09/13/2011

• New developments and scalable component families are constantly opening up new usage opportunities for the base braking system
• Combined with experiences in the area of tire technology, they bring Continental one step closer to our goal of preventing accidents and reducing their effects: the megatrend safety

Frankfurt am Main. High-performance braking systems are the basis for active driving safety – but despite enormous technological advances in the last 20 years, particularly through ABS and ESC systems, there is no end in sight when it comes to brake innovations. From brake actuation, brake pressure modulation, wheel brakes and to expanding the functional scope of the electronic braking system and networking it with data from the vehicle surrounding sensor system, there are always new challenges for the engineers.

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Future of dynamic braking - Continental's Brake System Family

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System competence is needed in order to face the “future of braking” – and that’s exactly what Continental offers as one of the world’s leading automotive suppliers, for a wide variety of product segments and from a single source.

“Modern braking systems, as the cornerstone of the perfect relationship between active and passive safety elements, are key in gradually moving closer to our vision of accident-free driving,” said Dr. Ralf Cramer, member of the Executive Board of Continental AG and President of the Chassis & Safety Division.

Scalable functional ranges according to requirements: from Base to Premium Compact

The Continental braking system for the “Base” category currently comes with ABS, a traction control system, electronic stability control (ESC) and an electronic parking brake. This equipment provides the most important elements for controlling the dynamics of a vehicle, with superior comfort. An adaptive cruise control system (ACC), included in the “High” system category, can provide increased comfort and safety and protect drivers from the effects of distraction, for instance when driving in tiring convoys.

Starting in the “Premium” category, the braking system gains additional features: in addition to the power assist brake system, this level also offers the option of remote brake intervention, in order to quickly reduce the vehicle’s kinetic energy in dangerous situations – which also reduces the severity of a possible accident. The intelligent braking system thus makes optimal use of the remaining time to take protective measures – even if the driver does not react quickly enough or fails to react at all. For instance, the emergency brake assist (EBA) recognizes the threat of a collision; it warns the driver while preparing the braking system, and provides the necessary braking force in case of an emergency. Being able to prioritize information from the vehicle surrounding sensor system and passing it on to the driver in an appropriate manner is an essential part of accident prevention. The most important information about the current driving situation provides the decisive impetus for the driver’s decision. With our integrated understanding of the human-machine interface, Continental is able to take every aspect of information management into account and combine them into a harmonic overall concept. In the area of pedestrian safety, for instance, it becomes clear how closely active and passive safety are linked: if a collision with a pedestrian takes place despite a braking maneuver, sensors in the pedestrian protection system (PPS pSAT) recognize the contact and activate protective measures on the vehicle, such as lifting the engine hood. Information management continues to play an important role even after an accident has taken place. Continental’s eCall service uses a crash-proof telematics unit to automatically place an emergency call after a collision, and to request help for the occupants in the vehicle.

Additional braking features for the future

For hybrid vehicles, the functional scope of the “Hybrid” level includes a smooth blending of the friction brake and the generator brake for decelerating up to 0.2 g – in other words, for 80 percent of normal braking procedures. This feature ensures that the driver always experiences the same pedal feel even if the initial braking is carried out only by the generator and in the next instance by the hydraulic brake system.

Despite the increasing functionality of the braking system, more weight still means higher CO₂ emissions. As a result, the best-performing braking system must be light and compact. The new generation of Continental brake boosters not only feature all-aluminum housingswith thinner walls, but also has a very compact design. Even the earlier generations were available with either a steel or aluminum housing. With the electric vacuum pump (EVP), Continental also offers a compact and efficient solution for vehicles when the engine either no longer provides a sufficient vacuum level in every operating situation, or when the combustion engine is temporarily turned off or is no longer present, for instance in electric vehicles.

In the area of wheel brakes, Continental is responding to this challenge with the new, very light FS fixed-type caliper brake. In comparison to fist-caliper brakes, the FS design has two major advantages: first, it is lighter; because of the smaller clearance possible with this design it responds very quickly, which increases its safety potential. In addition, Continental has been able to equip this brake type with drawn brake pads, which optimizes the acoustics of the brake.

In the new MK C1 generation, the braking function, the brake booster and the brake pressure control module (ABS, ESC) are combined into a compact, weight-saving braking unit. This is made possible because the system is completely electro-hydraulic, and it is no longer dependent on the relatively low energy density provided by the vacuum. Furthermore, the MK C1 fulfills the increased pressure dynamics requirements for advanced driver assistance systems – preventing accidents and protecting pedestrians – significantly better than the previous braking systems. Thus the braking distance for an electronically initiated emergency braking action was significantly shorter in tests with the MK C1. This reduces the likelihood of serious injuries in the event of an accident. The high pressure dynamics also create ideal conditions for other driving safety systems. For instance, a short braking distance reduces the time-slot in which active and passive safety systems can be coordinated and optimized in terms of timing. Since an increasing number of vehicles will be equipped with vehicle surrounding sensor systems in the future, dangerous situations and potential accidents can be detected even earlier. One of the main factors influencing such a risk analysis is always the braking system.

A hydraulic-by-wire system like the MK C1 provides the ideal conditions for determining every conceivable contribution to driving safety provided by the braking system, in a sustainable and calculable way. The “power on demand” principle of braking also reduces energy requirements for the braking system, and a pulsation-free linear pump means a much lower noise emission level than in conventional solutions with ESC multi-piston pumps and the electric vacuum pumps that are often required. Drivers of electric vehicles will also appreciate the quiet braking system because of the lack of “noise cancellation” from a combustion engine – especially if the system is also more dynamic. This level is scheduled for availability starting in 2015, as a “Premium Compact” braking system.

Ultimately, however, these additional options always rely on the basic braking system, which must therefore provide uncompromising quality, stability and longevity.

Bringing braking power to the road

Tires play a key role in safe braking because they transmit the braking power to the road. Continental holds a special position among the other suppliers here because it also has expertise in the area of direct contact with the road. New products such as the Conti Sport Contact 5 have been optimized in terms of the essential braking safety functions. This high-performance tire transmits braking power to the road surface very efficiently even in wet conditions. It also has improved cornering power, which gives it more grip when braking in a curve. Numerous wins in independent tire tests confirm these special qualities, especially when it comes to braking.