerated evaluation system for brakes as a complete sub system in laboratory.

This paper aims at the estimation of dynamic wheel loads of a two-wheeler through mathematical modeling that will aid during the initial stages of product development. A half car model that represents a two-wheeler was used for this purpose. Road displacements were given as input to the model and the wheel loads estimated. Actual road data obtained from two-poster rig was used as input to the model thereby making it possible to calculate the wheel loads for different customer usage conditions on different roads. In this paper, a severe rough road was chosen for verification of the model with that of the rig as the rider dynamics on such roads are the most difficult to simulate even on the rigs. The estimated values from model were verified with those measured using a two-poster rig for the same road displacement. Attempt has been further made to establish a correlation between the ride comfort predictions from the model and the two-poster rig.