
Introduction Our customer, a tier-one supplier to large motorbike manufacturers in India, wanted an on-road data acquisition system to test motorbike front disk brakes. The brakes were to be tested by measuring stopping distance during various road trials. The most straightforward way to determine stopping distance is to bring the motorbike to the required speed before reaching a certain predetermined marked point, and then to apply the brake from that point until the motorbike stops. Using a tape measure or a more sophisticated distance-measuring instrument, we can determine the stopping distance. This is a tedious and time -consuming process and not practical during long trials over different terrain. Additionally, in this method, other parameters relating to braking, such as the brake-pad temperature and hydraulic pressure, cannot be obtained.
We designed the on-road brake test system to measure the braking distance of a motorbike under different road conditions in real time. This data is used offline to compute the performance parameters of the disc brake as per the customer’s specifications.System DescriptionThe on-road brake test system is designed to acquire real-time road test data. The test required a dedicated onboard computer to run the system and acquire the test data. A laptop computer was considered and excluded, as it was not rugged enough to withstand the rigors of field test conditions. We developed a test system based on a small form factor rugged FieldWorks computer, with National Instruments data acquisition card, signal conditioning modules, and application software written in LabVIEW 6i.The following sensors are used in the data acquisition system:
Rotation encoder - for rotational displacement and the wheel speed
Thermocouple - for pad temperature during braking
Pressure sensor - for the brake hydraulic line pressure
Accelerometer - for the instantaneous acceleration of the vehicle
For user inputs and display, a small-sized integrated keyboard and LCD display was interfaced with the FieldWorks computer through the RS-232 port because the FieldWorks 2200 model does not include an integrated display. Using this display, the motorbike rider can send commands, set parameters, and receive feedback from the system, such as the braking distance. The motorbike’s 12 V battery powers the computer, the user-interface kit, and the signal conditioning modules. The conditioned signals from the transducers connect to National Instruments PCMCIA multipurpose high-speed data acquisition card installed in the FieldWorks computer. Three analog input channels and two counter/timers from the DAQ card are used for the data acquisition.
The encoder and the accelerometer are both used to acquire the data used in calculating the braking distance. Two complementary and independent methods are used to calculate the stopping distance. The first method uses the pulses per revolution (ppr) output of the encoder to measure both the speed and the displacement. The accelerometer data is used as supplementary data. The braking distance is obtained by using the initial speed of the motorbike and integrating the acceleration value twice. Because this accelerometer data is not as accurate as the encoder data, it is used only when a wheel lock is detected.