Zf trw integrated brake control

01.04.2021 By Vimi

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The IBC system will be launched in high volume in for a major vehicle manufacturer and supports both traditional braking safety functions as well as partially automated functions. The IBC replaces — in a single integrated unit — the electronic stability control system along with the vacuum booster and the associated cables, sensors, switches, electronic controllers and vacuum pumps where they are required for low or no vacuum configurations. It is a highly scalable solution that can support the brake system requirements from A-segment cars through to large Sport Utility Vehicles.

It supports all powertrain configurations and can integrate regenerative braking technology for hybrids and electric vehicles; helps deliver advanced safety in the form of rapid building of brake pressure for high dynamic demands such as automatic emergency braking; and will support the gamut of brake vehicle control and stopping requirements for partially to fully automated driving functions.

Integrated Brake Controller

At the heart of the system is an actuator that is driven by a fast acting motor capable of brake pressure builds that translate into up to one g vehicle deceleration in less than milliseconds for significantly reduced stopping distances. This is particularly important when seeking to comply with the stringent new test protocols for EuroNCAP that simulate pedestrian and crossing bicyclists in urban environments. This can add additional fuel savings and space savings for vehicle manufacturers.

Motherson Sumi explores new acquisitions at low valuations. Bharat Forge sees itself benefitting from supplier restructuring amid About Us Contact Us. Auto Components. April 1, In the January Brake Shop, we discussed regenerative braking systems. They also ensure that deceleration behavior and pedal feel are identical to conventional braking systems. The logical evolution of these systems would be the complete electrification of the braking system.

There have already been several variations on this technology, and there are certain to be more. Despite any superficial differences, all fall under the heading of brake-by-wire. It can be designed to supplement ordinary service brakes or it can be a stand-alone brake system. With electric parking brakes, the driver activates the holding mechanism with a button and the brake pads are then electrically applied.

Other drive-by-wire technologies that have already been widely installed on vehicles include steer-by-wire electronic power steering and throttle-by-wire. In a brake-by-wire system, the hydraulic force generated by pressing the brake pedal is used only as a sensor input to the computer, unless a catastrophic failure occurs. The brake actuator has an electric pump that provides the hydraulic pressure for the system, and valves to pressurize each wheel caliper to apply the friction brakes when required by the system.

The Sensotronic braking system SBCintroduced by Mercedes-Benz at the beginning of this century and installed on several M-B models, is one of the earliest brake-by-wire systems.

SBC provides the brakes with a brake fluid supply from the hydraulic high-pressure reservoir, which is sufficient for several braking events. When the driver presses the brake pedal—or when the electronic stability program ESP intervenes to stabilize the vehicle—the SBC control unit calculates the desired target brake pressures on each wheel. Through the use of four independent pressure modulators, the system regulates the hydraulic pressure at each wheel. Each pressure modulator consists of one inlet and one outlet valve, controlled by electronic output stages.

The control unit processes this information and generates the control signals for the wheel pressure modulators. Normally, the master brake cylinder is detached from the brake circuit. A pedal travel simulator creates normal pedal feedback.

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If ESP intervenes, the high-pressure reservoir supplies the required brake pressure quickly and precisely to selected wheels, without any driver involvement. By Marcha total of 1. Inhigh-volume models such as the E-Class returned to a conventional hydraulic brake system.

Things have improved somewhat since then.

zf trw integrated brake control

The sensors monitored as inputs on a typical brake-by-wire system include wheel speed sensors, traction battery state-of-charge, yaw sensor, brake pedal, stroke sensor, steering wheel angle, hydraulic actuator pressure, hydraulic pressures of each wheel caliper circuit and accelerator position.

Other information and inputs are also monitored. Brembo recently demonstrated its electric wheel-braking system. The Brembo design uses a central ECU and four corner modules. Overmiles of testing and safe operation have been conducted and the system is expected to be ready for use before The calipers retain hydraulic actuation because the current rotor and caliper do not provide the wheel space needed for a purely electrical system.

The rear braking system is fully electromechanical, and incorporates an electric parking brake.Sharing best practices and finding solutions to challenges within the automotive industry. Braking technology is just one of those sectors and electrification has enabled a wide variety of advances which contribute to safety, fuel efficiency and performance.

Electronic stability control, traction control, anti-lock braking, electronic brake force distribution, brake-by-wire, and regenerative braking a just a few examples of the technologies that have been gradually implemented by the automotive industry. At present and in the very near future, in-car communication networks and sophisticated sensor technology are enabling assisted driving functions such as automatic emergency braking and pedestrian avoidance systems.

While those functions may be a precursor to the eventual goals of autonomous driving, in the short to medium term regenerative braking is a vital concept towards e-mobility and fuel efficiency. This is a key safety measure that the IIHS estimates will prevent 28, crashes and 12, injuries during the extra three years it would have taken to push through the commitment on regulatory grounds. Of course AEB requires sophisticated electronic architecture, and this is indicative of the general trend towards electrification.

The report states that e-mobility can play a key role in delivering the EU transport white paper objectives of halving emissions in urban centres by ; attaining zero emission urban logistics by ; and banning conventionally-fuelled cars from cities by The platform identified six EU-level actions to address the principal barriers to the shift to e-mobility in Europe:.

Clearly these are wide ranging recommendations, and that which arguably affects the automotive industry the most is the effort to embed electro-mobility into the strategy of decarbonising transport. One of the barriers for electric vehicles has been, and continues to be, range. In addition the weight of batteries has also been a challenge in terms of weight reduction and improved fuel efficiency. It is not a new technology by any means, but more sophisticated systems are entering the market with a view to addressing the environmental issues.

Some of the latest innovations in regenerative braking systems are detailed below. Moreover, braking systems such as electronic stability control, anti-lock, smart cruise control and automatic emergency braking functions are also integrated.

In many conventional regenerative braking systems the pressure supply unit amplifies the power with which the driver steps on the brake, and the pressure control unit calculates and controls how much braking force will be applied to each wheel.

zf trw integrated brake control

These are usually separate modules and therefore less competitive in terms of cost and weight. Hyundai Mobis is one of the first parts suppliers to integrate the pressure supply and control units into a single system, contributing to greater efficiency. The IBC is a single integrated unit which replaces the electronic stability control system along with the vacuum booster and the associated cables, sensors, switches, electronic controllers, and vacuum pumps where they are required for low or no vacuum configurations.

Within the IBC a precision ball-screw actuator is driven by an extremely fast-acting brushless electric motor. This motor gives the system its superior braking performance and ESC capability, and can make a significant difference when combined with driver assist systems such as camera and radar to facilitate features such as AEB.

The IBC is also consistent with packaging and weight savings compared with current ESC systems, weighing just 5kg compared with 7kg for a conventional component set. For hybrid vehicles that require an electric vacuum pump the weight saving is an additional 1.

zf trw integrated brake control

The system delivers smooth brake performance for comfort, excellent NVH characteristics, very precise pressure control for systems such as ACC Stop and Go, and is tunable to the driving characteristics of the vehicle manufacturer.

In terms of regenerative braking the IBC system assists in meeting fuel efficiency targets by enabling the integration of full regenerative braking in both hybrid and electric vehicles, providing full brake blending and a fail-safe mode in regenerative systems. It is the first time the new Continental system has entered series production and it offers a variety of benefits compared with conventional braking systems. The high-efficiency MK C1 brake system is more dynamic, lighter and more compact than conventional systems.

It offers greater braking force for safety systems, and short braking distances to help prevent accidents and reduce accident severity. The new integrated system also reduces pedal vibrations so the driver always feels the same force-path characteristics in the pedal, thus providing greater comfort. The system weighs up to 3kg to 4kg less than conventional systems, therefore contributing to overall weight reduction. The electro-hydraulic MK C1 can build up braking pressure significantly faster than conventional hydraulic systems, thereby fulfilling the increased pressure dynamic requirements for new advanced driver assistance systems which e-mobility trends demand.

The system is can also meet the requirements for regenerative braking systems without any additional measures, making it compatible with the objectives of improved fuel economy and reduced emissions. With the trend towards electrification and e-mobility, regenerative braking is of greater than ever importance.

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The driving forces behind the move towards e-mobility include comfort, safety and functionality, but the key driver is the need to improve fuel economy and reduce emissions in line with specified targets. Regenerative braking systems make a significant contribution towards these targets by recuperating energy and increasing available power from the battery.ZF is developing intelligent assist systems that help enable vehicles to not only detect risks sooner, but are designed with the potential to be faster and better than human reactions.

Increasingly sophisticated airbags and seat belt systems are helping to provide improved occupant protection in cases of emergency. ZF innovations work together to protect vehicle occupants and other road users in pursuit of its Vision Zero goal. ZF innovations help vehicles to see, think and act. To support these actions, ZF delivers perfectly dovetailed solutions — a unique selling point of the technology company. Investor Relations.


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Annual Report. Sustainability Report. All Events. Career Events. Service Network. ZF Supplier Board. File exchange, processes. Home Technologies. Governance and Sustainability at ZF. Share Contact Locations. Share this page on:. Get in touch. Technologies Domains Integrated Safety. Integrated Safety. Helping to prevent traffic accidents or at least mitigating their severity are goals that ZF is pursuing with the most comprehensive safety technology portfolio in the supplier industry.

Integrated Safety

Key technologies developed and supplied by ZF include sensors, brakes, steering, seat belts, electronics and active chassis equipped with systems such as the active adaptive rear axle AKC. For decades, they have been putting their necks on the line to improve occupant safety — including at ZF. Emergency support.

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A pedestrian suddenly steps into the lane from the side — emergency braking or evasive action? Now it's time for the right manoeuvre. ZF develops emergency brake and avoidance assistants, which can support the driver in such situations.

On the Safe Side. In side impact collisions, there may only be a small crumple zone between a passenger and a potential incoming object. ZF has devised a pre-crash-system with airbags that can deploy on the outside of vehicles to help enhance occupant protection. An Airbag that is Quick to Offer Protection.Brake technology has continued to evolve, through passive, active, integrated and, most recently, automated braking applications.

The results: optimized brake materials and component design; a systems approach to brake system engineering and maintenance; and an ever-increasing role of software, sensors and electronic controls. Each innovation impacts what and how brake system service and repair are performed. Metrics such as increasing accidents, injuries and fatalities have prompted governments to enforce ever more stringent safety regulations as well as reduced stopping distances and performance. Electronic stability control, traction control, antilock braking, electronic brake force distribution, brake-by-wire and regenerative braking are just a few examples of the advanced technical advancements automotive brake manufacturers have introduced in the past to meet more stringent standards.

In the near future, expect to see new in-car communication networks, telematics, automatic and automated braking shape the brake services shops provide.

For example, suppliers are actively working toward introducing smaller and lighter products that reduce drag or provide other efficiencies and can reduce CO 2 emissions and provide other benefits. IBC eliminates the need for a vacuum pump and conventional large-size booster pumps, making actuation faster than ever before.

IBC uses a smaller pressure pump with fluid already in the piston so that when it moves, the pressure increases immediately. In addition, IBC weighs approximately 11 lbs. He shared that some manufacturers are beginning to reject warranty claims for premature failures of major, expensive components too soon after a vehicle service, which likely could have been avoided or minimized if instead of merely replacing failed parts, the technician conducted a thorough inspection of the whole vehicle system to uncover and replace other worn parts earlier, at a lower cost.

Shops and technicians need to recognize and adapt their service practices by fully inspecting the whole system for the root cause of reoccurring problems. Some, but not enough, shops and technicians have already recognized this. Software—used in simulation modeling, in-vehicle electronic control modules and braking, steering, suspension and powertrain systems—is rapidly changing the world of automotive safety. Software is driving fundamental shifts in system architectures.

It allows automakers to select functionality and optimize the computing power requirements to fit specific needs—from advanced active safety technologies to hybridization to automated driving.

From the pedal to the caliper—as well as for the detailed study of components such as the master cylinder, the booster. Brake system technology will continue to evolve. Automated emergency braking is the latest example. The automotive service industry must co ntinue to train and acquire the savvy, skills and expertise with other necessary resources well before new brake technologies like AEB enter the bay.Electric Park Brakes are used on passenger vehicles to hold the vehicle stationary on grades and flat roads.

This was traditionally carried out using a manual parking brake. With EPB, the driver activates the holding mechanism with a button and the brake pads are then electrically applied onto the rear brakes. In caliper integrated systems, the brake caliper provides a connection between hydraulic actuation of the foot brake and electrically actuated parking brake. The motor or transmission unit actuatorwhich operates the parking brake, is screw-fixed directly to the brake caliper housing.

The parking brake is actuated via a switch in the vehicle interior. The absence of a hand brake lever frees up space inside the vehicle.

zf trw integrated brake control

With no hand brake cables, there are no temperature problems such as freezing or mechanical wear, offering optimum brake power in all conditions. In addition to providing park brake functionality, EPB is a fully integral part of the brake system with features such as dynamic actuation and brake pad wear sensing and reduces the degradation associated with mechanical systems.

The EPB also helps enhances safety in emergency situations. For example, in the case of a hydraulic system failure which is the only reason to apply the parking brake during drivingthe rear wheels are alternately braked, so that breakaway of the vehicle caused by a blocked rear axle is ruled out.

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Further, the hill-hold function, which applies brakes to prevent roll-back when pulling away on a gradient, can also be implemented using the EPB. An example is driving into a full multi-storey car park. When vehicles are moving slowly, and the driver has to stop on a steep ramp, moving off smoothly is difficult.

However, EPB solves this issue by being equipped with a drive away assist system. This opens the parking brake automatically when the engine provides sufficient torque to safely get the car moving.

And in the unlikely event of the engine stalling and the car rolling backwards, the system detects this and automatically closes the parking brake. Emergency braking - If the EPB switch is actuated while driving, it is interpreted by the system as emergency braking. As immediate full braking would result in blocking the rear axle and the car breaking away at the rear, the parking brake is instead closed and opened again in rapid succession similar to the ABS function.

This mode ensures safe braking of the car to a standstill. Electronically controlled - EPB is electronically, rather than mechanically-controlled meaning it can work with a variety of vehicle systems and sensors. Design freedom for vehicle interiors - The EPB system, with its electronic cable and control switches, simplifies routing and allows for greater freedom of design for vehicle interiors.

Its smaller package becomes even more attractive as vehicle manufacturers continue to requisition vehicle space for new standard features and options. Home News. You will need to enter 4 digits and 3 digits, as a number sequence.

Child safety lock - The parking brake cannot be released when the ignition is off.Rarely do we get a chance to really dig into new braking systems, as the modern hydraulic system has very little room left for improvement. Typically what we run into is cars simply adding more pistons to the caliper, like the 6-pot units found on the Lamborghini Aventadoror larger rotors to help disperse some heat.

Industry front-runner, TRW, is finally getting closer to releasing an all-new braking system that should render the aging hydraulic system obsolete. This Integrated Brake Control IBC system will eliminate the need for a master cylinder, brake booster, valves, electronic stability control, and all of the related wires, hoses, and pipes, to replace it with a single unit that does it all.

Not only will this system translate into better braking performance and integrate ESC and braking into one clean unit, but it is also good for a 3 kg 6. That may not seem like much on the surface, but in the market as it is today with supercars heading into exotic metals just to save lbs over their competitors, a 6.

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According to the presser, this system should be ready and in vehicles by the model year. We are willing to bet that it makes it into only high-end racing cars first and street cars will follow suit after successful testing in several racing series. The IBC replaces — in a single integrated unit — the electronic stability control ESC system along with the vacuum booster and the associated cables, sensors, switches, electronic controllers, and vacuum pumps where they are required for low-or no-vacuum configurations.

At the heart of the system is an actuator that is driven by an extremely fast-acting brushless electric motor. This is monitored by a rotary encoder that provides the control ECU with data on revolutions turned, rotational speed and position. Pickenhahn continued: "The brushless electric motor gives the system its remarkable braking performance and ESC capability.

This provides an exceptionally fast pressure rise rate which translates into a one g vehicle deceleration in less than milliseconds. IBC also offers considerable packaging and weight savings compared with current ESC systems — weighing just under 4kg in contrast with 7 kg for a conventional component set. Another interesting news from tech jargon. Let see if they can really brake it. But with the advancement of technology today, I think the result will be pretty good.

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