Design and Experimental Analysis of a Low Cost Test Bed for Motorcycle Disc Brake Energy Performance

Abstract

This study aims to design, fabricate, and experimentally evaluate a low-cost test bed for assessing the energy performance of motorcycle disc brake systems. The prototype was developed to provide a practical laboratory-scale platform for studying braking energy characteristics, disc geometry variations, and friction material behavior under controlled conditions. The research applied a design and development methodology using the concept screening method to select the most efficient configuration based on manufacturability, cost, and operational simplicity. The final model was designed using SolidWorks and fabricated by combining commercial components and machined raw materials. Experimental tests were performed using a three-phase electric motor at variable operating frequencies of 10, 20, 30, and 40 Hz, with a constant lever pressure of 4.409 Nm.  The electrical energy generated during braking was measured to evaluate energy conversion performance. The results indicated that higher motor frequencies (10–30 Hz) produced greater current, voltage, power, and braking energy outputs, with a maximum recorded energy of 9,718.4 J at 30 Hz. However, at 40 Hz, a decline in braking efficiency was observed due to dynamic instability at higher rotational speeds. This study demonstrates the feasibility of a simple, affordable, and effective disc brake test bed capable of replicating real braking conditions. It offers a valuable tool for analyzing braking energy behavior and serves as a foundation for future research on regenerative braking systems for lightweight electric vehicles.