Analysis of TRW's latest brake system technology

    As global automobile fuel efficiency regulations tighten and safety requirements increase, the automotive industry is working on many aspects of automotive technology to meet new standards. From the engine and body to the components inside the car, any improvement in details can make the car more environmentally friendly and safer.

    TRW Automotive, a world-renowned auto parts manufacturer, has developed a number of new braking technologies/systems in response to new fuel efficiency and safety regulations. Before introducing its technologies, let's first give a general overview of the role of relevant global regulations in promoting automotive braking safety systems.

    In terms of protecting the environment and reducing fuel consumption, new energy vehicles, lightweight vehicles, and reducing vehicle driving resistance are all feasible solutions. TRW's lightweight product design and low-drag caliper design can be used in the above solutions. As the importance of active safety of automobiles grows, TRW's driver assistance system sensors can be used in various active safety systems. In terms of reducing automobile manufacturing costs, TRW has advanced integrated solutions for braking systems and driver assistance systems, which improve system integration, reduce costs, and improve safety.

    In the latest Euro NCAP car safety standards, the automatic emergency braking (AEB) system will become a judging criterion.

TRW Slip Control System (SCS)

    The system includes anti-lock braking system ABS, electronic stability control ESC, adaptive cruise control system ACC, etc. The system has three product series, namely EBC 450/455, EBC 460, and new EBC 460. Among them, the new EBC 460 will adopt a modular design and is planned to cover medium-sized, medium-large and SUV models from 2015 to 2017.

    The current EBC460 series is used in Volkswagen up!, Qoros 3 and other models.

Integrated Brake Control (IBC)

   TRW's IBC system includes vacuum brake assist and anti-skid control, and can be used in all vehicle powertrains (including hybrid and electric). The advantages of this system are weight reduction, fuel saving and simplified structure (no vacuum pump required). At the same time, the system can maximize the efficiency of brake energy recovery. Compared with traditional systems composed of multiple components, the weight of the integrated system is reduced from 7 kg to 3.8 kg.

    In addition, the IBC system can also realize multiple functions in the driver assistance system, such as emergency braking and advanced electronic parking brake (EPB).

Electronic Park Brake (EPB)

    TRW's latest EPB system has standardized functions, but can also be fine-tuned or expanded according to customer requirements based on different vehicle architectures and drive systems.

EPB caliper structure diagram

    In a static environment, EPB supports functions such as switch/release, clamping force reduction, wheel roll detection, etc. In a dynamic environment, that is, when the car is driving, it can realize rear wheel anti-lock and electronically controlled deceleration functions.

    Based on the EPB system, TRW also developed the EPBi system, which eliminates the control unit of the EPB itself and integrates it into the ESC unit, and uses existing components to realize all the functions of the ordinary EPB system.

Distribution of the EPBi system in the wheel

Lightweight foundation brake components

    Brake calipers: Among basic brake products such as brake calipers, TRW's latest aluminum shell brake calipers are 0.5-1.0 kg lighter than traditional iron calipers.

    The same lightweight design can also be seen in the vacuum booster.

    In the booster design, TRW also adopted the latest Tie Bar design to reduce the thickness of the booster shell. The thickness of a single vacuum booster with the new design is 0.8 mm, and the thickness of a tandem booster is only 1.0 mm.

Braking system combined with driver assistance system

    In the future, the various systems of a car will no longer exist independently. Instead, they will achieve more powerful functions through collaboration and interaction. For example, TRW will integrate the braking system with the driving assistance system.

    In terms of chassis and suspension, better handling is achieved by combining electronic hydraulic power steering, electronic power steering sensor on the steering column and active dynamic control system (Active Dynamic Control, ADC).

    The combination of wire control brake, electronic parking brake EPB and electronic stability control ESC module makes braking more timely and precise.

    TRW aims to fully implement "intelligent thinking, advanced thinking, and green thinking" through the integration of various systems and sensors, so that the car can continue to improve in terms of energy saving and safety.