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Evolution of Brake Controls to Motion System

Brake System Roadmap

Vehicles are currently being reimagined. Global megatrends are driving this transformation: Vehicle architecture is evolving with the electrification of the powertrain and the growing capabilities of automated driving (AD). Digitalization and connectivity are fundamentally reshaping the electrical and electronic (E/E) architecture of vehicles. This is increasingly based on software, because it’s more and more the software which defines the character of cars and the driving experience! Bytes are replacing horsepower. Apps and services are turning the car into an immersive experience that’s continously becoming safer and more comfortable.

The transformation toward the Software-Defined Vehicle is creating new requirements for brake systems. Brake systems of the future must be designed with built-in redundancy for brake-by-wire and automated driving by design, deliver optimal recuperation performance, and feature a modular architecture that enables the separation of hardware and software. Initial implementations will be seen in next-generation vehicles. A profound understanding of new vehicle and E/E architectures is essential to meet all emerging requirements while maintaining safety uncompromised. With our new generation of hydraulic and electromechanical brake systems, AUMOVIO is perfectly positioned to meet this challenge. Thanks to our extensive experience and strong collaboration with numerous OEMs, we continue to shape the future of braking.

Brake System Roadmap

With increasing vehicle digitalization, connectivity, electrification and automated driving capabilities, brake systems must have a wide range of additional requirements. AUMOVIO, as a long-standing and globally proven brake system specialist, is developing brake system technologies to address those needs. In the following, we outline the evolution of brake systems and present our Brake System Roadmap.

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Brake-by-wire with hydraulic fall-back

One Box Brake System
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  • Integrated brake system with optional HAD extension (MK C2, MK C2 HAD)
  • Hydraulic brakes on both axles (FN/FA, EPB)
  • Brake control software (enhanced functionality for ABS, TCS, ESP, and more)
  • Smart actuator capability with separated functional brake software (Holistic Motion Control)

  

AUMOVIO has developed the MK C2, a modularized and scalable system generation.

As the next generation of the MK C1, the MK C2 is even more compact, lighter, and more cost-effective, and offers performance characteristics superior to those of its predecessor. Additionally the MK C2 maintains a better performance in the event of a fault.  Its design makes it as well possible to eliminate the need for an expensive mechanical transmission lock for securely park the vehicle.

Our MK C2   forms the foundation of our Brake System Roadmap.

Brake-by-wire technology

Distributed Brake System

With the rise of new vehicle architectures, brake-by-wire systems and increased flexibility regarding installation space become increasingly important. Building on our extensive experience with electrohydraulic actuators, AUMOVIO has developed the MK C2D brake system. Thanks to its modular and scalable design, and its two independent actuators the system can provide either a mechanic fallback like classical brake systems or full brake-by-wire functionality.

Building on our extensive experience in tried-and-tested electrohydraulic actuation, the transition to a complete brake-by-wire system can now follow. To this end, AUMOVIO has developed the MK C2D concept, a modularized and scalable system generation that consists of two independent actuators.

  

MK C2 brake-by-wire with electronic brake pedal

  • Distributed brake system for electrical or mechanical brake pedal with redundancy (MK C2D)
  • Hydraulic caliper on both axles (FN/FA, EPB)
  • Brake control software (additionally boosted fallback, highly autonomous driving)
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To support the OEM in the transition from traditional to new vehicle architectures, the MK C2D (D = distributed) can continue to be used with a mechanical brake pedal, referred to as MK C2D mP (mP = mechanical pedal). In this configuration, the driver still provides the braking force in fallback mode.

The system can also be used in combination with an electronic brake pedal,   MK C2D eP (eP = electronic pedal). In this configuration, it maintains braking functionality even in the event of a system fault. The complete separation between brake pedal actuation and pressure generation offers significant integration advantages, a hallmark of true brake-by-wire systems. Apart from the brake pedal itself, no brake system components need to be mounted at a fixed location on the firewall in front of the driver, as is required in systems with hydraulic fallback.

  

This flexibility enables the MK C2D eP to support innovative vehicle concepts with varying interior layouts and dimensions , such as the skateboard chassis used in electrified vehicles, which allows for the mounting of diverse body types.

  

Additionally the MK C2D system generation is designed for AD in accordance with SAE Level 3 or higher. The platform uses existing components that have already proven themselves in the MK C2.

The brakes become “semi-dry”

Semi-Dry Brake System
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In hydraulic brake systems such as One Box and Distributed Brake Systems, pressure generation is fully integrated into the electronic brake system unit. The braking force, that is the “wet” part of the brake system, is transmitted via hydraulic fluid to the disc or drum brakes. In a Semi-Dry Brake System, hydraulic brake at the rear axle is replaced by electromechanical actuators controlled by the electronic brake system.

  

Full brake-by-wire, semi-dry (rear axle dry)

  • Integrated brake system  (MK C2 FA)
  • Hydraulic caliper at front (FN/FA)
  • Electromechanical brake at rear axle (Dry Braking Solution Caliper – DBS C 1)
  • Brake control software (additionally boosted fallback)

Hydraulic brake systems require additional production time for filling and bleeding, and routing the brake lines, especially to the rear axle, is labor-intensive. In addition, the brake fluid must be replaced regularly. To reduce production time and costs, and to simplify maintenance, hydraulic brake actuation can be replaced with electromechanical actuation.

  
The first logical step in the electrification of the brake system is the use of electromechanical brake actuators on the rear axle (semi-dry). This approach retains the proven hydraulic fallback on the front axle while eliminating the need for hydraulic brake lines to the rear. Electric cables offer greater flexibility in routing. Additionally, electromechanical calipers help reduce drag torque and enhance recuperation performance and efficiency.

The brake can be broken up into modules

Full-Dry Brake System

The last step on our Brake System Roadmap is a Full-Dry Brake System where hydraulics is completely eliminated. In this architecture the electromechanical brakes are becoming SMART actuators and there is no more central electronic brake control unit. The brake control software is completely separated from the hardware and can run on different hosts depending on the E/E architecture of the vehicle.

  

Full brake-by-wire with electronic brake pedal: dry & modular

  • Electro-mechanical brake on all wheels (Dry Braking Solution Caliper – DBS C 1) with smart actuator interface
  • Stand-alone functional brake software (Holistic Motion Control)
  • Scalable & modular hardware as software host for various EE-architectures (HPC, Zone Controller)
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A Full-Dry Brake System consists of four electromechanical wheel brakes. The software functions no longer run on a dedicated electronic brake system unit but are executed on central computing platforms. To ensure the required safety and redundancy, these functions are distributed across at least two of these hosts.  

The four individual brake actuators enhance system availability, as a brake actuators failure affects only a single wheel rather than an entire brake circuit. With the complete elimination of the brake fluid production efforts are further reduced and maintenance and repair are simplified.  

The dry brakes enable independent control of braking forces on each wheel, optimizing driving dynamics.

Conclusion

The shift from hardware-centric systems to software-defined vehicles is also reflected in the evolution of brake systems, brake actuators are becoming smart, and brake functions are becoming separate, independent motion control modules combining drivetrain and brake control. Safety must remain indispensable and continues to be the foundation of every brake system.

With its extensive experience, AUMOVIO is paving the way toward this future offering tailored brake system solutions for every stage of the transition.  

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