Smaller brake, greater performance: AUMOVIO unveils its new braking system and receives first series order

A key difference in this new development: Current one box brake systems for highly automated driving (HAD) contain two brake actuators, but only one is used during normal operation. The second actuator serves as a fallback. By contrast, the distributed brake system keeps both brake actuators permanently active, allowing them to generate the braking force together when required. Each braking system is designed to function independently in the event of a fallback. Distributed brake systems can therefore be made smaller, lighter, and more energy-efficient compared to previous one box systems. By coordinating the actuators, AUMOVIO has further increased braking performance compared with predecessor models, both in normal driving and in emergency mode.

One important reason is that while most other braking systems act on only two or three wheels in fallback mode, the distributed brake system continues to access all four wheels. This makes the system particularly suitable for highly automated driving, where safety in the event of an electrical failure is crucial. Distributed brake systems can be used for automated driving up to SAE Level 5.

For the distributed brake system, AUMOVIO leverages the E/E architecture of modern vehicles. It includes multiple power supply points and redundant electrical networks. Such architecture meets the requirements for braking systems without a hydraulic fallback, which must be equipped with a redundant system including its own electrical circuit. Since the driver’s braking commands are transmitted electrically and no hydraulic fallback with a mechanical connection to the driver is required, almost all braking system components – except for the electronic brake pedal – can be positioned freely in the front section of the vehicle. This flexibility supports new vehicle concepts and enables optimized use of installation space, for example through the use of larger batteries that extend vehicle range. The distributed brake system is suitable for many different vehicle types, as not only fully electric and hybrid vehicles but also many new combustion-engine vehicles are equipped with such redundant E/E architectures.

The absence of a mechanical-hydraulic connection between the brake pedal and braking system provides further benefits for the distributed brake system. For example, the air gap between the brake disc and brake caliper can be increased because brake pressure in the fallback level is built up electronically with greater precision and speed than before. This reduces unwanted friction between the brake disc and brake caliper.

At the same time, a single e-pedal braking system can be used for a wide range of vehicle architectures. Instead of slightly different variants, for example for left- or right-hand drive, combustion-engine or electric vehicles, all vehicles can be equipped with the same e-pedal braking solution. This significantly reduces the number of variants and helps lower development, manufacturing, and logistics costs for both suppliers and car manufacturers.

AUMOVIO draws on 120 years of experience in vehicle safety. The most recent major milestone in braking was the proven electrohydraulic pressure providers used in the one box brake systems of the MK C 1 and 2 series, more than 15 million of which have been sold since their market launch in 2016. This expertise has now been incorporated into the concept of a true brake-by-wire application that combines the strengths of hydraulic brakes with an electromechanical brake architecture. The result is a combination of both worlds: higher performance and more efficient use of resources such as energy, installation space, and costs across development, manufacturing, and the entire service life.