Brakes are indispensable driving aids: but what does the future hold for car braking systems? Let’s find it out together.

The brake of the future

Is the future here? Obviously not, but everything evolves quickly, and so it is with the car brake system: perhaps today we are on the eve of a revolution.

Why? Traditional systems are those with hydraulic brakes, and they haven’t changed much in the last century: small major improvements have been the switch from drum brakes to disc brakes, as well as the addition of anti-lock braking systems (ABS) and electronic stability programmes (ESP).

More recent innovations include regenerative braking and autonomous emergency braking (AEB) systems, all futuristic innovations designed to make vehicles safer.

The switch from hydraulic to electric braking transforms the engine braking system of the future, and G.G.N. is ready for the change with the best parts.

The evolution of brake systems

The brake of the future is created thanks to mechatronics and responds to the increasingly pressing need for more efficient, interconnected and intelligent vehicles: in addition, one of the key aspects of the futuristic braking system is maximum energy recovery, weight reduction and emissions.

Traditional mechanically controlled systems will therefore gradually be replaced by electronically controlled ones: but how did this evolution start?

The challenge started in the aerospace sector with Fly-by-wire technology, which saw control systems for steering, acceleration and brakes become fully electric to greatly improve reliability and achieve more compact dimensions.

Until now, the automotive sector has only adopted the electronically controlled systems method in Throttle-by-wire technology, and instead has 3 Brake-by-wire solutions for braking systems, which are:

• electro-hydraulic
• fully electric
• combined electro-hydraulic and all-electric

Here’s how they work.

How futuristic braking systems work today

The first system, the electro-hydraulic system, eliminates the need for the brake booster by using sensors and actuators that measure the pressure applied to the pedal and transfer it to the brakes from the main cylinder with hydraulic fluid and secondary cylinders. This system uses control units and powerful actuators to greatly increase the final pressure exerted on the brakes (2000 psi vs. 800 psi).

Vehicles that feature this technology are some Mercedes-Benz (e.g. E-Class) that use the Sensotronic Brake Control System (SBC): however, it only lasted four years because it caused safety problems in the event of a failure and was too expensive in the event of a defect.

The second solution is the all-electric braking system with control units and actuators attached to the brake callipers of each wheel, which also has additional sensors in each calliper to show temperature, clamping force and actuator position. System reaction times are 90 m/s compared to 300 m/s for a conventional hydraulic brake system. One of the leading companies in the adoption of electric brake systems is Brembo.

The third system combines the two systems and uses electro-hydraulic parts on the front axle and electric parts on the rear axle, and is in use on vehicles with larger front brakes, which are unsuitable for mounting all-electric components directly on the callipers.

Brakes of the future: current limitations

The main obstacle to the use of futuristic Brake-by-wire systems, the technology for which has been in development for the past 15 years, stems from the lack of a direct connection from the pedal to all four brakes, in order to be able to slow down or stop the vehicle completely in the event of a brake system failure. In addition, these systems may also need to have a battery supply separate from the main one, as a safety system in the event of a failure.

The potential of futuristic brake systems? The possibility of integrating stability programmes and ABS advances allows Brake-by-Wire technology to be even safer than conventional hydraulic brake systems.

But there are many obstacles to overcome in the field of safety in the event of a failure, and therefore the future of brake systems will depend on the ability of Brake-by-Wire systems to meet the regulations of international road vehicle regulations.