Brake cooling duct performance is governed by complex internal flow behaviour that is difficult to quantify using conventional methods. While temperature measurements indicate thermal outcomes and CFD provides predictive insight, neither directly captures the real-time aerodynamic conditions within the duct.
Embedding miniature pressure scanners such as the EvoScann® P4-A Micro Miniature Pressure Scanner enables direct measurement of internal pressure distributions, providing a practical method to resolve both airflow volume and direction under real operating conditions.
Brake ducts operate in highly unsteady flow fields influenced by wheel rotation, suspension wake interaction, and yaw variation. Internally, flow is subjected to curvature, area changes, and surface constraints, making it susceptible to separation and non-uniform distribution. As a result, inlet capture does not necessarily translate to effective cooling at the brake interface.
By instrumenting the duct with multiple pressure measurement points—at the inlet, along the duct length, and near the outlet—it becomes possible to reconstruct the internal flow behaviour. The relationship between total and static pressure allows derivation of dynamic pressure, from which local velocity can be inferred. When combined across the duct cross-section, this provides an estimate of volumetric airflow and highlights losses through the system.
More critically, spatial pressure variation reveals flow structure. Lateral pressure gradients indicate whether flow is centred or biased, while irregular distributions can identify rotational flow or separation zones. Poor pressure recovery toward the outlet is often indicative of internal inefficiencies that reduce effective cooling mass flow.
This approach enables identification of issues that are not observable through temperature data alone, such as mid-duct separation, skewed inlet alignment, or ineffective internal geometry. As a result, engineers can distinguish between insufficient airflow supply and poor flow utilisation.
The availability of real-time pressure data supports rapid iteration during track testing. Design modifications—such as inlet orientation, duct curvature, or internal features—can be evaluated directly through changes in pressure distribution and inferred flow behaviour. In parallel, measured data provides a basis for improving CFD correlation, particularly in regions where predictive accuracy is limited.
The use of embedded pressure scanning shifts brake cooling development from indirect assessment to direct aerodynamic measurement. By resolving both airflow volume and direction within the duct, it enables a more accurate understanding of cooling effectiveness and supports targeted optimisation of duct performance.