Continental Reveals New Aluminium Braking System for EVs
【Summary】Continental, one of the world’s largest automotive suppliers, has expanded its portfolio for electric vehicles, developing the 'New Wheel Concept' to meet the specific requirements of electric vehicles (EVs) that utilize regenerative braking.
Continental, one of the world's largest automotive suppliers, has expanded its portfolio for electric vehicles, developing the New Wheel Concept to meet the specific requirements of electric vehicles (EVs) that employ regenerative braking.
The wheel rim consists of two aluminum (Al) parts, the inner Al carrier star with the Al brake disc and the outer Al rim well with the tire. In contrast to conventional wheel brakes, the New Wheel Concept brake engages the Al disk from the inside. This allows it to have a particularly large diameter, which benefits the braking performance.
To increase the vehicle's range, deceleration in an EV generates as much electricity as possible through recuperation (braking using the electric motor), so the wheel brake is used less frequently. The corrosion-free aluminum brake disc also prevents the formation of rust (as is normal on cast-iron brake rotors) which can impair the braking effect.
"Electromobility needs new solutions for braking technology too," says Matthias Matic, Head of Continental's Hydraulic Brake Systems Business Unit. "Using conventional brakes is not very effective in this case. The New Wheel Concept meets all the demands that electric driving places on the brake. We used our braking know-how to develop a solution that provides a consistently reliable braking effect in the electric vehicle."
Thanks to the lightweight material, the New Wheel Concept reduces the weight of the wheel and brake, enabling lightweight construction in EVs. Advantages of the concept are much easier wheel and brake pad changes and that the disk is not subject to wear.
Reinventing the Wheel
The New Wheel Concept is based on a new division between the wheel and the axle. Here the wheel consists of two parts, the aluminum carrier star, which remains permanently bolted to the wheel hub, and the rim well, which is bolted to the star. The wheel brake is fastened to the wheel carrier of the axle and engages from the inside with an annular aluminum brake disc, which in turn is bolted to the carrier star. The internal brake permits a wide brake disc friction radius, since the space available in the wheel is optimally utilized.
During its development, the New Wheel Concept's braking performance was initially designed for medium and compact class vehicles. In accordance with today's requirements for this application, the brake is sturdy and fulfills all the established criteria – although it is used much less frequently in an EV.
The dual New Wheel Concept also reduces the weight of the wheel and brake and reduces service costs due to a lifetime brake disk and an easy brake pad change.
"In EVs, it's crucial that the driver expends as little energy as possible on the friction brake," says Paul Linhoff, Head of Brake Pre-Development in the Chassis & Safety Business Unit at Continental. "During a deceleration, the momentum of the vehicle is converted into electricity in the generator to increase the vehicle's range. That's why the driver continues to operate the brake pedal – but it certainly doesn't mean that the wheel brakes are active too."
The deceleration torque of the electric motor is only no longer sufficient by itself when the driver brakes more aggressively, or braking also has to carried out with the non-driven axle for driving dynamics reasons. The wheel brake is needed in this situation – and it must be available.
"Drivers want to be able to rely on a consistent braking effect – and too much rust on the brake disc in particular can really make this difficult," Linhoff emphasizes. The reason behind the reduced performance is less friction between the brake pad and the brake disk. The automatic emergency braking function also has to fully rely on the availability of the friction brake effect.
Material and Design
The design of the New Wheel Concept uses the strength of lightweight aluminum material for the brake. Due to the long leverage effect on the large brake disc, relatively low clamping forces are enough to provide a high level of braking efficiency – and since aluminum is a very good heat conductor, the heat generated in the disk during braking is quickly dissipated.
The design enables the use of a large aluminum brake disk and solves the problem of poor braking performance due to corroded brake discs.
Continental assumes, after the results of the initial practical tests, that the aluminium disc itself is not subject to wear, unlike cast-iron disc. With the New Wheel Concept, abrasion only takes place on the pads, and the design of the Concept makes replacing them – and the wheels – much easier.
The New Wheel Concept has yet another positive, less noise. "Because the brake disc is fixed on the outside and the brake engages from the inside, the brake caliper can be designed particularly light and stiff. The force is transmitted largely symmetrically into the center of the axle, and this has a favorable effect on the noise behavior of the brake," says Linhoff – and that's a side effect which is particularly attractive to drivers of a quiet EV.
Originally from New Jersey, Eric is an automotive and technology reporter specializing in the high-tech industry in Silicon Valley. Eric has over fifteen years of automotive experience and a B.A. in computer science. These skills, combined with technical writing and news reporting, allows him to fully understand and identify new and innovative technologies in the automotive industry and beyond. He has worked on self-driving cars and as a technical writer, helping people to understand and work with technology. Outside of work, Eric likes to travel to new places, play guitar, and explore the outdoors.
Volvo & NVIDIA Announce a New Partnership to Develop Autonomous Vehicles
NVIDIA Unveils a 'Supercomputer' to Speed Development of Self-Driving Cars
Self-driving Truck Startup TuSimple Launching ‘Autonomous Vehicle Operations Specialist Program’ with Local College
Tesla Denied Tariff Exemption for Chinese-made CPU in the Model 3
Uber Debuts its New Self-Driving Volvo XC90 SUVs, Designed to Operate Without a Safety Driver
BMW Introduces ‘Smart Glasses’ to Assist Service Technicians at its U.S. Dealerships
Silicon Valley Startup Aurora to Work with Fiat Chrysler on a Self-Driving Platform
Autonomous Delivery Startup Gatik Emerges From Stealth, Announces Partnership with Walmart
- Audi Turning to Green Factory to Manufacture EVs
- Volvo to Build the XC40 SUV in China to Meet High Demand
- China to Scale Back EV Subsidies to Push for Better Cars
- Daimler Acquires Stake in Sila Technologies to Develop Next-Gen EV Batteries
- Cadillac Boosts Super Cruise System With 70,000 Extra Miles
- EV Startup SF Motors Rebrands as 'Seres', Opening Preorders for its SF5 Crossover Next Week
- Honda E Officially Revealed With New Platform and 35.5 kWh Battery
- Tesla Reports Q1 Loss of $702 Million, CEO Elon Musk Says the Company Will Return to Profit in Q3
- GM Says its Vehicle Lineup Will Be Capable of Receiving OTA Updates Beginning in 2023
- China to Suspend Higher Import Tariffs on Autos & Parts from the U.S.