Overview

The Inertia Brake Dynamometer is a fully computerized automatic test rig for evaluating hydraulic and air brake systems of four-wheelers.
It supports ECE R90 standard tests with advanced control, data acquisition, and performance reporting features.

Main Features

• Tests hydraulic & pneumatic brakes under controlled conditions.

• Variable inertia simulation (4.84 to 201.5 kg·m²) for real-world vehicle dynamics.

• Programmable load, speed, and braking cycles via dedicated software.

• Automatic safety interlocks, emergency brakes, and cooling systems for operator protection.

• Comprehensive data acquisition and reporting through NI 6221 DAQ interface.

System Description

Mechanical Setup

• Prime Mover: 190 kW DC motor, base 660 RPM, max 1500 RPM.

• Variable Speed Drive: Solid-state DC drive with tachometer feedback (150–1500 RPM).

• Main Shaft: Direct gear coupling with inertia wheel assembly.

• Inertia Wheels: Configurable up to 201.5 kg·m² using modular wheels (0.5–64 kg·m²).

• Tailstock Assembly: Motorized and manual movement; supports calipers, discs, or drums.

• Reaction Force Measurement: Dual load cells mounted on torque arm.

• Safety Guards: Telescopic covers with limit switches and visibility windows.

• Cooling & Exhaust:

  • 5 HP blower (15 m/s max air velocity).

  • Exhaust blower (5 HP, 1430 RPM) for dust & smoke removal.

• Water Spray System: Solenoid-based wet testing with flow control.

Technical Specifications

Instrumentation & Sensors

• Load Cells: Adi Artech (200 kgf & 10 T)

• Pressure Sensors: Meas (0–20 bar & 0–500 bar)

• Flow Meter: Beda VS10

• Electro-Pneumatic Valve: ASCO 0–12 bar, 24 VDC

• Air Velocity Transmitter: Kimo 0–30 m/s

• Encoder: Autonics E40 series

• Tacho Generator: ADOT DTG-4000

• Temperature Indicators: Selec PID-500 series

Software & Control System

• Windows-based, user-friendly control interface for complete test automation.

• Real-time display of torque, temperature, pressure, air velocity, and braking cycles.

• Automatic inertia selection, test scheduling, and repeatable test execution.

• Custom vehicle data input (mass, rolling radius, system type).

• Graphical & numerical reporting with export to Excel/PDF.

• Integrated error detection and diagnostic system.

Testing Capabilities

• Dynamic Brake Test: High-speed tests with programmed load & pressure profiles.

• Static Brake Test: Low-speed testing (0.45–1 RPM) for parking or holding performance.

• Wet/Dry Testing: Water spray system for performance comparison.

• Temperature Fade & Recovery Tests: Up to 1000 °C brake temperature range.

• Torque, Pressure, and Wear Measurement: Recorded through NI DAQ system.

Reports Generated

• Numerical Data Report – tabular torque, temperature, and pressure data.

• Graphical Report – brake torque, temperature, and time plots.

• Overall & Performance Reports – test summary and wear analysis.

• Wear Data Report – pad/disc mass and thickness before and after test.

NI 6221 Data Acquisition Card

Safety & Maintenance

• Automatic emergency brake activation on air pressure failure.

• Interlocked sliding doors and guards to prevent operation while open.

• Regular greasing every 200 hours (AP3NLG13).

• Hydraulic fluid: DOT 3 Brake Oil – maintain top level before each test.

• Temperature sensor and air pressure checks before startup.

• Multi-point emergency stops on machine and control panels.

Troubleshooting Highlights

• Motor not running: Verify R-Y-B phase, air pressure ≥ 13 bar, and door interlocks.

• Torque not displayed: Recalibrate load cell via torque arm calibration.

• Load not applying: Check air pressure, SMC voltage, and transducer calibration.

• Temperature faults: Inspect thermocouple wiring and indicator continuity.

Calibration

• Torque Calibration: Using 250 kg dead weights and torque arm.

• Span & Zero Adjustments: Through torque amplifier in control panel.

Formulas Used

• MFDD (Mean Fully Developed Deceleration): Calculated between 80%–10% speed range.

• Torque Calculation:

  $$T=I\times R\times A$$

  where I = Inertia (kg·m²), R = Rolling radius (m), A = Deceleration (m/s²)

Manufacturer

Pyramid Precision Engineering (India) Pvt. Ltd.
3/79, PKS Gardens, E.V.R. Periyar Road, Palavakkam, Chennai – 600041
📞 +91 44 2448 2257 | 📧 info@ppeindia.com | 🌐 www.ppeindia.com