Overview

The Variable Speed Friction Tester is designed for brake pad quality testing under constant load or torque.
It meets ECE R90 Annexure 9 specifications and allows both dynamic and static tests through a fully automated control system.

General Description

• Prime Mover: 45 kW DC motor, 1000 RPM base speed, software-controlled via DC drive.

• Adaptor: Single adapter per brake type (customizable for multiple assemblies).

• Tail Stock Movement: Manual wheel and lock handles for positioning caliper and rotor.

• Temperature Monitoring:

  • Disc: Rubbing-type thermocouple on movable stand.

  • Pad: Embedded K-type thermocouple (0–1000 °C, 0–10 V output).

• Cooling System: Blower with duct auto-activated above set temperature.

• Load Application: Electro-pneumatic servo valve, hydraulic pressure 0–50 bar.

• Pressure Cell: Measures real-time brake pressure.

• Torque Arm: Load cell measures torque up to 62.5 Nm @ 660 RPM.

• Static Test: Separate 1 kW AC motor (0.45–0.7 RPM variable).

Technical Specifications

Key Components

• Load Cell: ADI Artech, 250 kg (S-Type)

• Pressure Transducer: Meas M5 156-05-0882-040 BG

• Amplifiers: Canopus LCAV / Isolation type

• Relay Driver Board: Eagle ULN 2803

• Temperature Indicators: Selec PID 500 (×3)

• SMPS: Mean Well MDR-60-24 / NED 50A

• Drives: Danfoss FC 51 (Blower), Eurotherm ERP (DC Drive)

• Motors:

  • Dynamic – 45 kW Kirloskar

  • Static – 0.37 kW AC

  • Cooling – 2.2 kW + 0.75 kW blowers

• Sensors & Valves:

  • SMC ITV 2051 (0–9 kgf/cm²)

  • Proximity speed sensor, SMC mist separator & regulator, solenoid valves

Software & Control System

Fully integrated LabVIEW-based control software provides:

• Dynamic & static test execution

• Pressure or torque-based control

• Live display of torque, speed, pressure & temperature

• Automated data logging & reporting

Main Functions

• Run Test: Dynamic or static mode (new or existing test)

• View Reports: ECE-R90 pressure/torque modes, Excel raw data

• Create Schedules: Define test name, mode, pressure, speed, temperature, blower, skip options

• Vehicle Data Setup: Input brake type, radius, piston dia., pad dimensions

• Manual Check Mode: Individual sensor & actuator testing

• Dust Collection System: Separate executable for dust tests

NI USB-6008 Card Details

Analog Inputs:
AI0 – Torque | AI1 – Speed | AI2 – Pressure | AI3–AI5 – Temperatures | AI6 – Low Pressure Switch
Analog Outputs:
AO0 – Load | AO1 – Speed
Digital Outputs:
Static/Dynamic switching, drives, blower, solenoids (1–3)
Digital Inputs: DI1 – DI3

Testing Modes

• Dynamic Mode: High-speed friction simulation (45 kW motor)

• Static Mode: Low-speed endurance & holding torque test (AC motor)

• Pressure / Torque Control: Adjustable via schedule.

• Temperature & Load Feedback: Real-time monitoring and protection.

Reporting

• Auto-generated test results in Excel & graphical form.

• Select X-Y parameters (Load, Time, Speed, Temperature).

• Reports stored automatically in desktop report folder.

Power & Safety

• 410 V 3-Phase supply with neutral & ground.

• Protected by Hager MCBs and Minilec single-phase preventor.

• Emergency stop & interlocks built into control panel.

Manufacturer

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