ZF presents new brake-by-wire system for the first time

ZF presented its new, purely electro-mechanical braking system for the first time at the "Next Generation Mobility Day" in Shanghai. The braking force on each wheel is generated by an electric motor, without a hydraulic system or brake fluid. "Our purely electrically controlled braking system is a significant expansion of our portfolio of networked chassis systems," says ZF CEO Holger Klein. "With such by-wire systems, we are opening the door to a new era of vehicle control."

In a so-called "dry" braking system, the deceleration effect is no longer generated by the pressure of fluids in the hydraulic system, but by electric motors. The brake signals from the pedal to the electric motor are also transmitted purely electrically (by wire). Compared to conventional braking systems, this enables shorter braking distances. In the case of automatic emergency braking from a speed of 100 km/h, these can be up to nine meters shorter. Electric cars are also said to achieve up to 17 percent more range thanks to the improved recovery of braking energy.

In addition, especially with dry brake-by-wire systems, the residual drag torques that occur with conventional brake systems due to minimal contact between the brake pads and the brake discs can be reduced to almost zero. This results in fewer particulate emissions due to brake wear and the lower resistance when driving saves energy and increases range. Dispensing with a hydraulic system also reduces assembly and logistics costs during vehicle production, as the system consists of fewer parts. And during the vehicle's service life, the user benefits because brake fluids no longer need to be changed, reducing the amount of servicing required in the workshop.

Even if there is no longer a mechanical connection between the brake pedal and the brake actuators, the braking feel should be similar to that of a hydraulic brake. ZF guarantees the safety of data transmission and processing as well as the power supply to the electric motors by doubling all connections and systems, as is also common practice with by-wire systems in aviation. (aum)