Gruelling brake tests for efficiency

Braking efficiency depends on two factors, distance and trigger time. More often than not, slamming on the brakes at the right moment is all you have to safeguard yourself and others, as well as avoid damaging your vehicle and all those around you. In spite of all these precautions, how many times do you find yourself thinking: "that was really close". A bit like an insurance policy, you appreciate the value of it at the most critical times. Hence, motorists should develop the good habit of not neglecting the brakes of their vehicle, reserving for them all the care and attention they deserve, after all safety for the driver, passengers, pedestrians and other vehicles depend on it. Like all parts subject to a huge workload and stress, brakes are understandably subject to wear and tear: each time they are called into action to slow down or bring a vehicle to a halt, their efficiency and effectiveness diminish. In order to avoid unnecessary risks, the first rule is therefore to keep your eyes and ears open to detect any sign of malfunction before it’s too late. Fortunately, some are quite obvious. For example, the grinding noise produced when braking, typically caused by the friction between pads and discs, indicates without a doubt that one and/or the other have reached the end and must therefore be replaced. Another sign that should not be overlooked is the need to press the brake pedal too far, which may be due to damage to the pads, brake fluid leakage or even wear on the brake shoes. Vibrations, on the other hand, may be due to a deformation of the discs. And finally, it can indicate a far from insignificant problem with the brakes, such as a blocked calliper with the vehicle "pulling to one side". Paying attention to these signs is important, but it is not enough. In fact, it is necessary to check the vehicle's braking system regularly. It is no coincidence that brakes are extensively checked during an inspection whether it is a scooter, motorcycle, car or heavy-duty vehicle. The objective of the test is to observe and measure how the brakes behave under different loads and speed conditions to ensure that braking is not only effective, but also balanced and evenly distributed among the wheels. This operation is normally carried out in workshops, service points and DMV centres with the use of advanced equipment and instruments specifically designed for this purpose: brake test benches (or "roller brake testers"). The market offers a variety of solutions grouped mainly into two types of brake testers: roller testers and platform (or plates). The former consists of sets of cylindrical rollers of different lengths, which are usually embedded in the workshop floor and move the wheels to test its braking behaviour. The latter consists of platforms or plates that can be mounted on the floor or even on special lifts. The pressure exerted by each wheel makes it possible to assess the effectiveness of the braking action. Brake testers are also equipped with a computer to manage control parameters, carrying out the procedure and collecting the data acquired during the test. On the Italian market there is no lack of solutions that combine efficiency with the specific needs of the workshop.

 

 

Base

The Base Group's range of brake test benches - which includes brands such as Tecnotest and Beissbarth - stands out for its completeness, with roller and platform solutions for testing two-, three- and four-wheel vehicles up to 3.5 tons as well as heavier vehicles. The platform brake benches, in particular, represent an interesting option able to combine speed and efficiency during a test with power consumption close to zero. All testers available in both Tecnotest and Beissbarth product lines allow to optimize space: an example of this are the universal roller brake testers, including the BD660 and BD651 S52 for vehicles with wide track, but also some universal platform brake testers including an innovative version that can be installed on a scissor lift with a capacity of up to 5.0 t, specially designed to offer maximum strength in the smallest possible space. Like all the other products in the Tecnotest and Beissbarth ranges, the roller or platform brake benches are approved and comply with the MCTCNET2 protocol and are therefore suitable for use in Italian DMV inspection centres. Additionally, the Base Group supplies also heavy-duty vehicle solutions such as Class 2 roller brake test benches and multi-plate platforms.

 

Corghi

Corghi's BT100E S2-BOX is a valid tool for measuring the efficiency of the braking system on a variety of vehicles ranging from cars and vans, three-wheel vehicles, quads, mopeds and motorcycles (international categories L1 and L3). The sturdy extended track layout allows braking tests to be carried out even on vehicles with a greater distance between wheels such as motor homes. The one-piece body is made of sheet steel with an integrated weighbridge under the frame. The rollers combined with self-braking gearmotors are coated with a special corundum-based plastic treatment with a high coefficient of adherence. The rear rollers are slightly raised to better hold the vehicle in place during braking. The axle weighing system consists of four high-precision cells and guarantees correct measurement of the weight of the vehicle when braking.

The MCTC Net 2 standard electronics housed in an external unit allows the use of the brake tester in DIR and NET mode. In NET mode, the system comes with PC, monitor and an A4 printer. The remote control allows to manage the whole test procedure and send the resulting data to the operating program. The latter will guide the operator step by step through all the phases of the test and the relative pressure applied to the pedal or to the lever (motorcycles, three-wheelers, and quads). In its basic version, Corghi's BT100E S2-BOX bench is designed for testing light vehicles up to 3.5 tonnes. However, thanks to its modular structure, it is possible to configure the system for testing two, three or four-wheel vehicles.

 

Giuliano Industrial

In the Xedra range of brake test benches by Giuliano Industrial two models in particular stand out: the RBT 34 XL and RBT 100. The first is a universal roller brake tester that can be used for two, three or four-wheeled vehicles with a mass of up to 3.5 t. The internal distance between the rollers of 450 mm allows to accommodate mopeds, motorcycles, three-wheelers, and quads. The external dimension, increased to 2,250 mm, however, allows it to be used with campers and motorhomes. The distinctive equipment of the RBT 34 XL includes a patented weighing system and an integrated lift. At the end of the test, the latter allows the wheels of the vehicle to easily leave the roller bed. Further features of RBT 34 XL are: axle capacity 25,000 N (axle), power output of the motors 2 x 5.5 kW, roller speed 5.3 km/h, roller coating in epoxy resin with high resistance Corundum®. The RBT 100, on the other hand, is an "all-in-one" brake tester that includes all the components necessary for the operation. Moreover, the RBT 100 brake tester is "plug-in" ready for use: just connect the power supply and the data output cable. With an internal track width of 780 mm and an external track width of 2,200 mm, RBT 100 can be used with mopeds, motorcycles, three-wheel scooters and vehicles up to 3.5 t. There are two possible power-unit options: 2x4.5kW or 2x5.5kW. As with all other models in the Xedra range, both the RBT 34 XL and RBT 100 feature a Corundum-based treatment since 2003 and it is guaranteed for more than 200.000 test sessions, ensuring perfect grip and above average resistance to wear.

 

Hpa-Faip

The HPA-Faip Videosystem P185 roller brake tester meets the most stringent approval standards in accordance with Circular RU26248 and RU17937 in the field of brake tests for industrial vehicles. It is classified as a Class 2 brake test bench for a maximum test axle weight of 13 tons. Thanks to a highly reinforced mechanical structure and a transmission based on a high torque and high efficiency planetary gear motor unit, the HPA-Faip Videosystem P185 is capable of working even with fully loaded industrial vehicles.

The Windows operating program shows the test phases on screen guiding the operator throughout the tests whether on vehicles with hydraulic and/or mixed braking system, simulating the loading conditions of the vehicle through a specific "at full load" procedure. For vehicles with hydraulic braking system there is a special test mode. The central unit, in addition to the data acquisition system, features a PC, monitor and an A4 printer for the final test document. The HPA-Faip Videosystem P185 roller brake test bench can be upgraded by connecting it to the soon-to-be-introduced data network for heavy vehicles.

 

Mondolfo Ferro

DINA BRAKE/COMBI by Mondolfo Ferro is a four-plate brake test bench for light vehicles: cars and vans with maximum mass up to 3.5 t., two-, three- or four-wheeled vehicles and quads. DINA BRAKE/COMBI is easy to install thanks to its simple and functional mechanical structure. Moreover, the galvanized plates guarantee a high durability of the measuring elements. The modularity of the test is ensured by specific software licenses that allow to test the different types of vehicles. The remote control facilitates the complete management of the whole test procedure and the pressure applied to the pedal or to the lever (motorcycles and/or tricycles and quadricycles). The operating program, simple and intuitive, guides the operator through all phases of the test. As with other similar systems, the central unit in NETWORK mode, features a PC, monitor and an A4 printer.  DINA BRAKE/COMBI by Mondolfo Ferro can be used in stand-alone mode for a precise pre-test control or in the context of an MCTC Net 2 inspection protocol. It is also approved for use in DIR and NET mode.

 

Snap-Nt

SNAP-NT is a company specialized in the design and manufacture of equipment for DMV testing of motorcycles, cars and heavy vehicles and boasts a wide range of products for this specific market niche. The brake tester category, in particular, includes solutions designed to be used in the most different working contexts, reconciling space and performance. The SNAP-NT offer is divided into "roller" and "platform" brake testers. Among the latter, the innovative F2212 TQS stands out, a universal brake tester for two-, three- and four-wheel motor vehicles and motorcycles, whose peculiarity is that it can be installed directly on a garage lift, thus concentrating several functions in a single solution just 5 meters long. The technologies adopted here - some of which are covered by patents - guarantee performance similar to that of a traditional floor solution minimizing its overall dimensions, allowing the braking test to be carried out at extremely low vehicle speeds. Moreover, in a single step, it acquires data on weight, braking efficiency and dynamic behaviour, recreating the same braking conditions a regular motorists would find on the road. F2212 TQS is powered by a normal 220V cable for significant savings on fixed operating costs. For the trucking world, on the other hand, the F3214 platform brake tester stands out. It is specifically designed for vehicles with a ground mass of more than 3.5 tons and industrial vehicles, even those with particularly low ground clearance, such as buses. It consists of 10 platforms and allows the measurement of the braking efficiency of four axles simultaneously in a single step. The test simulates normal road braking so that, even in the presence of several driving axles, the operator does not need to take any special precautions. Thanks to particularly sensitive cells, tests can be conducted at low speeds. The tester’s versatility allows both in-floor and off-floor installations.

 

Snap-On Total Shop Solutions

Snap-On TSS TotalShopSolutions is about to launch a new 20-ton roller brake test bench for heavy-duty vehicles, available in Italy from January 2022 in two versions with the motors under the rollers (N) and one with motors on the exit side (G). Depending on the individual needs and operating conditions of the site, the mechanical units can be installed outdoors or next to an inspection pit as the structure facilitates installation procedures. Both models are equipped with self-braking motors in their standard configuration and Class 1 brake testers are equipped with dual-speed motors. The aluminium rollers are coated with Corundum and are 1mt long. The frame is fully galvanized and therefore rust-proof. Both models are available in one- and two-speed configurations, with or without counter-traction (4WD). Standard equipment also includes remote control, computer connection capability, management software and MCTCNet communication protocol that makes the product certified for Industry 4.0. Through the PC, the operator can then register the reservation and enter the vehicle data and the types of measurements to be made. The data is automatically sent to the PC-Station installed on the test bench or to a separate unit. The operator can then display the reservation, add the data and start the test. The PC-Station software automatically communicates with the test bench software that controls the test, the result of which is sent to the PC-Reservation software. Finally, multiple displays, necessary for testing longer vehicles with or without trailers, are also available: up to three analog displays and up to two digital monitors and/or tablets in addition to the main workstation.

 

Vamag

Vamag offers a complete range of roller and platform brake test benches for cars, motorcycles and trucks. Among them, the platform test benches stand out, designed for DMV test centres that need to carry out accurate tests quickly and with lower energy costs compared to the use of traditional roller brake testers. The current Vamag production includes models with standard and enlarged track widths with mesh platforms, Corundum coating and the new U1 Profile covered by proprietary patent. Over time, Vamag has expanded the range for cars and motorcycles by building and integrating platforms on garage lifts: a solution that makes it possible to reduce the overall dimensions to just six meters. The brake test benches by Vamag are not only designed to work on cars, but also and above all on transport vehicles. For this sector, in addition to the classic rollers, Vamag has recently introduced further benches ranging from four to twenty platforms. These make it possible to build tailor-made inspection lines and to carry out the combined testing of trucks, trailers and semi-trailers at once, testing up to six axles. Thanks to a wide range of solutions, Vamag is able to identify the best solution for each inspection centre looking at the available space, the possibility to adopt an in-floor model without neglecting to take into consideration the working habits and the aesthetic tastes of the customer.