BYD Song PLUS Project Overview
Upgrading the braking system is critical for both high-performance and commercial vehicles, as it directly impacts safety and vehicle lifecycle costs
Our client—a major fleet management company in Stuttgart—sought to reduce maintenance downtime and enhance vehicle safety margins under heavy-duty, repeated braking cycles.
Our Solution
We delivered a turnkey upgrade package covering component design, validation, and in-field support:
- OEM Bridge Code
- Custom Caliper
- Disc Center hub
- Installation Fitment Optimization
- Caliper oil circuit and oil pipe sealing test
- High-Temperature Performance Testing
Results
Post-upgrade data and client feedback demonstrated:
Up to 13-Foot Reduction in Stopping Distance
Measured in ABS emergency stops from 62 mph, consistent across dry, wet, new, and worn tire conditions
Elimination of Pad & Rotor Wear
PVD-coated (“PureForge”) rotors ran with negligible wear and generated significantly less dust, cutting pad replacement costs by over 20%
Dramatically Improved Fade Resistance
No significant increase in rotor temperature after 50 repeated stops, versus a 15% performance loss on OEM units
Enhanced Driver Confidence
Operators reported more consistent pedal feel under heavy-load braking and reduced stopping variability, boosting operational safety.
