In modern automotive engineering, the brake motor is undoubtedly an indispensable part of the brake system. It not only controls the braking performance of the vehicle but is also directly related to the safety of the driver and passengers. This article will explore the structure/working principle, types, applications, importance of testing, and testing methods of automotive brake motors in depth, aiming to provide readers with a comprehensive and in-depth understanding.

Ⅰ. Structure and working principle of automotive brake motor

The automotive brake motor is usually a fully enclosed, self-fan-cooled squirrel-cage asynchronous motor, whose key feature is the attached DC electromagnetic brake. When the motor is powered on, the electromagnetic brake is also powered on and generates suction. At this time, the brake does not work and the motor rotates freely. When the motor is powered off, the brake quickly breaks the motor under the action of the spring to achieve a quick stop.

The working principle of the brake motor is based on the combination of electromagnetic induction and mechanical friction. The tail of the motor is equipped with an electromagnetic brake device. When the motor is powered on, the DC suction generated by the coil separates the friction surfaces, allowing the motor to rotate freely. Once the motor is powered off, the restoring force of the spring causes the friction surfaces to contact and generate friction, thereby breaking the motor.

Ⅱ. Types of automotive Brake Motors

Automotive brake motors are mainly divided into two categories: brushed and brushless, but brushless motors currently dominate the market.

■Brush brake motor:

The brushed brake motor is a traditional design that transmits current through the contact between the brush and the commutator to drive the motor to rotate. This motor has a relatively simple structure and low manufacturing cost, but during use, the brushes will gradually wear out and need to be replaced regularly and may generate sparks and electromagnetic interference. Although brushed brake motors still have a certain market in certain specific applications, with the development of technology, their market share is gradually being replaced by brushless motors.

■Brushless brake motor:

Brushless brake motors use electronic commutators instead of traditional mechanical brushes and detect rotor position through Hall sensors or encoders to accurately control the direction and size of the current. This type of motor has higher efficiency, lower noise, and longer service life because the problem of brush wear is eliminated. Brushless brake motors also have better speed regulation performance and dynamic response capabilities, and can more accurately control the braking force and response time.

Due to these advantages, brushless brake motors dominate automotive brake systems, especially in modern vehicles with high requirements for performance, reliability, and safety.

Ⅲ. Importance of automotive brake motor testing

The brake motor plays a vital role in the vehicle braking system. It must not only be able to quickly respond to the driver's braking command but also be able to withstand long-term, high-frequency braking operations while maintaining stable braking performance. Once the brake motor fails or its performance deteriorates, it will directly affect the vehicle's braking effect and may even cause serious traffic accidents. Therefore, strict testing of the brake motor is an important means to ensure driving safety and improve vehicle performance.

Ⅳ. automotive brake motor test solution

① Customer pain points:

There are many types of brake motors, and the testing requirements for different vehicle models and application scenarios vary greatly, which is difficult to meet with traditional general-purpose testing equipment.

② AIP brake motor test solution

At present, brushless brake motors dominate the market. AIP's brake motor testing solutions cover motor stator testers, motor rotor testers, and motor testers .

AIP's brake motor tester includes:

■ Modular design: plug-in structure, convenient for after-sales maintenance, modular functions, no interference between projects;

■ Data sharing: The equipment is connected to the Internet to realize data interaction and resource sharing; when connected to the MES system, the test data can be automatically uploaded to the customer server. This function is optional;

■ Remote maintenance: With a built-in network module, the test system can be remotely maintained and upgraded after being connected to the network, ensuring the timeliness of equipment maintenance.

■ Customized development: The AIP Automotive Brake Motor Test System can be customized according to motor characteristics and enterprise process requirements to ensure that every defective product is detected.

③AIP brake motor tester customer case

AIP motor test equipment has successfully attracted the favor of many internationally renowned brands with its excellent performance and precise testing capabilities and has established in-depth cooperation with many well-known motor companies around the world, such as Bosch, Volkswagen, Schaeffler, Emerson, BorgWarner, Nidec, Valeo, etc. These companies choose AIP not only because its equipment performs well in test accuracy and stability, but also because AIP can provide customized testing solutions according to the needs of different customers. The following are some photos of customized brake motor test systems for customers :

④ Competitive advantages of AIP motor tester

In the field of motor testing equipment, AIP faces challenges from competitors around the world. However, through a comparative analysis of the following aspects, we can clearly see AIP's competitive advantages:

■ Technological innovation capability: AIP has been committed to the research development and innovation of motor testing technology, and has continuously launched new products with independent intellectual property rights. Its unique testing algorithm and efficient testing process put AIP equipment in the leading position in the industry in terms of testing accuracy and testing speed.

■Product quality and reliability: AIP equipment uses high-quality materials and advanced manufacturing technology to ensure product stability and durability. At the same time, AIP has also established a strict quality control system to conduct strict factory inspections on each device to ensure that the product meets customer requirements.

■ Brand reputation and customer word of mouth: AIP has won the recognition and praise of customers for its high-quality services and excellent product quality. It has established a good brand image in the industry and has become a trusted partner of many customers.

■After-sales service and support: AIP has established a complete after-sales service system to provide customers with timely and professional technical support and maintenance services. No matter what problems customers encounter, AIP can respond and solve them in the shortest time.

■Sustainable development and environmental protection: AIP actively responds to national environmental protection policies and is committed to developing more environmentally friendly and energy-saving testing equipment. Optimizing equipment structure and improving testing efficiency, reduces equipment energy consumption and emissions, creating a greener and more sustainable production environment for customers.

■Global layout and service network: Compared with its competitors, AIP has a more complete global layout. Currently, AIP has established 15 offices around the world, which can provide customers with more timely and effective service support. 

V. Conclusion

Automotive brake motor testing is an important means to ensure driving safety and improve vehicle performance. Through comprehensive testing content and scientific testing methods, the performance of brake motors can be accurately evaluated, providing strong technical support for automotive manufacturing and maintenance. In the future, AIP will continue to be committed to technological innovation and service optimization, and work with customers to promote the advancement of automotive brake motor technology and contribute to traffic safety.