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Testing the brakes for a sports car manufacturer


An exclusive sports car manufacturer required a systems integrator to design and build a carbon composite brake bedding system (Brake Conditioning Rig). This would help with determining the rate of wear on the brake pads as well as the degree of heat generated.

The brake callipers and disc for each wheel are fitted prior to running the test. When the rig is in a safe condition, a predefined brake bedding schedule is run. This consists of numerous iterations of spinning the disks up to a predefined speed, then applying the brake callipers to bring the brake disks to rest. Actuating the brake calliper pistons is achieved with a compressed nitrogen gas system controlled by a current output demand from within the test schedule.


Our Solution

The solution requirements were achieved by using the Siemens S7 1500 PLC, where standard and safe I/O are better integrated. The overall design was simplified and the objectives of the project were achieved as follows:

  • Functionality to remote access server and user front end
  • HMI display
  • Rig Temperature controlled by software front end
  • Error States indicated on screen to user
  • Safe recovery from power surge or dip
  • Customer has the ability to modify the total brake bedding parameters through a simplified interface
  • Tool wear monitoring systems and calibrations of pressures
  • Safe entry system for access into the cell with safety lock until cycle complete
  • Read back (minimum 2 points) of disc temperature (outer & Inner)
  • Read back of brake line pressure applied
  • Safety lockout for all automated or manual clamps
  • Check the status of the DC tool confirmation, preventing the test from starting if incorrect
  • Full controls manual



  • Functionality to remote access server & user front end
  • Able to modify the parameters through a simplified interface
  • Safe entry system for access into the cell

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iconsys enhance performance through integration of automation technologies.
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