Brake Noise Testing
According to VDA 303 Guideline

Dewesoft Brake Noise testing solution, also known as Brake Squeal, is ideal for detecting and tracking noise caused by mechanical vibration in various braking systems based on the VDA 303 guideline algorithm.

The solution offers a direct connection of accelerometer and microphone sensors with the automatic setup using TEDS. It will calculate all the needed parameters and statistics required for the analysis of the brake noise.

Sound
Sound
Sound pressure
Sound pressure
Vibrations
Vibrations
Temperature
Temperature
Acceleration
Acceleration
Velocity
Velocity
RPM
RPM
Force
Force
CAN bus
CAN bus
CAN FD
CAN FD
XCP/CCP
XCP/CCP
FlexRay
FlexRay
Polygon
Polygon
Video
Video
Thermal video
Thermal video
High-speed video
High-speed video
GPS and GLONASS
GPS and GLONASS
Inertial platforms
Inertial platforms
IP67
IP67
Shock rating 100g
Shock rating 100g

Main Features

  • VDA 303 GUIDELINE: Detection of brake noise caused by mechanical vibration based on VDA 303 guidelines.
  • COMPLETE ANALYSIS: Out-of-the box comparison of sound and acceleration frequency spectrum.
  • EASY SENSOR PAIR DEFINITION: Detects squeal events from pairs of microphone and accelerometer measurements. Pairs are generated automatically from specified accelerometer and microphone channels. 
  • AUTOMATIC CALCULATION: Squeals are determined from amplitudes of sound and mechanical vibration. Fourier transformation settings are integrated. Only direct time-domain measurements are needed to detect squeal events. 
  • FLEXIBLE CONFIGURATION: The number of microphone and accelerometer channels is not limited by the software or hardware. Configurations with any number of channel inputs are supported. 
  • OTHER MEASUREMENT SIGNALS AND PROTOCOLS: Connect any other sensors and data protocols such as thermocouples, RTDs, strain gauges, GPS positioning, CAN bus, and CAN FD, XCP/CCP, Video, and others. All data sources are completely synchronized to each other.
  • GUN - HUN - MOAN - SQUEAK - SQUEAL TRACKING: Each detected squeal is tracked. During the squeal event, statistics on squeal parameters and other Dewesoft X channels (temperatures, RPMs, vehicle speed...) can be calculated.
  • COMPATIBLE WITH OTHER APPLICATIONS: Our solution is very flexible and offers easy extendability of the data acquisition systems to perform other vehicle tests such as brake testing, combustion analysis, vehicle dynamics, NVH tests, etc. 
  • DEWESOFT QUALITY: Enjoy Dewesoft’s industry-leading 7-year warranty and world-class quality assurance. Your investment into the Dewesoft modal testing and analysis solution is protected.
  • LIFETIME FREE SOFTWARE UPGRADES AND SUPPORT: Our data acquisition systems come bundled with award-winning Dewesoft X data acquisition software. The software package is always evolving and new features are being added. We offer lifetime FREE software upgrades and technical support to all our users.

Brake Noise Detection

The detection of brake noise is based on the comparison of sound and the mechanical vibration amplitude spectrum. The only inputs needed to detect brake noise events are sound and vibration measurements.

Amplitude spectrum calculation with a fast Fourier transform (FFT) algorithm is integrated into the DAQ software. The software detects and tracks multiple brake noise events in multiple sound-vibration detection pairs simultaneously during the measurement. Statistical parameters of the noise event, or any scalar Dewesoft X channel, can be calculated in real-time during an actual brake noise event.
 
Brake noise solution is very flexible regarding DAQ hardware configurations. With an automatic pairing of defined sound and vibration inputs in detection pairs, the configuration workload is significantly reduced for large measurement setups. Any number of arbitrary channels such as temperature, RPM, brake pressure, etc. can be added, and statistics calculated.

The number of brake systems measured and analyzed is only limited by the available computer resources. Similar to any DewesoftX math modules, Brake squeal can also be used in the post-analysis mode to recalculate the data and correct initial setup mistakes.

Brake Noise Detection

Types of Brake Noise in Vehicles

The table below explains the different types of brake noise and judder experienced in vehicles:

JudderNon-resonant, velocity-dependent vibration. Caused by non-uniformities.
Cold judder ≈ 10 Hz no noise, felt on the brake pedal, steering wheel.
Hot judder ≈ 200 Hz can produce noise.
Groan
Hun
Moan
Groan < 100  Hz caused by stick-slip effect, axial vibration mode of the black clipper, and suspension components.
Hum ≈ 100 - 400 Hz caliper mounting torsional vibration.
Moan ≈ 600 - 700 Hz caliper whole-body movement. 
Squeal
Squeak
Squelch
Caused by vibration modes of braking components (disc and pad, brake drum, and brake shoe).
Squeal ≈ 1 - 4 kHz, most intrusive.
Squeak ≈ 4 - 15 kHz, higher-order modes.
Squelch amplitude-modulated version of squeak noise,
Wire brushNon-resonant high-frequency noise (up to 20 kHz). Random amplitude modulation. Often occurs before and occurrence of unstable squeak noise.

Dewesoft brake noise solution is mainly used to detect and analyze Groan - Hun - Moan and Squeal - Squeak - Squelch noises.

Types of Brake Noise in Vehicles

Brake Noise Input Channel Configuration

Dewesoft brake noise solution offers a very flexible and simple channel configuration:

  • Inputs and statistics are defined in channel groups
  • Each microphone or accelerometer channel will generate an FFT output
  • Statistics are output for each microphone-accelerometer pair
  • Global microphones are paired with all accelerometers in local groups
  • Local microphones are paired only with accelerometers in the local group
  • Global channel statistics are calculated on all squeal pairs, local only on local pairs
  • The number of local groups is unlimited
Brake Noise Input Channel Configuration

Brake Noise Setup

DewesoftX offers a simple approach to set up your brake noise measurement, tracking, and analysis from a single screen. The setup user interface can be divided into four major parts:

  • Fourier transformation
  • Sound weighting
  • Noise detection
  • Channel groups

The setup will define and enable output channels where noise analysis results are written. There are three different types of outputs:

  • Amplitude spectrums: the result of the amplitude spectrum calculation of each microphone and accelerometer is written in an asynchronous array channel.
  • Statistic outputs: the statistic calculations on each microphone-accelerometer detection pair are going to have it own outputs. The results of statistic calculations are going to be written each time the noise event was finished. Statistic result is always output in the asynchronous scalar channel.
  • Tracking status: only one tracking status can be output by the plugin. It outputs the state of the tracking algorithm according to Tracking status.

You can learn more about settings and outputs in the brake noise online manual.

Brake Noise Setup

Measurement - Time- and Frequency-Domain (FFT) Data

When the measurement is performed, Dewesoft will measure time-domain and frequency-domain data (FFT) from the vehicle cabin microphone and vibration from accelerometers installed on brake calipers. Time-domain data will be transformed to frequency-domain in real-time using the Fast-Fourier transform (FFT).

Noise Peak Detection

Brake noise event detection and tracking work by comparing the amplitude spectrum of sound and vibration signals. Amplitude peaks from both spectrums have to be above a threshold that is specified for each sound and vibration channel on its own. Amplitude peaks that are above the threshold are then checked in the detection algorithm.

Measurement - Time- and Frequency-Domain (FFT) Data
Measurement - Time- and Frequency-Domain (FFT) Data

Brake Noise Analysis Results

Results of plugin calculations are written in the outputs. There are three different types of outputs:

  • Amplitude spectrum: Result of the amplitude spectrum calculation of each microphone and accelerometer is written in an asynchronous array channel.
  • Statistic outputs: The statistic calculations on each microphone-accelerometer detection pair have their own outputs. Results of statistics calculations are noted for each noise event when it finished. Statistic results are always outputs in an asynchronous scalar channel.
  • Tracking status: One tracking status only can be output in the plugin. The state of the tracking algorithm is output in accordance with Tracking status.
Brake Noise Analysis Results

Dewesoft Brake Noise Applications

Dewesoft brake noise testing solution can be applied to various brake noise detection applications such as:

  • Passenger cars front and rear brakes
  • Truck brakes
  • Heavy machinery brakes
  • Train brakes
  • Airplane brakes
  • Wind turbines
  • Conveyor belts

Brake noise is undesirable and can cause several undesired outside effects:

  • Reducing environmental noise pollution.
  • Reducing driver and passenger comfort.
  • Reduce warranty claims on new vehicles.
  • Can be regarded as a user fault, even if system braking performance isn’t impacted.
Dewesoft Brake Noise Applications

Great Investment
Future-Proof Application

Dewesoft orbit analysis is a great investment in your future. Our solutions are constantly being improved, and new features are being added all the time. All updates to the modal testing software suite are free of charge.

Our industry-leading 7-year warranty on Dewesoft data acquisition systems means worry-free measurements for you. We are committed to ensuring that your investment in our measurement equipment was a good one - even when the unexpected occurs. 

Together with world-class data acquisition technology, Dewesoft provides the best Modal testing and modal analysis solution your money can buy.

Great Investment
Future-Proof Application

Additional Brake Squeal Resources

Brochures:

Manual:

Webinars:

Additional Brake Squeal Resources

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