How to maintain the brake system of an electric wheelchair: a comprehensive guide

How to maintain the brake system of an electric wheelchair: a comprehensive guide

For international wholesale buyers of electric wheelchairs, it is essential to understand the maintenance knowledge of the brake system. Whether you want to provide customers with quality after-sales information or ensure the long-term performance of the product.

1. Introduction
Electric wheelchairs provide great convenience for people with limited mobility, and the brake system, as one of its core safety components, is directly related to the user’s safety and driving experience. A good braking system can not only ensure that the user can stop in time when the car needs to stop, but also provide stable braking force under complex road conditions such as downhill. However, after frequent use and long-term operation, the brake system will inevitably wear and deteriorate. Therefore, regular maintenance of the brake system is essential to maintain the reliability and safety of electric wheelchairs.

2. Main types of electric wheelchair brake systems
Electromagnetic brake system: This is the most common brake system at present. When the controller of the electric wheelchair detects that the operating joystick is in the parking gear or the emergency brake button is triggered, the drive control system will activate the electromagnetic brake, so that the electromagnetic brake is in close contact with the rotor or brake disc of the motor, thereby generating braking force to stop the wheelchair from moving. In daily use, the electromagnetic brake system will play a role every time the wheelchair is started and stopped, so its wear is relatively large and needs special attention.
Mechanical brake system: mainly relies on manually operated brake devices, such as hand brakes. The user pulls or rotates the brake handle to make the brake pads contact the brake drum or brake disc of the wheel, generating friction to prevent the wheel from turning. The mechanical brake system is usually used as an auxiliary brake or parking brake, but it can also play an important role in emergency situations, such as providing backup brakes when the electromagnetic brake system fails.

3. The importance of brake system maintenance
Ensure user safety: The brake system is the last line of defense for electric wheelchairs. If the brake system fails, the user may not be able to stop in time during driving, especially when going downhill, turning or encountering emergencies, it is very easy to cause collisions, rollovers and other accidents, causing injuries to the user. Regular maintenance of the brake system can detect potential problems in time, ensure the reliability and sensitivity of the brake system, and provide users with safe travel guarantees.
Extend the service life of electric wheelchairs: The brake system is closely connected with other components, such as motors, batteries, controllers, etc. A good braking system can reduce the impact and load of these components during emergency braking or frequent braking, reduce the wear rate of components, thereby extending the service life of the entire electric wheelchair, reducing maintenance costs and replacement frequency.
Improve driving experience: A good braking system can make the start and stop of the electric wheelchair smoother and smoother, reduce vibration and noise during braking, and improve the user’s comfort and satisfaction. This is especially important for users who use electric wheelchairs for a long time, allowing them to control the wheelchair more easily and pleasantly.

4. Daily maintenance methods
Check before each use: Before using the electric wheelchair every time, you should develop a basic habit of checking the braking system. First, turn on the power, put the operating joystick in different gears, and test whether the electromagnetic brake can respond normally. On a flat ground, gently push the wheelchair to observe whether it can roll smoothly on its own and whether it can stop quickly when braking. For mechanical braking systems, pull the brake handle to check whether the contact between the brake pad and the wheel is tight, whether the braking force is sufficient, and ensure that the wheel cannot rotate when braking. In addition, check whether the appearance of the brake device is obviously damaged, deformed or loose, and whether the brake line is worn, broken or stuck. If a problem is found, repair or adjust it in time before using the wheelchair.
Regular cleaning: The electromagnetic brakes, brake pads, brake discs and other components in the brake system are easily affected by impurities such as dust, oil, mud and water, which will reduce the performance of the brake system. Regularly use a clean soft cloth or cotton swab to wipe the surface of the electromagnetic brake to remove dust and oil. For brake pads and brake discs, you can use compressed air or special cleaning agents to clean them, but be careful to avoid the cleaning agent entering the friction surface between the brake pads and the brake disc to avoid affecting the braking effect. After cleaning, check the wear of the brake pads. If it is found that the thickness of the brake pads is close to or below the prescribed wear limit, it should be replaced in time.
Proper lubrication: On certain parts of the brake system, such as brake lines, brake bearings, etc., it is necessary to add an appropriate amount of lubricating oil regularly to reduce friction and wear and ensure the smooth operation of the brake system. Choose a suitable lubricant, such as lithium-based grease, and lubricate according to the manufacturer’s recommendations. But be careful to avoid the lubricating oil from entering the friction surface between the brake pads and the brake disc, otherwise it will cause the brakes to slip and affect the braking effect.

5. Regular deep maintenance
Quarterly maintenance: Perform a comprehensive inspection and maintenance on the brake system every quarter. In addition to repeating the daily inspection items, it is also necessary to further check whether the coil of the electromagnetic brake has insulation aging, weakened magnetism or short circuit. You can use a multimeter to measure the resistance value of the coil and compare it with the standard value provided by the manufacturer. If the resistance value deviates too much, it may indicate that the coil is faulty and needs to be replaced in time. At the same time, check whether the circuit connection of the brake system is firm, whether the plug and socket are loose, oxidized or damaged, and ensure the normal connection and disconnection of the circuit.
Annual deep maintenance: Perform deep maintenance on the brake system at least once a year. In addition to the above inspections, it is recommended to send the wheelchair to a professional repair center or contact the manufacturer’s after-sales service team for a comprehensive disassembly, inspection and maintenance of the brake system. Professionals can use professional equipment and tools to inspect the internal structure of the electromagnetic brake, including brake discs, brake pads, electromagnetic coils, return springs and other components, and evaluate their wear and performance. According to the inspection results, replace the severely worn parts, such as brake pads, brake discs, etc., and reassemble and debug the electromagnetic brake to ensure that its braking torque, braking distance and other parameters meet the safety standards.

6. Common problems and solutions
Insensitive brakes: Possible reasons include severe wear of the brake pads, loose brake lines, weakened magnetism of the electromagnetic brake coil, oil or impurities between the brake disc and the brake pad, etc. First, check the wear of the brake pads. If the friction material of the brake pads has been worn thin or worn off, the brake pads need to be replaced in time. Secondly, check the tightness of the brake line. If the brake line is too loose, it needs to be adjusted so that it can provide sufficient tension when braking. For the case of weakened magnetism of the electromagnetic brake coil, you can try to clean the surface of the coil, check the resistance value of the coil, and replace the coil if necessary. If there is oil or impurities between the brake disc and the brake pad, you need to clean the contact surface of the brake disc and the brake pad first, and then readjust the brake clearance to ensure that the brake pad and the brake disc can be in close contact.
Brake lock: This is usually caused by too small a gap between the brake pad and the brake disc, failure of the brake system return spring, or a fault in the control circuit of the electromagnetic brake. When the brake is locked, the wheel cannot roll normally, which will cause difficulty in driving the wheelchair and even damage the tire and motor. Check the gap between the brake pad and the brake disc. If the gap is too small, you need to readjust the brake device to increase the brake gap. At the same time, check whether the return spring is broken, loses elasticity or is stuck. If there is a problem, you need to replace the return spring. For control circuit failures of electromagnetic brakes, it is necessary to check the circuit connection and working status of components such as the controller, brake switch, and electromagnetic coil, and repair or replace damaged circuit components.
Abnormal brake noise: Abnormal brake noise may be caused by uneven wear of the brake pad, debris between the brake pad and the brake disc, loose brake system components, etc. First, check the wear of the brake pad. If the brake pad is unevenly worn, it may be caused by an uneven surface of the brake disc or incorrect installation of the brake pad. You need to replace the brake pad and check the condition of the brake disc. Secondly, check whether there are stones, metal chips and other debris between the brake pads and the brake disc. If there are, clean them up in time. In addition, check whether the various connecting parts of the brake system, such as brake brackets, screws, etc., are loose. If they are loose, they need to be tightened in time to eliminate abnormal noise.

7. Maintenance precautions in special environments
Humid environment: In a humid environment, the brake system is prone to moisture and rust, affecting its performance. If the electric wheelchair is often used or stored in a humid environment, you should take moisture-proof measures. Cover the wheelchair with a waterproof cover or plastic film, especially on rainy days or near water sources. After use, wipe off the moisture on the brake system components in time. If necessary, use dehumidification equipment or desiccant to reduce the ambient humidity. For rusted parts, you can use professional rust removers to treat them and then relubricate them to restore their normal function.
Dust environment: In an environment with more sand and dust, fine sand particles can easily enter the brake system, accelerating the wear of brake pads, brake discs and other components. After using an electric wheelchair in dusty weather, the brake system should be cleaned immediately, and the sand and dust should be removed with a soft brush or compressed air. At the same time, check the wear of the brake pads and brake discs. If the wear is serious, they need to be replaced in time. When storing the electric wheelchair, it is best to place it in a closed indoor environment to prevent sand and dust from invading the brake system.
High temperature environment: High temperature environment will affect the performance of the brake system, especially the coil of the electromagnetic brake and the friction material of the brake pad. When using an electric wheelchair in hot weather, you should be careful to avoid frequent braking and long-term continuous braking to prevent the brake system from overheating. If the temperature of the brake system is found to be too high, the wheelchair should be stopped for a period of time and the brake system should be cooled before continuing to use it. At the same time, regularly check the insulation performance of the electromagnetic brake coil and the wear of the brake pad to ensure that it can work normally in a high temperature environment.

8. When to replace the brake system components
Brake pads: Generally speaking, the service life of the brake pad depends on factors such as frequency of use, braking force and driving habits. When the friction material of the brake pad is worn to a certain extent, its braking force will drop significantly. You can judge whether it needs to be replaced by observing the wear indicator mark on the brake pad or measuring the thickness of the brake pad. Usually, when the remaining thickness of the brake pad is close to or less than 3mm, the brake pad needs to be replaced in time. In addition, if you hear a sharp metal friction sound when braking or feel a significant increase in the vibration of the brake pedal, it may also be that the brake pads are severely worn and need to be replaced.
Brake disc: The service life of the brake disc is relatively long, but it will gradually decrease as the brake pads wear. When there are obvious grooves, cracks or uneven wear on the surface of the brake disc, the brake disc needs to be replaced. Generally speaking, when the thickness of the brake disc is worn to about 1/3 of the original thickness, it is necessary to consider replacing it. At the same time, if you feel the steering wheel shaking or abnormal vibration of the car body when braking, this may be caused by deformation or severe wear of the brake disc, and the brake disc should also be replaced in time.
Electromagnetic brake coil: The service life of the electromagnetic brake coil is usually long, but if the electric wheelchair is often used in a humid, high temperature or harsh environment, the insulation performance of the coil may decrease and the magnetism will also weaken. When it is found that the braking force of the electromagnetic brake is significantly weakened, the braking distance is longer, or the surface of the coil is scorched or deformed, the electromagnetic brake coil needs to be replaced. In addition, if the resistance value of the coil does not meet the manufacturer’s standard value and still cannot return to normal after repair, the coil also needs to be replaced.

9. Summary
Regular and comprehensive brake system maintenance is an important part of ensuring the safety of electric wheelchair users, improving driving experience, and extending the life of the equipment. From daily pre-start inspections to cleaning and lubrication, to quarterly and annual in-depth maintenance, each step is like injecting new vitality into the brake system of the electric wheelchair. In the face of special environments such as humidity, dust, and high temperature, additional maintenance measures are required to protect the stable operation of the brake system. When faced with problems such as insensitive brakes, locking, or abnormal noise, being able to quickly locate the cause and take effective solutions is a strong guarantee for the user’s travel safety. At the same time, clarifying the replacement time of brake pads, brake discs, and electromagnetic brake coils can avoid the risk of brake failure caused by aging or damage of components.
In the maintenance process of electric wheelchairs, we are well aware that every inspection, every adjustment, and every cleaning of the brake system is related to the user’s travel safety and comfort. For international wholesale buyers, the mastery of brake system maintenance knowledge not only demonstrates the importance of product quality, but also reflects responsibility for customers and care for users. When you incorporate these meticulous maintenance concepts into the after-sales support of your products, you will undoubtedly win the trust of your customers, build a good brand reputation, and lay a solid foundation for the long-term development of your electric wheelchair business.