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ZF, a leading global technology group, has introduced a comprehensive portfolio of Brake-by-Wire (BbW) systems, marking a significant advancement in braking technology. With over 50 years of experience in developing braking solutions, ZF offers purely electric, purely hydraulic, or hybrid options to meet diverse customer needs. These innovations support the evolution of software-defined, networked, and electrified vehicles, enabling safer and more efficient mobility.
Key Highlights
- Brake-by-Wire Evolution: ZF’s BbW systems are more responsive, sustainable, and economical compared to traditional brakes.
- Flexible Solutions: Options include purely electric “dry” systems, hybrid combinations, and integrated hydraulic controls.
- Automated Driving Support: BbW enables functions up to Level 4 automation, leveraging connected chassis potential.
- Market Adaptability: Tailored for global markets, with strong demand in Asia for dry systems and in the US for hybrids.
- Environmental Benefits: Reduces emissions, residual drag torque, and energy losses, enhancing vehicle range.
The Shift to Brake-by-Wire Technology
In modern vehicles, braking systems must integrate software control and electrical operation to handle advanced features like automated emergency braking. Philippe Gasnier, Head of Research and Development at ZF Chassis Solutions, emphasizes that BbW is essential for highly automated driving, electrified drives, and chassis networking. ZF’s portfolio provides vehicle manufacturers with flexible choices to optimize future model platforms.
Purely Electric “Dry” Systems
ZF’s “dry” Brake-by-Wire eliminates the need for brake fluid, using electric motors directly on the wheels to generate braking pressure. This design transmits signals electrically from the pedal to the actuator, resulting in faster response times and improved recuperation in electric vehicles. Danny Mlot, Head of Engineering Product Line Braking, notes that these systems excel in building ideal brake pressure quickly, especially in heavier vehicles. By minimizing residual drag torque to nearly zero, they reduce particulate emissions from brake pad abrasion and lower energy consumption, extending the range of battery electric vehicles. Manufacturers benefit from simplified assembly and reduced costs due to fewer components. Demand for these systems has surged, particularly in Asian markets, reflecting ZF’s innovative edge.
Hybrid Brake-by-Wire Solutions
For markets like the US, where heavy-duty light trucks and pickups dominate, ZF offers hybrid BbW systems. These combine a dry electric system on the rear axle with a hydraulic brake on the front, providing high clamping forces without relying on traditional electric parking brakes. This setup eliminates the vacuum brake booster, simplifying chassis development while maintaining safety and performance. ZF secured a major order for such a hybrid system from a global OEM earlier this year, underscoring its practical viability.
Integrated Brake Control for Versatility
At the core of ZF’s offerings is the Integrated Brake Control (IBC), an electro-hydraulic solution in production since 2018. Compact and lightweight, IBC serves as a stability control, brake booster, and central ECU for driving safety programs. It supports all vehicle types, from compact electric cars to performance crossovers, and integrates with third-party software. Combined with BbW, IBC delivers future-proof braking and dynamics control, easing integration into innovative architectures.
ZF’s Legacy in Mobility Innovation
ZF has produced over 3 billion brake components worldwide, solidifying its role as a key supplier to automotive manufacturers and mobility providers. The company’s BbW portfolio not only enhances vehicle interior and engine compartment flexibility but also contributes to emission reduction and climate protection. For more details, visit ZF’s press site.
This advancement positions ZF at the forefront of braking evolution, ensuring vehicles are safer, more efficient, and ready for the demands of tomorrow’s mobility landscape. With its global presence in 30 countries and a workforce of around 161,000, ZF continues to drive innovation in passenger cars, commercial vehicles, and industrial technology.
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