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For over 50 years, ZF has been a global leader in developing and manufacturing advanced braking systems, with more than 3 billion components produced. As the automotive industry shifts towards software-defined, networked, and electrified vehicles, ZF is pioneering the next evolution in safety with its comprehensive Brake-by-Wire (BbW) solutions. These systems provide the critical technological foundation for modern vehicles, enabling powerful, fail-safe braking while offering greater design flexibility for vehicle interiors and engine compartments.
Key Highlights
- ZF’s Brake-by-Wire (BbW) portfolio offers purely electric, purely hydraulic, and hybrid braking systems to meet diverse customer needs.
- The technology is more responsive, sustainable, and economical, making it essential for the future of mobility.
- BbW systems are ready for automated driving functions up to Level 4, fully utilizing the potential of a connected chassis.
- The technology enhances performance in electric vehicles by enabling optimized energy recuperation and reducing energy loss.
The Future of Braking Technology
Modern braking systems are no longer just mechanical components; they require sophisticated software control and electrical operation. This evolution is crucial for supporting advancements in automated driving, electric powertrains, and chassis networking. “Particularly in view of the advances in highly automated driving assistance features, electrified drives and chassis networking, there is no way around Brake-by-Wire in the long term,” stated Philippe Gasnier, Head of Research and Development at the Division ZF Chassis Solutions.
ZF’s portfolio provides vehicle manufacturers with maximum flexibility, allowing them to select the ideal braking solution—whether purely electric, purely hydraulic, or a hybrid combination—to realize the vehicle platforms of tomorrow.
Brake-by-Wire “Dry”: Purely Electric Braking Power
A “dry” Brake-by-Wire system represents a significant leap forward by eliminating the need for brake fluid. Instead of using hydraulics, pressure is generated by electric motors located directly at each wheel. Brake signals are transmitted electrically from the pedal, resulting in a more responsive system. This electromechanical brake (EMB) design is particularly beneficial for electric vehicles, as it allows for optimized energy recuperation and lower maintenance costs.
These dry systems excel in highly dynamic situations that involve simultaneous braking and steering. Danny Milot, Head of Engineering Product Line Braking, summarized, “Modern vehicles are becoming heavier and heavier, so it is all the more important that the ideal brake pressure is built up in the shortest possible time. And this is exactly what our by-Wire systems master.”
Furthermore, BbW technology reduces residual drag torque—the minimal contact between brake pads and discs in conventional systems—to nearly zero. This results in fewer particulate emissions and helps avoid energy losses, which can translate to additional range in battery electric vehicles. The simplified design with fewer parts also streamlines logistics and assembly for manufacturers, with demand for these systems rising sharply, especially in the Asian market.
Brake-by-Wire “Hybrid”: The Best of Both Worlds
While the Asian market shows a strong preference for dry by-wire brakes, “hybrid” solutions are gaining traction in the United States. These systems typically feature a dry system on the rear axle and a conventional hydraulic brake on the front axle.
This configuration is especially well-suited for the heavy-duty light and pick-up trucks common in the American market. The high clamping forces needed to park these large vehicles can be handled by the electromechanical brake (EMB) on the rear axle, which functions as both a service brake and a parking brake. This hybrid approach eliminates the need for a vacuum brake booster, reducing complexity and offering greater flexibility in chassis development without compromising the safety and performance of Brake-by-Wire technology. In January 2025, ZF announced it had secured its first major order for such a hybrid system from a global OEM.
Integrated Brake Control: A Highly Integrated Solution
At the heart of ZF’s advanced braking systems is the Integrated Brake Control (IBC). This electrohydraulic brake actuation control system, on the market since 2018, is a compact, lightweight solution suitable for all vehicle types and powertrains. The IBC delivers first-class responsiveness and deceleration performance.
It functions as a stability control system (ESC), brake booster, and a central electronic control unit (ECU) for all relevant driving safety and dynamics programs. A key advantage is its ability to integrate not only ZF software but also software from third-party providers, potentially eliminating the need for separate ECUs in the vehicle. “The combination of IBC and our Brake-by-Wire systems guarantees our customers a future-proof solution for controlling braking and driving dynamics,” concluded Gasnier.
For more information, visit ZF.
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