Electronic wedge brakes will change the way we stop

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Old 11-09-2006, 11:40 PM
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Electronic wedge brakes will change the way we stop

Electronic wedge brakes will change the way we stop - - By GREG KABLE - - Source: Autoweek

Never heard of the EWB or electronic wedge brake? Don’t worry. Chances are you’ll be hearing a lot about it in coming years.

That’s the opinion of German electronics specialist Siemens, which claims the high-tech stoppers, currently being tested for use on upcoming models by Europe’s leading carmakers, will revolutionize the safety standards of future generations of road cars by dramatically shortening stopping distances compared with more traditional hydraulic braking systems.

Efforts to improve the efficiency of braking systems have led to some interesting innovations in recent years, including the use of ceramic carbon materials in brake discs and electronic activation of parking brakes. But those developments will seem minor compared to the leap Siemens is claiming for its new electronic wedge brake.

Not to be confused with the electrohydraulic Sensotronic brakes introduced by Mercedes-Benz in 2001 but subsequently removed from sale early this year due to unsolved reliability issues, the electronic wedge brake represents a bigger breakthrough. The idea behind the system is not exactly new, with similarities to the arrangement found on horse-drawn carriages from the 18th century, where a wedge was used to bring the wheel to a standstill. But rather than relying on a hardened piece of wood for a binder, the electronic wedge uses state-of-the-art electronics and an innovative wedge-shaped connection to provide the sort of stopping ability that existing hydraulic units cannot match.

Unlike today’s traditional hydraulic brake, which requires the buildup of forces before the caliper is able to grip the disc, the electronic wedge brake uses a series of interlocking triangular teeth that offset between the caliper and the disc. In all, it is claimed to require just one-tenth the energy used by hydraulic braking. A small electric motor pushes the pad toward the rotor by a lateral movement—much like how a watermelon seed can be ejected at high velocity by squishing it between your fingers. The entire system runs on the standard 12-volt electrical system found in most cars.

Really clever, however, is that the kinetic energy of the car automatically increases the braking performance. In theory, the faster you are traveling when the brakes are applied, the more powerful they become. When the pad is applied to the disc, the momentum of the rotating disc draws the pad farther up an interlocking series of wedges, applying greater braking pressure and increasing stopping efficiency.

A series of electric motors push in and pull out at an extremely high frequency, while a torque sensor controls the braking force and keeps the wheels from locking up, thus alleviating the need for a conventional antilock braking system. With each brake unit operating independently from the others, it also means the electronic stability control can be programmed to operate on a much finer calibration, without the typical pulsating effect evident in some cars today.

In tests, a prototype with the wedge brakes regularly required less than half the distance to come to a complete stop than the prototype with the standard brakes, a company official said.

As well as providing greatly improved braking ability, wedge brakes are significantly lighter than today’s most advanced hydraulic units. With fewer moving parts, they also could be more reliable and last longer.

When will we see the new brakes begin filtering through to the road? Sources say the first car with wedge brakes, an Audi, BMW, Mercedes-Benz or Porsche, is planned for launch in 2008.
Old 11-10-2006, 01:13 AM
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Cool! I can't wait to see this stuff.
Old 11-10-2006, 01:19 AM
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2008!!!!!! holy shit thats WAY sooner than I thought it would have been. It sounds like it will REALLY be necessary to put your seatbelt on with these things, as I think you may sail straight through the windshield under hard-braking if you don't!!!!
Old 11-10-2006, 07:30 AM
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That is cool technology even though it's been used as early as the 1700s. Based upon the description of the 'wedge' ... it would seem like simple technology (well, a little more complicated than a piston pushing on a pad). But this uses the speed of the car (ie velocity of the rotor) to its advantage in braking. Why didn't they think of this sooner?!

On the other hand, this may affect the balance of the car. Imagine a front-heavy FWD car. When you brake hard ... there is going to be significant nosedive if the car is going to stop in 1/2 the distance!

I wonder when the Japanese will incorporate this technology to their cars?
Old 11-10-2006, 08:46 AM
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Isn't half the problem locking up the brakes? I've only driven a couple cars without ABS, but neither was difficult to lock up the brakes and slide on the tires. Better efficiency is always great but I don't get how it improves/shortens distances.
Old 11-10-2006, 10:26 AM
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Most of the time the tires are the limiting factor - I don't see how any system can cut in half the stopping distance. A good cars' 120ft stop from 60MPH would be 60ft? Where is all that extra energy being dissipated to? Sounds a bit too good to be true. And like the MB system that was taken off due to reliability issues, one has to worry when you rely on electronics to save your life.
Old 11-10-2006, 10:30 AM
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This is gonna suck when the car in front of you slams on their brakes for a yellow light and stops twice as fast as you can!

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Old 11-10-2006, 12:17 PM
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Cool!
Old 11-10-2006, 12:43 PM
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Originally Posted by Ashburner
This is gonna suck when the car in front of you slams on their brakes for a yellow light and stops twice as fast as you can!
Old 11-10-2006, 03:14 PM
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As for the claims of stopping distance, we have to see what kind of car it was, tires used, weather conditions, etc. Tires are a big factor on braking distances (especially on ice!). But I do believe it will shorten distances significantly in real world situations on most cars.
Old 11-10-2006, 03:32 PM
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Originally Posted by biker
Most of the time the tires are the limiting factor - I don't see how any system can cut in half the stopping distance. A good cars' 120ft stop from 60MPH would be 60ft? Where is all that extra energy being dissipated to? Sounds a bit too good to be true. And like the MB system that was taken off due to reliability issues, one has to worry when you rely on electronics to save your life.
I agree. Alot of how fast a car can brake is limited to traction of the tires. (that and many other factors like weight=enertia)
Old 11-10-2006, 05:32 PM
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Tire technology cannot keep up with this. As is modern cars are limited by their tires when it comes to braking - the 100ft mark seems to be the benchmark for a road car. I don't see how better brakes is goin to help with stopping distances.

WHen the E60 M5 came out, it was mentioned in a mag article that it only had 2 piston calipers instead of some of the 6/8 piston monstrosities found in AMG cars - the reason: BMW stated that braking performance was limited by the tires and not the brakes.
Old 11-10-2006, 06:50 PM
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[QUOTE=vishnus11]Tire technology cannot keep up with this. As is modern cars are limited by their tires when it comes to braking - the 100ft mark seems to be the benchmark for a road car. I don't see how better brakes is goin to help with stopping distances.
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