Analisis Comparativo Pruebas de Frenado

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International Journal of Automotive Technology, Vol. 13, No. 5, pp. 735-742 (2012) DOI 10.1007/s12239-012-0072-x Copyright © 2012 KSAE/ 066-05 pISSN 1229-9138/ eISSN 1976-3832 735 COMPARATIVE ANALYSIS OF VEHICLE BRAKE DATA IN THE MINISTRY OF TRANSPORT TEST ON THE ROLLER BRAKE TESTER AND ON FLAT GROUND C. SENABRE * , E. VELASCO and S. VALERO Miguel Hernández University, Elche 03202, Spain (Received 27 May 2010; Revised 5 January 2011; Accepted 23 December 2011) ABSTRACT-This study performs a comparison between what occurs when braking on a Ministry of Transport (MOT) brake tester and on flat ground. The tire pressure is changed, but the other parameters remain constant. The results from this research and from the in-depth comparative study conducted by the mechanical engineering staff in the mechanical laboratory at the Miguel Hernández University in Elche have led to the following main conclusions: By varying the tire pressure, false results can be obtained with the MOT brake tester, which means that, if the tires are inflated at a low pressure but the brakes are in good condition, the vehicle will not pass the MOT. Conversely, if the brakes are in poor condition but the tire pressure is higher than what is recommended by the manufacturer, a false pass is produced. This article shows that the MOT brake testing equipment is often wrong and inexact, and the data and graphs presented prove that the tire pressure is a determining factor when assessing the condition of brakes. KEY WORDS : Braking, Ministry of transport (MOT), Roller brake tester, Roller bed, Tire pressure 1. INTRODUCTION Currently, the International Motor Vehicle Inspection Committee (CITA) states that the condition of brakes must be checked at the Ministry of Transport (MOT) Test Stations. The European Community Law (2002) in Law no. 29 237, Article 14, states that “the driver of the vehicle must present the vehicle to the MOT Ministry of Transport Test Station, with the right tire pressure.” However, the “MOT procedure manual” from Ministry of Industry, Tourism and Trade of Spain (2006) does not mention the tire inspection procedure at the stations. This paper analyzes how the tire pressure and extra weight on the vehicle can affect the longitudinal braking action and sliding on a MOT brake tester, and this braking action is compared with brake sliding on a flat road. When a vehicle is taken to a MOT testing facility, the brakes are tested on a roller bed to check the brake circuit. Several questions on the efficiency of the MOT testing facilities need to be answered: Does the braking on a roller brake tester accurately reproduce braking on flat ground? To what extent does the tire pressure affect the measurements taken on the rollers? Is this test safe enough to assess the condition of the brakes? Is this brake test 100% effective? The aim of the study is to calculate a vehicle's braking capacity by measuring the slippage on a roller brake tester at a MOT center, compare this slippage with similar measurements taken on flat ground, and use these results to assess the machine’s reliability to test brake systems. This is the first time that a comparative analysis of the longitudinal braking on a MOT roller brake tester and on flat ground has been conducted. The contributions from many authors on longitudinal braking have been analyzed. 1.1. Background The oldest model, Fiala (1954), was the first to ever produce an iteration of the tire on the ground, although the tire was not considered with dimensions. Bergman (1965) conducted the first theoretical analysis of the drift during braking. Meyer and Kummer (1962) published a study on the transmission mechanisms of the forces between the wheel and the ground. Nordeen and Cortese (1963a) studied the relationship between the F side and the F drive and braking. Nordeen and Cortese (1963b) published studies on the characteristic forces and moments that are involved in tire rolling. Frank and Hofferberth (1967) studied the mechanical properties of tire technology and the qualities of rubber. Bekker (1969) published the first study on the interactions in terrain-vehicle systems. Livingston and Brown (1969) compared the effects of different types of brake pressure. Dugoff et al. (1971) *Corresponding author. e-mail: [email protected]

description

analisis de frenado

Transcript of Analisis Comparativo Pruebas de Frenado

  • International Journal of Automotive Technology, Vol. 13, No. 5, pp. 735742 (2012)

    DOI 10.1007/s122390120072x

    Copyright 2012 KSAE/ 06605

    pISSN 12299138/ eISSN 1976-3832

    735

    COMPARATIVE ANALYSIS OF VEHICLE BRAKE DATA IN THE

    MINISTRY OF TRANSPORT TEST ON THE ROLLER BRAKE TESTER

    AND ON FLAT GROUND

    C. SENABRE*, E. VELASCO and S. VALERO

    Miguel Hernndez University, Elche 03202, Spain

    (Received 27 May 2010; Revised 5 January 2011; Accepted 23 December 2011)

    ABSTRACTThis study performs a comparison between what occurs when braking on a Ministry of Transport (MOT) brake

    tester and on flat ground. The tire pressure is changed, but the other parameters remain constant. The results from this research

    and from the in-depth comparative study conducted by the mechanical engineering staff in the mechanical laboratory at the

    Miguel Hernndez University in Elche have led to the following main conclusions: By varying the tire pressure, false results

    can be obtained with the MOT brake tester, which means that, if the tires are inflated at a low pressure but the brakes are in

    good condition, the vehicle will not pass the MOT. Conversely, if the brakes are in poor condition but the tire pressure is higher

    than what is recommended by the manufacturer, a false pass is produced. This article shows that the MOT brake testing

    equipment is often wrong and inexact, and the data and graphs presented prove that the tire pressure is a determining factor

    when assessing the condition of brakes.

    KEY WORDS : Braking, Ministry of transport (MOT), Roller brake tester, Roller bed, Tire pressure

    1. INTRODUCTION

    Currently, the International Motor Vehicle Inspection

    Committee (CITA) states that the condition of brakes must

    be checked at the Ministry of Transport (MOT) Test

    Stations. The European Community Law (2002) in Law

    no. 29 237, Article 14, states that the driver of the vehicle

    must present the vehicle to the MOT Ministry of Transport

    Test Station, with the right tire pressure. However, the

    MOT procedure manual from Ministry of Industry,

    Tourism and Trade of Spain (2006) does not mention the

    tire inspection procedure at the stations. This paper

    analyzes how the tire pressure and extra weight on the

    vehicle can affect the longitudinal braking action and

    sliding on a MOT brake tester, and this braking action is

    compared with brake sliding on a flat road.

    When a vehicle is taken to a MOT testing facility, the

    brakes are tested on a roller bed to check the brake circuit.

    Several questions on the efficiency of the MOT testing

    facilities need to be answered:

    Does the braking on a roller brake tester accurately

    reproduce braking on flat ground?

    To what extent does the tire pressure affect the

    measurements taken on the rollers?

    Is this test safe enough to assess the condition of the

    brakes?

    Is this brake test 100% effective?

    The aim of the study is to calculate a vehicle's braking

    capacity by measuring the slippage on a roller brake tester

    at a MOT center, compare this slippage with similar

    measurements taken on flat ground, and use these results to

    assess the machines reliability to test brake systems.

    This is the first time that a comparative analysis of the

    longitudinal braking on a MOT roller brake tester and on

    flat ground has been conducted.

    The contributions from many authors on longitudinal

    braking have been analyzed.

    1.1. Background

    The oldest model, Fiala (1954), was the first to ever

    produce an iteration of the tire on the ground, although the

    tire was not considered with dimensions. Bergman (1965)

    conducted the first theoretical analysis of the drift during

    braking. Meyer and Kummer (1962) published a study on

    the transmission mechanisms of the forces between the

    wheel and the ground. Nordeen and Cortese (1963a)

    studied the relationship between the F side and the F drive

    and braking. Nordeen and Cortese (1963b) published

    studies on the characteristic forces and moments that are

    involved in tire rolling. Frank and Hofferberth (1967)

    studied the mechanical properties of tire technology and

    the qualities of rubber. Bekker (1969) published the first

    study on the interactions in terrain-vehicle systems.

    Livingston and Brown (1969) compared the effects of

    different types of brake pressure. Dugoff et al. (1971)*Corresponding author. e-mail: [email protected]

  • 736 C. SENABRE, E. VELASCO and S. VALERO

    developed the friction coefficient slip-speed expression of

    the tread. Hays and Browne (1974) made a list of the

    theory and data from the friction of rubber tires. They also

    studied the physical properties of the drive wheel. Moore

    (1975) conducted an extensive study on the relevant slip

    and friction properties of the vehicle. Bernard et al. (1977)

    published a study on the semi-empirical tire model used for

    continuous slipping. Potts et al. (1977) studied the

    vibrations that tires. Shearer (1977) analyzed the rolling of

    the wheel and established methods to improve tires of the

    wheels. Pacejka (2005) came up with mathematical models

    that outlined the behavior of the steady drift and the

    relationship between the rim and other parameters. Topkins

    (1981) provided a massive collection of tire theory and

    data. Sakai (1981) conducted in-depth theoretical and

    experimental studies of advanced tire models and their

    dynamic properties. Milliken and Rice (1983) published a

    study about non-nimensionalizing tire data for vehicle

    simulation. Sharp and El-Nashar (1986) conducted a

    computer application-based mathematical model to

    simulate rupture forces on the tires of wheels. Bakker et al.

    (1989) devised a pseudo-experimental model, which is

    called the Magic Formula model. Gim and Nikravesh

    (1990), from the University of Arizona, conducted studies on

    tire forces. Senabre et al. (2004) developed mathematical

    models to simulate tire movement and interaction with the

    surface (Mechanical Conference). Garca-Pozuelo et al.

    (2009) studied improvements in the inspection procedure of

    brake disc warping (Securitas Vialis).

    2. TESTING METHODS

    The vehicle used in this test was a Renault 21 model

    Nevada that seats 7 and has a diesel engine. It has front disc

    brakes with sliding clamps, uses DOT 4 brake fluid, and

    uses a tandem brake pump. The rear wheels have drum

    brakes.

    The measurements were taken from 2 encoders fitted to

    the roller brake tester, and the wheels of the vehicle and a

    pressure sensor were attached to the vehicle's brake circuit.

    These instruments were used to measure the pressure in

    the hydraulic circuit after pressing the brake pedals and to

    correlate the data to the speed of the wheels

    The two tests conducted are described below:

    2.1. Test 1

    The braking is measured on the roller brake tester at a

    MOT center by placing the vehicle on rollers that rotate at

    5 km/h (see figure 2). All roller banks on the MOT brake

    testers rotate at 5 km/h in all MOT stations in Spain. This

    velocity is enough to obtain 100% wheel slip.

    The vehicle tries to stop the wheel through braking. A

    sensor in the hydraulic pipe placed on the front right wheel

    is used to obtain data on the brake. The slip value was

    measured using the angular velocity of the rollers and the

    vehicle wheel data.

    The emergency brake should not be on. The brake pedal

    has to be pressed down until 100% slippage is obtained.

    After 100% slippage and with a fully locked wheel, the tire

    cannot transmit additional brake torque to the terrain or the

    roller tester sensor, which means that the pressure in the

    brake circuit after this point is ineffective.

    The torque on the rotation axis of the rollers is measured

    using a strain gauge. The pressure in the hydraulic brake

    circuit on the right front wheel of the vehicle is also

    measured using a sensor in the hydraulic pipe of the right

    front wheel, as shown in figure 1. There is a pipe for the

    brake of each wheel, and the pipe in the right front wheel is

    no longer than 2 m; therefore, the position of the sensor on

    the pipe does not affect the measurements because there are

    no flow losses.

    Measurements were taken from the 2 encoders attached

    to the roller brake tester and the right front wheel of the

    vehicle, and a pressure sensor is attached to the vehicle's

    brake circuit. These instruments were used to measure the

    pressure in the hydraulic circuit after pressing the brake

    pedals and to correlate the data to the speed of the wheels.

    The test data were recorded using an LMS Pimento

    portable, multi-channel analyzer. This analyzer provides for

    real-time monitoring of the process and data recording.

    To measure the revolutions of both the rollers and the

    vehicle wheels, 2 OMRON encoders were used. One

    encoder was the E6B2-CWZ6C model, and the other

    encoder was the E6B2-CWZ1X model. One encoder was

    attached to the right-hand roller of the roller brake tester (see

    Figure 1. Position of the hydraulic sensor.

    Figure 2. Hydraulic sensor in pipe to right front wheel.

  • COMPARATIVE ANALYSIS OF VEHICLE BRAKE DATA IN THE MINISTRY OF TRANSPORT TEST 737

    figures 3 and 4), and the other encoder came in contact with

    the front right-hand wheel of the vehicle (see figure 4). To

    ensure that the rotation of the encoders was synchronized

    with the rollers and the wheels, connectors were built as

    shown in figures 3 and 4 such that a spring guarantees that

    good contact is achieved.

    The slip in test 1 was calculated from the data recorded

    during the test using expression (Dixon, 1996):

    (1)

    where rvehicle wheel is the brake torque on the wheel / the brake

    force on the roller.

    The torque at the roller axis is measured using the MOT

    sensor, which is a gauge that determines the torque on the

    shaft.

    The brake torque was calculated in the following

    manner. The driver released the brake pedal until the

    torque generated at the wheel was higher than the

    pressure applied to the brake circuit such that the torque

    produced a rotation of the wheel (see figure 5). A triggers

    is used, it measure 0 volts when the wheel rotate and a

    circuit with a 5 volts battery is open, in that point the

    measurement of the pressure in the brake circuit is

    measured to calibrate the pressure sensor.

    2.2. Test 2

    In this test, the vehicle runs on flat ground until it attains a

    velocity of 40 km/h, which is required to obtain 100%

    slippage. In the test 2, It is braked the vehicle until the car

    slides by 100%. The same signals as in test 1 are recorded

    for the brake test. Both sensors are used in the two tests to

    make sure that the measurement has been acquired in the

    same manner.

    A fifth wheel, driven by the vehicle, has been attached to

    measure the slippage (see figure 6). This is used as a

    reference. The track is assumed to be completely flat, with

    no changes in the adhesion coefficients of the route. A

    spring was attached to the fifth wheel to ensure good

    contact. The velocity of the car is 40 km/h, as this velocity

    is required to obtain 100% wheel slippage.

    The values of the coefficient of adherence () (Dixon,

    1996), which are affected by several internal factors

    associated with the wheel and the vehicle, by external

    factors, and even by environmental conditions where there

    is movement, appear to be constant.

    The adhesion coefficient is 1 for test 1 and 1 for test 2

    (Dixon, 1996). This coefficient from the tester value is the

    factory-supplied value for the MOT testers.

    Therefore, the only difference in the measurements is the

    change in tire pressure in both tests.

    In test 1 and in test 2, once the test data were recorded,

    any data points that were not characteristic were filtered and

    deleted so that better results and a suitable interpretation

    could be obtained.

    Slip 1speed of vehicle wheel

    roller speed-------------------------------------------------------=

    1rvehicle wheel* Wr of vehicle wheel

    rroller* Wr of roller-----------------------------------------------------------=

    rroller 0.1 m=

    Figure 3. Test 1 roller brake tester at the MOT center.

    Figure 4. Encoder attached to the roller brake tester.

    Figure 5. Pressure relation in the brake circuit and brake

    torque on the wheel.

    Figure 6. Fifth wheel or the drive wheel.

  • 738 C. SENABRE, E. VELASCO and S. VALERO

    Sick Stegmann DKS-40 encoders were used in this

    test, and the encoder was attached to the fifth wheel of the

    vehicle, the drive wheel (see figure 4), and the other

    encoder was attached to the front right-side wheel of the

    vehicle, which is the same as that in the previous test.

    The slip was calculated from the data recorded during

    tests by means of expression (Aparicio, 2001):

    (2)

    The slip can be calculated if the angular velocity is

    calculated:

    All of the slip data are obtained when the wheel is

    locked, hence: wr of vehicle wheel = 0 and wr of fifth wheel >0, where re

    fifth wheel is the fifth effective rolling radius and can be written

    as re fifth wheel = Vvehicle / wr of fifth wheel, r e vehicle wheel is the wheel

    effective rolling radius, and Vvehicle is the vehicle velocity.

    The value of wvehicle wheel/wfifth wheel are multiplied by the

    fraction re vehicle wheel / re fifth wheel , which is considered to be

    constant to simplify the calculation.

    The vehicle velocity is determined with a Wilcoxon

    784A accelerometer that is placed inside the car, as shown

    in figure 7.

    The velocity is obtained by integrating the acceleration

    values acquired from the accelerometers, located on the

    floor by the rear seats of the vehicle, which is the center of

    gravity of the vehicle.

    Additionally, 2 more accelerometers were installed to

    make sure there is no vertical (z axis) or horizontal (y

    axis) acceleration.

    3. RESULTS

    A tire with pressure that is too low overheats, the surface

    does not wear uniformly so more fuel is consumed. The tire

    is less durable, becomes more sensitive to impact and has a

    lower resistance to stress and strain, which means it might

    become irreparably damaged. At a pressure lower than 1

    bar, the tire may even come loose from the rim. This did

    not happen in this study because a pressure of 1 bar or

    greater was used. The tires have been inflated to have

    pressures of 1, 1.5 and 2 bar. These three values clearly

    show how events occur, although the range was increased in

    later studies.

    The measurements of the brake pressure on the vehicle

    and the slippage in the braking wheel were obtained for

    both tests.

    A comparative analysis was conducted on the braking

    and slip measurements for the same test performed with

    different tire pressures to examine how the test evolved.

    The braking and slippage data were also compared for both

    tests at the same tire pressure to investigate if there are any

    differences in the braking measurements between the roller

    tester and flat ground.

    3.1. Comparison of the Braking-slip Ratio Data at Various

    Tire Pressures for Both Tests

    3.1.1. Results and discussion from test 1

    When the brake pedal is pressed down, the pressure values

    in the circuit and the corresponding slippage that is obtained

    in test 1 for different tire pressures are shown below.

    The measurements produced from the pressure sensors

    versus time are as shown in figure. 8:

    From the data obtained, only the measurements taken up

    to the maximum slippage are considered, which corresponds

    to 100% wheel slip.

    Once the measurements have been processed, which

    Slip 1speed of vehicle wheel

    seep of fifth wheel-------------------------------------------------------=

    Slip 1speed of vehicle wheel

    speed of fifth wheel--------------------------------------------------------- ==

    1re vehicle wheel* Wr of vehicle wheel

    re fifth wheel* Wr of fifth wheel--------------------------------------------------------------=

    Figure 7. Accelerometer installed inside the vehicle.

    Figure 8. Pressure measurements in the brake circuit of the

    vehicle versus time on the MOT roller brake tester and on

    flat ground with 1-1.5-2 bar of wheel pressure.

    Figure 9. Start and end points of the measurements.

  • COMPARATIVE ANALYSIS OF VEHICLE BRAKE DATA IN THE MINISTRY OF TRANSPORT TEST 739

    means removing anomalies, such as sensor or wire

    disconnection, the useful part of the measurement is

    obtained. All data files have a clear start and end point (see

    figure 9). The starting point has to be the last point with 0

    pressure in the brake circuit, and the last point is the

    maximum slip value. If the measurements begin with a

    torque value greater than 0 the file is removed, and if the

    measurement finishes without a maximum and constant

    slip value, the file is deleted.

    A summary for test 1 was obtained for each tire pressure

    value and is shown in figure 10.

    As seen in the graph in figure 10, when the tire pressure

    increases, the braking pressure required for the braking

    system to be able to stop the vehicle on the MOT roller

    tester increases as well, and there is some delay in the slip

    increase. This means that when the tire pressure is too low,

    the maximum slip value can be obtained with less pressure

    on the vehicles brake circuit.

    3.1.2. Results and discussion from test 2

    This test shows that there are smaller differences in the

    brake curves in relation to the slippage at various tire

    pressures compared with the MOT test 1, as shown in

    figure. 11.

    The maximum pressure applied in the brake circuit to

    stop a vehicle moving on flat ground is observed to decrease

    by 6.09% from 128.62 to 121.24 bar as the tire pressure

    increases from 1 to 2 bar, as shown in the maximum values

    in figure 11. This, however, is not as significant as the

    48.1% increase in the maximum value of the pressure in the

    brake circuit in test 1, which increased from 45.07 to 86.83

    bar and was enough to obtain 100% slippage as the tire

    pressure increased from 1 to 2 bar (see figure 9).

    3.2. Comparison of the Results from Both Tests

    When comparing the pressure curves in the brake circuit

    for both tests and the slippage for various tire pressures, the

    graphs in figs. 11, 12 and 13 show a clear and distinct

    difference in the pressure required in the brake circuit to

    stop the vehicle.

    As shown in figure 12, the % difference of the maximum

    value of the pressure in the brake circuit between both tests

    for a tire pressure of 1 bar is 65% if 100% slippage is to be

    obtained. This difference decreases to 40.64% when the

    tire pressure is 1.5 bar (see figure 11), and it drops to

    28.38% when the tire pressure is 2 bar (see figure 14).

    Figure 10. Pressure in the brake circuit for the slippage in

    test 1 at various tire pressures.

    Figure 11. Pressure in the brake circuit for slippage in test 2

    at various tire pressures.

    Figure 12. Comparison of the pressure in the brake circuit

    versus slippage when the vehicle is on the roller tester and

    on flat ground at a tire pressure of 1 bar.

    Figure 13. Comparison of the pressure in the brake circuit

    versus the slippage of the vehicle on the roller tester and on

    flat ground at a tire pressure of 1.5 bar.

  • 740 C. SENABRE, E. VELASCO and S. VALERO

    Although figure 14 shows a reduction in the difference

    in braking pressure between both tests, a roller brake tester

    does not reproduce braking on flat ground.

    3.3. Comparison of the Braking Data for Both Tests

    According to the tests conducted, the pressure in the brake

    circuit required to stop the wheel for the test on flat ground

    decreases as the tire pressure increases. Therefore, at tire

    pressures lower than 2 bar, a higher pressure is required in

    the brake circuit to stop the vehicle. This should be avoided

    so that less energy is consumed and the vehicle can be

    stopped in time.

    However, this result does not correspond to what occurs

    on the roller brake tester. As observed in fig. 15, the

    maximum pressure applied to the brake circuit to obtain

    maximum slippage (and the vehicle leaves the tester, as a

    result) increased as the tire pressure increased, and

    therefore, a greater hydraulic pressure in the brake circuit

    has to be applied in the case of higher tire pressure for the

    vehicle to leave the tester.

    One of the possible reasons why this tendency is

    observed at the peak braking values in the MOT is that the

    tire deforms on the rollers, and at higher tire pressures, it

    deforms less, resulting in less contact area between the tire

    and roller. This means that with a smaller frictional area, a

    greater force is required with the rollers before the vehicle

    can leave the tester.

    In contrast, the braking force required to stop the vehicle

    on flat ground, regardless of the tire pressure, is always

    greater than the force required on the roller tester. This is

    due to the fact that, when a moving vehicle is stopped, the

    forward inertial motion must be counteracted, and this does

    not occur on the roller brake tester.

    Quantitatively, if the tire pressure is 2 bar, the pressure

    sensor in the roller brake tester sensor captures a 28%

    difference in the measurements from the test on flat

    ground, and this increases to 65% if the tire pressure drops

    to 1 bar.

    The minimum brake efficiency required to pass the

    MOT test is 48-50% for vehicles without ABS. Our vehicle

    does not have ABS. This is pursuant to Directive 96/96

    CEE (EC) and the MOT vehicle inspection manual.

    The efficiency is:

    where E is the efficiency, F is the sum of the braking forces

    from all the wheels, M.M.A is the maximum permissible

    vehicle mass in kg (1350 kg), and g is the acceleration due

    to gravity.

    If there is a pressure of 1 bar in the brake circuit, 13.87 N

    of force is available to brake each wheel (see figure 5).

    Therefore, 121.24 bar (maximum brake value) in the

    brake circuit is equal to 1681.5 Nm, and this value over 4

    wheels is 6726 N.

    If the pressure of the brakes is equal in the 4 wheels, the

    efficiency is:

    E= 6726 N/(1140 kg*10 m/s2)= 59%

    Therefore, this vehicle should pass the MOT test

    because its brakes are in good condition, and this vehicle

    should pass the test with pressure of 2 bar or less in the

    tires.

    However for 2 bar of wheel pressure, the maximum

    value in the brake circuit is 86.83 bar for test 1, and for 4

    wheels, the brake torque is 4817.3 N.

    E = 4817.3 N/1140 kg*10 m/s2= 42.2%

    Therefore, this vehicle will not pass the test 1 with 2 bar

    of tire pressure or less.

    If the tendency of the maximum bar in the brake circuit

    for test 1 (figure 12) is captured by the following:

    EF

    M.M.A.g---------------------100=

    EF

    M.M.A.g---------------------100=

    Figure 14. Comparison of the pressure in the brake circuit

    versus slippage of the vehicle on the roller tester and on

    flat ground at a tire pressure of 2 bar.Figure 15. Relation of the maximum pressure in the brake

    circuit for different tire pressures when the vehicle is

    running on the MOT roller tester and on flat ground.

  • COMPARATIVE ANALYSIS OF VEHICLE BRAKE DATA IN THE MINISTRY OF TRANSPORT TEST 741

    y = 41.78x+8.81,

    where x is wheel pressure, the maximum brake value for

    2.5 bar of wheel pressure can be predicted.

    Hence, the efficiency for 2.5 bar of tire pressure will be:

    E = 107*13.87*4 N/1140 kg*10 m/s2 = 52.4% > 48%

    The car will pass test 1 with 2.5 bar of wheel pressure

    because the efficiency is greater than 48%.

    Our conclusion is that the car will pass test 1 only with a

    wheel pressure 2.5 bar or more, and it will fail the MOT

    test with a wheel pressure lower than 2.5 bar even if the

    brake system is in good condition.

    4. DISCUSSION AND CONCLUSIONS

    This study was conducted after ensuring that the measurement

    control was the same in both tests. Indeed, large differences in

    the pressures in the vehicle brake circuit were required to

    stop the vehicle before obtaining 100% wheel slip. The

    maximum pressure applied in the brake circuit to stop the

    vehicle movement on flat ground was observed to decrease

    by 6.09% from 128.62 to 121.24 bar as the tire pressure

    increased from 1 to 2 bar (see figure 7). However, this is

    not as significant as the 48.1% increase in the maximum

    value of pressure in the brake circuit, from 45.07 to 86.83

    bar, in test 1 to obtain 100% wheel slippage, as the tire

    pressure increased from 1 to 2 bar (see figure 6). Therefore,

    there is an adverse tendency in tracking the pressure

    measurements in the brake circuit related to the wheel slip

    for the 1 and 2 bar tire pressures in both tests.

    On flat ground, less braking force was required to stop the

    vehicle as the tire pressure increased, and the opposite was

    observed with regard to the roller test when tire pressure

    increased. The braking force was required to increase as

    well, i.e., the pressure in the brake circuit has to be increased

    to obtain 100% slippage. This means that, as the tire pressure

    increases, the roller brake tester captures the measurements

    that are closer to those of the flat ground test.

    In summary, a low tire pressure on the MOT roller brake

    tester produces values in the brake pressure circuit that may

    vary up to 65% from the real braking force required on flat

    ground.

    The difference in the measurements between the two

    tests may be due to the following:

    (1) There is a visible difference between the processes

    compared: in test 2 (on flat ground), the brake circuit

    pressure required to stop the vehicle was measured,

    and (on the roller tester) in test 1, the pressure required

    to eject the vehicle from the roller tester was also

    obtained.

    (2) On flat ground (test 2), the forward motion inertia has to

    be counteracted, which is not observed on the roller

    tester.

    (3) The contact zone between the tire and the MOT roller

    test track decreases as the tire pressure increases;

    therefore, a larger area of friction with the rollers will

    involve a greater braking force.

    (4) The contact zone between the tire and the flat ground is

    230 mm2 and the contact zone between the tire and the

    roller is 48.04 mm2 for a wheel pressure of 2 bar. This

    difference affects the maximum value of the pressure in

    the brake circuit because less contact means that 100%

    slippage with a lower pressure in the brake circuit can

    be obtained (see figures 16 and 17).

    (5) According to the measurements taken when the vehicle

    is stationary, the contact surface between the tire and

    the roller, at any tire pressure, is always less than the

    contact area of the wheel on flat ground.

    (6) The velocity could be a reason why there is a difference

    between the brake measurements in the two experiments.

    Therefore, the brake efficiency has been demonstrated to

    depend on the condition of the brakes and on the tire

    pressure during inspection on a roller brake tester. As

    mentioned before, the car would pass test 1 only with a tire

    pressure of 2.5 bar or more, and the car would fail the

    MOT test with a tire pressure lower than 2.5 bar, even if the

    brake system was in good condition.

    Consequently, the suitability of a roller brake tester to

    determine whether a vehicles brakes are in good condition

    Figure 16. Print on flat ground.

    Figure 17. Print on the MOT brake tester.

  • 742 C. SENABRE, E. VELASCO and S. VALERO

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