Customized Testing

Beyond the Standard: Tailored Tests for Every Product Need

When regulations are not enough and you need to reproduce the real-world behavior of the braking system under extreme, specific, or never-before-tested conditions, TecSA R&D steps in with fully customized tests.

Thanks to a direct interface between our laboratories and our Clients’ R&D teams, we define together:

  • Which critical parameters to monitor (hydraulic pressure, braking torque, clamping force, temperature, DTV, residual thickness, particulate emissions, vibrations, energy consumption, etc.)
  • How to faithfully recreate the lifecycle or extreme event encountered on the road, track, or vehicle test bench on the dynamometric test bench
  • Which additional sensors or dedicated actuators to develop to acquire data impossible with standard instrumentation

Some examples of "tailored tests" already performed

  1. Particulate Emissions (Brake Emissions)
  • Isokinetic sampling in a climate chamber (PM10, PM2.5)
  • Granulometric analysis and elemental composition (ICP-MS, SEM-EDX)
  • WLTP vs. real-world cycles correlation (RDE, Los-Angeles Taxi, etc.)
  • Tests on hybrid/EV vehicles: quantification of dust produced during the energy recovery phase
  1. Telemetry Event Reconstruction
  • Import of .vbo, .csv, .mdf, .mat files from onboard instrumentation
  • Resampling and scaling of the speed/torque profile
  • Lap-by-lap replication of circuits for:
    • Formula 1 (Monza, Silverstone, Suzuka)
    • WEC (Le Mans, Spa)
    • Formula E (Berlin, NYC)
    • NASCAR (Daytona, Martinsville)
  • Addition of aerodynamic loads, regenerative blending
  1. Braking under Extreme Climatic Conditions
  • Snow spray (0 °C, 80 % RH, 3 mm/h)
  • Salt spray (5 % NaCl, 35 °C, 50 µm mist)
  • Water splash at -20 °C (simulation of entering an alpine tunnel)
  • Thermal shock: from +60 °C to -10 °C in < 3 min
  • Ice build-up on the disc: 2 mm ice, subsequent emergency brake application
  1. “What-if” Tests and Failure Mode Analysis
  • Cavitation in the hydraulic circuit
  • Brake-by-wire with degraded actuator response
  • Over-torque and cross-threading during tightening
  • Corrosion stacking: salt + humidity + vibration + temperature
  • Pad thermal runaway: 800 °C for 60 s, then forced cool-down
  1. Development of New Sensors and Actuators
  • 6-axis load cell for floating caliper
  • 640 × 512 pixel infra-red array for real-time disc thermal mapping
  • Laser triangulation for online wear-rate (1 µm resolution)
  • 128-channel acoustic camera for 3D squeal localization
  • 50,000 fps high-speed video for contact patch analysis
Customized testing

High-Productivity Industrial Burnishing

Before delivery to customers or the start of durability campaigns, it is often necessary to burn-in/bed braking systems to:

  • Remove the initial transfer layer
  • Stabilize torque and thickness
  • Generate baseline DTV/Run-out

TecSA R&D has developed an automated flow:

  • 30 systems/day per line
  • 97% first-pass yield
  • Complete traceability (QR-code, data-matrix, RFID)
  • Automatic report in < 5 min/system

Do you have an “impossible” idea to test?

Bring us your edge case: TecSA R&D turns the impossible into a standard protocol.
Contact us for a free brainstorming session and you will receive a turnkey test plan within 24 hours.