<![CDATA[Brake fading is a critical safety problem caused by excessive heat accumulation on disc brake components during repeated or prolonged braking, leading to a significant reduction in braking force. This research develops an ESP32-based early warning system that monitors disc brake temperature and vehicle speed in real time to detect brake fading risk before a critical condition occurs. The system uses a K-type thermocouple with a MAX6675 module for temperature acquisition and a BN-220 GPS module for speed acquisition, with OLED, LED, and buzzer as local outputs, plus a Telegram bot and web dashboard for remote monitoring. The R&D method was applied, covering design, hardware/firmware implementation, sensor calibration, and road testing on a real vehicle. Calibration results show a thermocouple accuracy of 97.10% (error 2.90%) and a GPS speed-reading accuracy with an average error of 2.75% against the vehicle speedometer. Road tests across six speed variations (20–120 km/h) confirm that brake disc temperature rises proportionally with speed, with the warning indicator correctly switching from green to yellow at the caution threshold and to red with an active buzzer above the critical threshold. The system is expected to serve as a preventive safety tool supporting motor vehicle inspection and testing. Keywords – brake fading, early warning system, disc brake, ESP32, Internet of Things]]>
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