Development and Experimental Validation of a Full-Scale Brake Disc/Pad Test Rig for Passenger Vehicles

Brake systems are among the most critical safety components in passenger vehicles, making the accurate evaluation of braking performance essential during the design and development process. This study presents the development of a low-cost, multifunctional brake test rig capable of evaluating the performance of disc–pad friction pairs under controlled laboratory conditions. The test rig consists of a hydraulic braking unit, an electric motor drive system, a frequency inverter, a hydraulic control unit, and a data acquisition system. Braking tests were performed using an OEM ventilated brake disc and pad set at an equivalent vehicle speed of 100 km/h under a hydraulic braking pressure of 20 bar. Vehicle speed, friction coefficient, and brake disc temperature were continuously monitored throughout the experiments. The results showed that the developed test rig provided stable and repeatable braking cycles. The coefficient of friction varied between 0.03 and 0.36, while the brake disc temperature gradually increased from approximately 60 °C to 80 °C during repeated braking cycles. The developed system successfully reproduced braking characteristics under the specified laboratory conditions and provides a practical, reliable, and cost-effective platform for brake performance evaluation and future friction material investigations.