Test Planning & Preparation
Prepare test vehicles and brake system prototypes, ensuring all instrumentation (e.g., pressure sensors, thermocouples, accelerometers) is correctly installed and calibrated.
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.
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.
Test Execution
Conduct noise, vibration, and harshness (NVH) tests to identify and address issues such as brake squeal, judder, or vibration during braking.
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.
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).
Execute dynamic tests such as brake fade testing, ABS (Anti- lock Braking System) evaluation, EBD (Electronic Brakeforce Distribution) performance, and brake cooling assessments.
Validate simulation models by comparing real- world test results, ensuring that virtual predictions of braking performance align with actual vehicle behavior.
Ensure that all braking systems meet internal performance standards and comply with global safety regulations (e.g., FMVSS, ECE, GTR).
Monitor and record real- time data during tests using advanced data acquisition systems, ensuring the accuracy of data and proper calibration of test equipment.
Data Analysis & Reporting
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.
Identify trends, anomalies, or performance deviations and collaborate with the development team to propose design improvements or tuning adjustments.
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.
Problem Solving & Troubleshooting
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.
Identify and diagnose issues related to brake system performance, such as insufficient stopping power, brake fade, uneven braking, or overheating.
Collaboration & Communication
Collaborate with external testing partners, regulatory bodies, and suppliers to ensure comprehensive validation of braking systems.
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.
Present findings and recommendations in technical reviews, design meetings, and validation discussions.
Communicate test procedures, results, and performance recommendations to internal stakeholders, including product management, safety teams, and quality control.
