Manufacturer:
Pyramid Precision Engineering (India) Pvt. Ltd.
174, Vandalur–Kelambakkam Road, Melakottaiyur, Chennai – 600127
📞 +91 93804 05080 | ✉️ info@ppeindia.com

Customer:
A3S Autocomp LLP, Palwal, Haryana, India

Overview

The Friction Coefficient Test Rig is an advanced laboratory system designed to evaluate the friction and wear characteristics of brake linings and pads. It complies with SAE J661 and IS 2742 standards for automotive friction material testing, providing highly accurate, repeatable, and programmable testing capabilities for R&D and quality validation.

Key Features

• Tests brake linings, pads, and friction materials per IS 2742 / SAE J661

• Fully computerized system with LabVIEW-based control software

• Tests up to 1000 °C with programmable heating & cooling rates

• Variable drum speed: 100 – 750 RPM

• Load range: 20 – 125 kgf (reactive force up to 100 kgf)

• Real-time data acquisition using NI USB-6001 DAQ

• Automatic calibration (load, force, displacement, speed, temperature)

• Generates graphical & numerical reports instantly

• Compact, vibration-free design with integrated safety controls

Technical Specifications

System Description

• Main Frame: Rigid MS frame with cast-iron bed and noise dampers

• Drum System: Dynamically balanced with integrated heater & blower

• Load Application: Pneumatic-hydraulic actuator with precision load cell

• Measurement: LVDT for displacement, thermocouples for temperature

• Software Control: Automates test setup, data logging, and report creation

Test Capabilities

• Heat & Cool Curve Tests (automatic control)

• Burnish, Baseline, Fade, Recovery, and Wear Tests

• Real-time monitoring of speed, load, frictional force, temperature, displacement

• Automatic data export (CSV, PDF, USB)

Software Features

• Password-protected user login (Default: FCTR)

• Automatic calibration & test scheduling

• Data visualization – graphical & tabular

• Multiple test modes: Manual, Auto, Standard (IS 2742 / SAE J661)

• Report types: Calibration, Heat/Cool Curve, Main Test

Calibration

Automated calibration routines for:

• Load & Force: Using dead weights and ratio arms

• Displacement: With slip gauges and LVDT (± 0.001 mm)

• Speed: Verified with digital tachometer

• Temperature: Using millivolt injector for thermocouple verification

Safety Features

• Dual emergency stop switches

• Door interlock & high-temperature alarm

• Over-speed, over-load, and phase-failure protection

• Pneumatic low-pressure detection

• Proper grounding and interlocked electrical system

Major Components

• Electrical: Siemens MCBs, contactors, relays, SELEC PID controller

• Pneumatics: SMC valves, regulators, mist separators, precision air filters

• Sensors: Senstronics load cells, Gefran LVDT, Tempsens thermocouple

• DAQ System: NI USB-6001 (14-bit, 20 kS/s)

• Cooling: Eminent blower 400 CFM

Maintenance

• Verify air pressure (7 bar) and oil levels before operation

• Clean filters monthly; drain air line every 10 days

• Do not operate without proper earthing

• Perform calibration checks periodically

Applications

• Brake lining and friction material development

• OEM and supplier quality testing

• Research on friction coefficient and wear behavior

• Educational and industrial laboratories