In my former job at Brembo SGL Carbon Ceramic Brakes, we would receive following requirements from our customers, mainly OEMs: - Safety Based on norms and internal experience - Performance Based on vehicle characteristics and customers expectations - Cost (including part and maintenance costs)

In addition, I believe that continuous monitoring and adaptation are crucial elements in refining braking systems. Staying attuned to advancements in technology, industry trends, and user feedback allows for ongoing improvements. A dynamic approach ensures that the braking system remains effective and relevant over time, enhancing its capabilities beyond initial implementation. This commitment to evolution aligns the system with emerging safety standards and keeps it at the forefront of innovation in the automotive industry.

Check the type of breaking type (drum, disc) proposed for the vehicle system. Then check control of the brake that happens based on the normal brake system (numatic) or the brake command comes over CAN via ABS system and design breaking action. As break is considered as ISO26262 function safety component defines correct ASIL classification based on full vehicle ASIL rating. Once it is defined diagnosis of brake and fail safe reaction to be defined as per function safety goals.

As for any system, the analysis of the stakeholders needs and operational analysis are the first steps. The life phases (including assembly, maintenance, parking, driving,...) are listed first and then usecases for each life phase and expected features are listed too (for example in driving phase : brake when the driver brakes, brake when an obstacle is detected, brake to prevent going backward in a slope, ...). At this step it is efficient to consider the whole vehicle as your system before you allocate the requirements to braking subsystem, otherwise you may not manage properly the respective roles of braking and powertrain in some usecases.

When approaching braking system requirements, my perspective centers on a holistic understanding. Beyond meeting standards and specifications, it's about tailoring the system to optimize safety, performance, and user experience. I've learned that integrating these factors—considering the vehicle's behavior under various conditions, user expectations, and real-world scenarios—creates a more comprehensive set of requirements. This approach ensures that the braking system not only meets regulatory standards but also enhances the vehicle's overall functionality and safety, aligning with customer needs and expectations.

Ensuring brake safety involves selecting appropriate components. Decide between rapidly cooling disc brakes or the simplicity of drum brakes. Opt for high-quality brake pads or shoes with strong grip and durability. Choose a dependable brake fluid for smooth functioning. Ensure even application of brakes by calipers or wheel cylinders. Utilize sturdy, corrosion-resistant brake lines. Incorporate an anti-lock braking system (ABS) for improved control during abrupt stops. Thoroughly test each part across various scenarios. Persistent evaluation and adjustment are essential to assemble the most effective brake system, enhancing safety through careful part selection and continuous refinement.

To make brakes safe, you need to pick the right parts. Choose between disc brakes that cool down quickly or drum brakes that are simpler. Use good brake pads or shoes that grip well and last long. Pick a reliable brake fluid for smooth operation. Make sure the calipers or wheel cylinders evenly apply the brakes. Use strong brake lines that won't rust. Include an anti-lock braking system (ABS) for better control in sudden stops. Test each part well to make sure they work in different situations. Keep trying and fixing to make the brakes really safe by choosing and putting together the best parts.

To select a component is only when you are looking one on the shelf. You can also, based on your product strategy, on your installation constraints, your electronic and software architecture, your features level, to start to define the necessary requirements to develop a specific product. In this case, innovation is one of your target.

The components selection will be influenced by 3 aspects: - Vehicle requirements. - Legal Requirements. - Commercial and marketing requirements. At Entecnia we define the braking system components through our internal SW that verify all requirements at different driving conditions (loads, roads, temperatures…)

Component selection: Choose materials and components based on: Friction characteristics: High friction for strong stopping power, but avoid overheating and fade. Heat dissipation: Components like discs and pads should dissipate heat efficiently. Weight and durability: Balance weight with strength and longevity. Compatibility: Ensure all components work seamlessly together.

For top-notch brake safety, carefully position the pedal, master cylinder, and booster. Ensure the brake system is responsive and evenly distributes pressure. Strategically place ABS components for control during sudden stops. Regularly test and refine the setup to guarantee consistent, reliable performance in diverse driving conditions.

To make brakes super safe, you need to plan how everything is arranged. Decide where the brake pedal, master cylinder, and brake booster should go for easy and quick use. Make sure the brake pedal is easy to reach and works well. Plan how the hydraulic system is set up so that brake fluid pressure is even. Put the parts for the anti-lock braking system (ABS) in the right places for good control during quick stops. Test the layout to see how it works in different driving situations, and fix anything that needs improvement. Keep testing and adjusting to make sure the brake layout keeps you safe by working well all the time.

For the integration of all parts in the real vehicle it’s important to understand the specific assembly requirements of each component, gaps and tolerances required and a close communication with OEMs. Usually the packaging of the vehicle is not fully defined and may change during the integration process to accommodate all systems.

Right sir , of course if you disregard the vehicle or machine load a disaster will take place. If you disregard a condition like time or temperature or element used brake performance decreases , there are other ways to increase the brake power , but every development has its costs , nevertheless the all-over product price like drums or discs brake, like pneumatic or fluid braking is a major industrial criteria.

Hay diferentes aplicaciones y/o programas en 3D tipo CAD que ayudan en la elaboración del software para las fórmulas del frenado convencional y que contribuyen en el mejoramiento de los sistemas que componen el frenado.

Ensuring brake safety involves establishing clear performance standards, utilizing computer models to simulate various scenarios, and conducting real-life tests to assess durability and consistency. Integrate sensors and monitors to monitor brake performance during driving, facilitating quick issue identification. Analyze gathered data to enhance braking efficiency, such as improving even distribution of stopping power or achieving faster response times. Continuous evaluation and refinement based on collected information contribute to making brakes more effective and reliable.

To make sure brakes are really safe, you need to check how well they work. First, decide on clear rules for how good the brakes should be, like how quickly they can stop the vehicle. Use computer models to see how the brakes would do in different situations, like when you need to stop suddenly or if the road is slippery. Then, actually test the brakes in real life to see how they perform – how long they last and if they work the same way every time. Add sensors and monitors to keep an eye on the brakes while you're driving, so you can quickly spot any issues. Look at all the information you gather to find ways to make the brakes even better, like spreading the stopping power more evenly or making them work faster

While a lot of simulations and CAE can help in the design phase, true Performance analysis is based on a robust Validation Plan. Validation plans are a product of 1) System Requirements 2) Functional and Performance Requirements 3) Safety requirements 4) Failure Mode and Effects Analysis 4) Reliability Requirements A well rounded and robust Validation plan is the only guarantee for performance from a new brake system. With Braking systems getting smarter and more complex, tests are often divided into 1) individual component level tests 2) sub system level tests 3) system level bench tests 4) vehicle level testing These divisions are to make testing cost and time efficient.

Consistant abuse testing at planned (and sometimes unplanned) intervals is how i would acheive the confidence in the design, build and even final product phase of the project to ensure all safety specs have been met prior to handing it over to the consumer.

Performance Testing:Conduct rigorous performance tests, including braking distance, response time, and stability on different surfaces.

Evaluate the braking system's functionality through rigorous testing aligned with performance standards. Ensure the system performs according to expectations, addressing any identified errors or defects promptly. Utilize a variety of testing methods and equipment such as dynamometers, test benches, and vehicles. Employ sensors, data loggers, and software for thorough data recording and analysis, allowing a comprehensive assessment of the braking system's performance and facilitating effective adjustments for optimal functionality.

Environmental Testing:Assess the system's performance in various environmental conditions (e.g., extreme temperatures, wet surfaces) to ensure reliability. Durability Testing:Subject the braking system to long-term durability tests to evaluate its lifespan and resilience to wear and tear.

I was involved with a start up who was building an EV conversion vehicle. They knew little about vehicle design. They had put too much regen in the rear and I could feel it driving their prototype. I told them this after my drive but they did not believe anything was wrong. Out front of their building was a gravel parking lot. So I took them out there, brought the vehicle up to speed, maybe 25 mph, turned the steering wheel and took my foot off the accelerator pedal and the vehicle did an immediate 180 on the gravel. The point being, that testing must include everything a real World driver might experience and also including the vehicle development and vehicle dynamics people in the testing is important.

Test brake system functionality through a series of procedures: 1. **Visual Inspection:** - Examine all components for visible damage or wear. 2. **Road Test:** - Evaluate braking performance in various driving conditions. - Assess responsiveness, pedal feel, and noise levels. 3. **Dynamometer Testing:** - Conduct controlled tests on a dynamometer to simulate different driving conditions 4. **Performance Testing:* 5. **Heat Dissipation Testing:** 6. **ABS (Anti-lock Braking System) Testing:** - Verify proper functioning of ABS during controlled stops. 7. **Vibration Analysis:** 8. **Endurance Testing:* 9. **Hydraulic System Testing:** 10. **Compliance with Standards:**

Individually test components such as master cylinders and callipers for pressure and function. Dynamometer Testing: On a rolling road machine, simulate vehicle brakes to assess stopping distances and fade resistance. On-Vehicle Testing: Run real-world testing on a test track or on public highways under a variety of driving conditions and speeds.

Iterative refinement: Based on testing results, refine the design by adjusting component materials, system architecture, and control algorithms. Repeat the simulation and testing cycle until the desired level of safety and performance is achieved. Regulations and standards: Ensure the braking system complies with relevant safety regulations and standards (e.g., FMVSS 135, UNECE R13-H) to guarantee legal compliance and consumer safety.

The first step towards completion is evidenced in the test results and data. the braking sensation can mask the real braking situation, the driver's feel is very important, but it is prudent to compare both the data and the driver's feeling

Validation encompasses stringent tests under diverse conditions: extreme temperatures, humidity, vibrations, and corrosive environments. Adherence to ISO and SAE standards is imperative, representing the pinnacle of quality assurance. Employing methods like accelerated life tests, reliability checks, and FMEA ensures a rigorous evaluation. This phase isn't just about safety; it's about certifying a robust braking system, guaranteeing unwavering performance in varied circumstances.

The first step towards completion is evidenced in the test results and data. the braking sensation can mask the real braking situation, the driver's feel is very important, but it is prudent to compare both the data and the driver's feeling

Imagine a scenario where a vehicle is navigating steep, winding mountain roads. A well-designed braking system with effective heat dissipation and precise control becomes crucial in preventing brake fade during extended downhill descents. Rigorous testing in simulated mountainous conditions helps ensure the braking system can handle such demanding terrains, providing optimal safety for both the driver and passengers. Also collaboration with experienced engineers and adherence to industry standards are essential throughout the design and testing phases for optimal safety.

No projeto de um sistema de freios é muito importante pensar em quem realizará as manutenções e os reparos futuros. É necessário que a tecnologia seja compreendida pelo reparador. O reparo bem feito mantém o padrão de originalidade, assegura as mesmas características de segurança, eficiência e confiabilidade do momento que o veículo saiu de fábrica.

In order to ensure that the brake system will be safety, it is mandatory to do the fail safe analysis. The fail safe analysis shall be done around the safe state where the brake system will be safe (for example minimum brake capability to bring the car to a safety stop condition). As a consequence, the only way to determine as earlier as possible if the brake system will be safe enough is when the safety analysis will be able to answer the question where, for ALL possible failures that the system will may have, there will be no one where the hazard will happen. Or even when the failure may happen, there will be a mitigation in place bringing the brake system to a defined safe state. In that way, the brake system will be considered safety.

Benutzerfreundlichkeit: Das Bremssystem sollte nicht nur sicher, sondern auch benutzerfreundlich sein. Es sollte eine intuitive Reaktion des Fahrzeugs auf die Aktionen des Fahrers ermöglichen und Feedback geben, das der Fahrer leicht interpretieren kann. Noch weitere wichtige punkten bzw, Wartungsanforderungen Kostenfaktoren, Umweltauswirkungen, Zukünftige Technologien: (Einfachintegration), Normen und Vorschriften, Rückmeldung und Erfahrungen aus dem Markt, und Schließlich Krisenmanagement: man soll ein Plan für den Umgang mit möglichen Rückrufaktionen oder anderen Krisensituationen in Bezug auf das Bremssystem bestehen.Rückrufaktionen.

The previous 6 steps are a nice action plan to follow, but don't strive for perfection at the first shot. Braking systems are crucial for any vehicle. You must have the final version 100% reliable and safe. So before that, you must: Fail Often and Fail Early. Do as many as needed cheap, quick and dirty prototypes then go ahead and Fail. Computer simulations for sure are helpful, but you must see your product failing in real situation. Embrace the failure before releasing your product for serial production. Work with Lean Manufacturing principles and always have UX/UI ideas. Otherwise you'll fail later and that will be too late. You will just end up with Mass Production and a lot of Quality Assurance for the lifetime of your product.