Overview

The Constant Speed Test Rig is designed for brake pad quality testing under both constant load and constant torque conditions, following ECE R90 Annexure 9 standards.
It performs dynamic and static tests to evaluate brake performance, wear, and frictional characteristics using a computerized control and data acquisition system.

System Description

• Prime Mover: 55 kW AC motor (1478 RPM) with automatic Star/Delta starter and overload protection.

• Gearbox: Oil-lubricated unit delivering constant 678 RPM at output shaft.

• Adaptor: Interchangeable adapters for multiple disc brake types.

• Tailstock Assembly: Adjustable and lockable mechanism for brake caliper alignment.

• Temperature Monitoring:

  • Disc: Rubbing-type K thermocouple (0–1000 °C)

  • Pad: Embedded K-type thermocouple (0–1000 °C)

• Cooling System: Air blower with duct for automatic thermal regulation.

• Load Application: Controlled by electro-pneumatic servo valve (2–50 bar).

• Torque Arm: Load cell-based torque measurement (up to 750 Nm @ 678 RPM).

• Test Selection: Switchable between constant load or constant torque modes.

• Static Test: Secondary motor and gear unit provide 0.45–1 RPM variable for endurance tests.

• Safety Interlock: Prevents static and dynamic systems from running simultaneously.

Key Features

• Fully automated LabVIEW-based DAQ software with GUI interface.

• User-programmable schedules and factory-standard templates.

• Software-assisted calibration and automatic self-checks before testing.

• Real-time data visualization: torque, pressure, temperature, and speed.

• Automatic report generation – graphical and numerical (Excel/PDF).

• Interlocked operations for safety and reliability.

General Specifications

Software Functions

• CSTR Software (Windows-based)

  • Main, Torque, and Static test modes.

  • Schedule creation & editing.

  • Vehicle data setup.

  • Real-time data display (pressure, torque, temperature, speed).

  • Automated bleeding and blower control.

  • Report generation: ECE-R90 pressure & torque modes, static results.

Test Workflow

1. Power ON system (Mains → Drive → Blower).

2. Launch CSTR Control Software.

3. Enter vehicle and test details.

4. Select or create schedule.

5. Start test (Main / Torque / Static).

6. Monitor real-time data and graphs.

7. Generate and save reports (graphical + numerical).

Reports

• Dynamic Pressure Mode Report: Load, torque, temperature vs. time graphs.

• Torque Mode Report: Real-time torque characteristics and brake fade data.

• Static Mode Report: Holding torque and pressure results.

• Formats: Printable, savable (Excel/PDF).

NI USB-6008 DAQ Card Configuration

Installation

1. Mount machine on vibration isolators.

2. Ensure correct 3-phase (R-Y-B) connection and earthing.

3. Verify free rotation of shafts.

4. Place control panel ~600 mm from rig.

5. Confirm phase sequence and motor rotation (anti-clockwise).

6. Perform all electrical work with power OFF.

Safety

• Dual earth connections (machine & control panel).

• Emergency interlock between static and dynamic drives.

• Overload, phase sequence, and single-phase protection.

• Follow standard operating procedures — qualified personnel only.

Manufacturer

Pyramid Precision Engineering (India) Pvt. Ltd.
🌐 www.ppeindia.com
📧 info@ppeindia.com