Brake System Roadmap

Brake systems are becoming increasingly intelligent so they can meet the future needs and requirements of automated driving and electrification. First implementations will happen in next-generation vehicles with a modified architecture. This requires a profound understanding of new vehicle architectures in order to combine uncompromising safety in future brake systems. In the long-term, brake systems become modular and distributed. AUMOVIO is therefore in the middle of the driver seat. Due to excellent collaboration with many automobile manufacturers (OEMs) we will be able to shape the future of brakes.

Vehicles are currently being reconceived. Global megatrends are driving these efforts: Vehicle architecture is changing with the electrification of the powertrain and the growing capabilities of automated driving (AD). Digitalization and connectivity are fundamentally realigning the electrical and electronic architecture (E/E architecture) of vehicles, which is increasingly based on software – because it’s the software which will define the character of cars and the driving experience! Bytes take the place of horsepower. Apps and services are expanding the car into an immersive experience that’s steadily becoming safer and more comfortable.

Brake System Roadmap

With digitalization and connectivity, electric drives and AD capabilities, brake systems must therefore fulfill a broad number of additional tasks. To this end, AUMOVIO, as a long-standing, globally proven brake system specialist, is developing brake system technologies: The Brake System Roadmap.

In the following, we outline the journey of the brakes, and an innovation roadmap to a far-reaching, step-by-step transformation.

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Brake-by-wire with hydraulic fall-back

One Box Brake System

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.

Explore our MK C2 products

As a more advanced development, it is even more compact, lighter and more cost-effective and, thanks to Multi-Logic, has performance characteristics superior to those of the MK C1. With Multi-Logic, the MK C2 features two printed circuit boards and two processors that can be used to uphold more functions in the event of a fault. This allows, for example, that the parking brake can be actuated redundantly. This makes it possible to dispense with a highly expensive mechanical transmission lock for immobilizing the vehicle. Owing to its benefits, the MK C2 evolutionary stage will form the basis for the Brake System Roadmap.

Brake-by-wire technology

Distributed Brake System

Building on the long experience gained with tried-and-tested electromechanical 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)

The MK C2D (D = distributed) can be used as before with a mechanical pedal – MK C2D mP (mP=mechanical pedal) (an One Box Brake system with hydraulic fallback mode by the driver and brake pedal). But as well with an electronic brake pedal – MK C2D eP (eP=electronic pedal). In this case, like in highly automated driving (HAD) mode, the second actuator takes over in case of a fallback situation instead of the driver’s foot.

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 complete separation of pedal and pressure generation without fallback mode provides a huge advantage for integration, which is characteristic of real brake-by-wire systems: The brake system no longer has to be mounted directly at a specific location on the firewall in front of the driver to enable mechanical fallback. Instead, a Distributed Brake System with electronic pedal supports new vehicle concepts involving different vehicle interiors and dimensions, such as the skateboard chassis of electrified vehicles, on which various bodies can be mounted.

The brakes become “semi-dry”

Semi-Dry Brake System

In today’s brake systems, as well as with One Box Brake System and Distributed Brake System solutions, pressure generation is still fully integrated into the brake system unit. The hydraulics (i.e. the “wet” part of the brake system) transmit the force to the brake calipers of the disk brakes or the drum brakes.

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)

However, the more E/E architecture and vehicle architecture evolve, the more attractive it becomes to eliminate this inflexible “One Box arrangement”. A first step, for example, could be to no longer actuate the brakes hydraulically on the rear axle, because hydraulics have a disadvantage: The fluid has to be changed and disposed of regularly – which is not environmentally sustainable. Moreover, if the brakes were actuated electromechanically, installation of the rear axle would be simplified because rigid hydraulic lines could be dispensed with. At the same time, the hydraulics on the front axle would still be available as a fallback system.

If the rear axle wheel brakes are operated electromechanically, i.e., “dry”, this could be utilized regeneratively, for example for systematic energy recuperation at the rear axle during each braking operation. Once the rear axle brakes become independent of the hydraulic system, they provide the ideal conditions for this. This would require a certain degree of “intelligence” in the brake system. This decentralization and “breaking-up” of the conventional architecture would further increase the degree of freedom for vehicle architectures.

The brake can be broken up into modules

Full-Dry Brake System

In a very long-term view, the hydraulic system could be eliminated completely: To achieve this, all four wheel brakes could be actuated electromechanically and would thus be completely “dry”. The current focus on pressure generation and modulation with appropriate control intelligence would then no longer be necessary.

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)

A Full-Dry Brake System consists of the four dry wheel brakes (calipers or drums) and a series of software function blocks which, for reasons of safety and redundancy, can run on several of the existing High-performance Computers (HPC) with integrated Wheel Control Units providing the redundancy required for safety. The dry brakes enable independent control of braking forces on each wheel, optimizing driving dynamics.

To make this long-term transformation to a Full-Dry Brake System possible at all, the individual functions of a brake system must be encapsulated as stand-alone products in modular, validated and proven software blocks that can be integrated into various vehicles thanks to standardized interfaces based on the principle of re-use.

Conclusion

Motion functions remain the cornerstone of active driving safety. Nowhere is that clearer than in brake systems. At the same time, however, the general conditions for motion control functions are changing very significantly due to the new E/E architecture and new vehicle capabilities such as AD. Here, AUMOVIO is actively seeking to exchange ideas with vehicle manufacturers in order to shape the further development of brake systems in dialog with them.

Drive-Brake Unit (DBU)

The Drive-Brake Unit is an efficient and low cost Wheel Hub Motor with an integrated brake.

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Calipers

Our hydraulic and electric caliper porfolio include mechanical, electromechanical and full electrical solutions for different use-cases.

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Electronic Brake Systems (EBS)

At AUMOVIO, we prioritize safety as the foundation and pave the way for brake and motion technologies for the future. Integrated and connected electronic brake and suspension systems enable dynamic driving, high comfort, and sustainable mobility – whether sporty or automated.

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Motorcycle Braking Technologies

AUMOVIO brings advanced safety to two wheels. Based on our tried-and-tested passenger car ABS technology, our electronic brake systems for scooters and motorcycles enhance active safety across all classes.

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Actuation

We offer customer-specific, robust and attractively priced brake actuation systems from our modular concept. All actuation components originate from our modular system and can be individually combined with each other as needed.

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Brake System Roadmap

Brake System Roadmap