Performing a brake test

A brake test is generally understood to be a test function that checks the functionality and performance of one or more brakes. The test function is usually implemented as a software function. However, testing methods without software are also known.

The key aspect of the test is to verify whether the brake is still capable of opening and closing. You must also test whether the brake still has a sufficient braking torque.

To test the torque, the brake is preferably tested with a static load. For this purpose, the closed brake in the idle state is loaded with a defined torque that the brake must hold. The defined torque can be generated, for example, as a motor torque or by a testing weight. The test causes no wear on the brake and can therefore be performed frequently.

In addition to the static test, you can also perform a dynamic test. In this case, the machine is brought from motion to the idle state by the brakes. The braking distance expected for the test conditions should be achieved by the brake.

A dynamic test causes wear on the brake, which must be taken into account when dimensioning the brake. In machines in which multiple brakes act on the same axis, a separate dynamic test of each brake typically leads to stresses within the mechanical structure of the machine and to a longer braking distance. Alternatively, all the brakes can be tested simultaneously, but this is not in compliance with the separate testing required by the standards.

The dynamic test is generally unsuitable as the sole test method in a machine.

In machines with more than one brake, each brake is tested individually (e.g. group drives or a motor brake in combination with another brake on the same drive axis). Any mechanical stress during the separate test must be taken into consideration in the design of the machine or must be avoided using suitable automation.