Test Planning & Preparation
- Develop test plans to evaluate the performance of brake systems, covering key metrics such as stopping distance, brake fade, pedal feel, brake noise, and thermal stability.
- Collaborate with design and engineering teams to define test criteria, ensuring alignment with braking performance targets and regulatory requirements (e.g., FMVSS, ECE R13).
- Select appropriate test methodologies (e.g., dynamometer testing, on-road testing, simulation-based testing) and define the necessary testing equipment, sensors, and instrumentation.
- Prepare test vehicles and brake system prototypes, ensuring all instrumentation (e.g., pressure sensors, thermocouples, accelerometers) is correctly installed and calibrated.
Test Execution
- Conduct tests on both proving grounds and laboratory setups to evaluate braking system performance under a wide range of conditions, including dry, wet, icy, and emergency braking scenarios.
- Execute dynamic tests such as brake fade testing, ABS (Anti-lock Braking System) evaluation, EBD (Electronic Brakeforce Distribution) performance, and brake cooling assessments.
- Monitor and record real-time data during tests using advanced data acquisition systems, ensuring the accuracy of data and proper calibration of test equipment.
- Conduct noise, vibration, and harshness (NVH) tests to identify and address issues such as brake squeal, judder, or vibration during braking.
- Validate simulation models by comparing real-world test results, ensuring that virtual predictions of braking performance align with actual vehicle behavior.
- Work with cross-functional teams to validate control strategies for advanced braking systems, such as electronic stability control (ESC), autonomous emergency braking (AEB), and regenerative braking systems for electric vehicles (EVs).
- Ensure that all braking systems meet internal performance standards and comply with global safety regulations (e.g., FMVSS, ECE, GTR).
Data Analysis & Reporting
- Analyze test data to assess braking performance metrics such as deceleration rates, pedal pressure, brake temperatures, and stopping distances under different load and speed conditions.
- Identify trends, anomalies, or performance deviations and collaborate with the development team to propose design improvements or tuning adjustments.
- Document test results in detailed technical reports, including data plots, graphs, and comprehensive performance summaries.
- Provide clear recommendations based on test findings to enhance brake system performance and ensure compliance with safety standards.
Problem Solving & Troubleshooting
- Identify and diagnose issues related to brake system performance, such as insufficient stopping power, brake fade, uneven braking, or overheating.
- Utilize root cause analysis techniques (e.g., 8D, 5 Whys, FMEA) to investigate and address performance issues.
- Collaborate with braking system designers, materials engineers, and suppliers resolving problems and retest solutions to validate performance improvements.
Collaboration & Communication
- Work closely with design, simulation, and manufacturing teams to refine braking system components such as brake calipers, rotors, brake pads, and hydraulic systems based on test results.
- Communicate test procedures, results, and performance recommendations to internal stakeholders, including product management, safety teams, and quality control.
- Collaborate with external testing partners, regulatory bodies, and suppliers to ensure comprehensive validation of braking systems.
- Present findings and recommendations in technical reviews, design meetings, and validation discussions.