The Future of Braking: Why Expertise Matters in Integrating Advanced Electronics

Fortunately for today’s drivers and passengers, significant advancements have been  made to improve vehicle safety, stability, and performance. Some of the most notable improvements include anti-lock braking systems (ABS), electronic stability control (ESC), traction control systems (TCS), and electronic parking brakes (EPB), all of which are electronically driven.

These technologies were initially developed for passenger vehicles, but they’re now being applied to a wide range of on-road and off-road vehicles, including motorcycles, electric vehicles (EVs), SxSs and UTVs. This trend reflects a growing emphasis on sophisticated, safety-focused systems, even in vehicles not traditionally associated with such advanced features.

Conceptually, these algorithm-based safety features operate similarly across various vehicles. However, designing, engineering, and preparing brakes for integration into different vehicles and systems requires a brake manufacturer with the expertise to meet the demands of increasingly complex vehicle architectures.

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Designing for Seamless Integration

"Design for Integration" is an engineering and design approach that ensures a product, component, or system seamlessly integrates with other elements within a larger framework.

As a brake manufacturer, Hayes Performance Systems’ focus is with design of braking components, rather than software development or modules like ABS and ESC – but we must design our products to integrate with and around these systems. Doing so ensures that our products are ready for incorporation into more advanced system-level architectures. In this process, we’re responsible for understanding the intricacies of specifications, including the design of the electronic systems we plan to integrate. For example, when designing a brake system, Hayes engineers must ensure that it aligns with the vehicle's overall control systems, including ABS, ESC, and other safety features. The key concepts when designing for integration include:

• Compatibility: Designers and engineers must guarantee that the braking system is compatible with other elements it needs to work with, including mechanical, electrical, software, and communication components. Brakes must be responsive and able to keep pace with electric automation's rapid application and release demands to ensure the system's overall safety, predictability, and reliability. Modularity: Components should be designed in a modular way so that they can be easily integrated, swapped out, or upgraded without affecting the rest of the system, making it more flexible and easier to maintain.
• Standardization: Using industry standards for dimensions, connections, and protocols makes it possible for designs to be integrated with other systems following the same standards, reducing the risk of incompatibility and simplifying the integration process.
• Interoperability: Designing for interoperability ensures that different systems, even from various manufacturers, can work together seamlessly.
• Ease of Assembly and Installation: Designing products for easy assembly and integration into a larger system reduces installation time and costs, and helps prevent errors during the process.
• Scalability: A design that allows for easy scalability allows additional components or systems to be integrated without requiring significant redesign or rework.

Testing and validation are also integral to Design for Integration. These steps affirm that the product will function properly when integrated into the larger system. Typically, simulation and prototyping are used to verify successful integration.

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A Real-World Example

Hayes has been involved in numerous integrations over the years, whether through R&D projects, new product development initiatives, or experimental investigations. Our most recent was an R&D project focused on the design of an electronic parking brake (EPB) for a non-automotive application.

EPBs, once a common feature only in passenger vehicles, are now widely  applied, including non-automotive applications like off-road and construction vehicles. These systems are designed to replace traditional mechanical setups with a simple button that engages the EPB.

The Future of Brake Integration

At Hayes, our R&D efforts are closely tied to those of our product development and integration teams so that manufacturers can effectively apply these new innovations across different vehicle types. As the industry evolves, some technologies, like brake-by-wire, are still in development, while others, such as EPBs and regenerative braking, are already making significant inroads.

• Electronic Brakes: Also known as "brake-by-wire" systems, electronic braking systems use electronic controls to manage braking force instead of relying solely on traditional hydraulic or mechanical systems. In these systems, the driver's input is converted into electronic signals, which signal a computer to process the control of force applied to each wheel. Applications for electronic braking systems include electric and hybrid vehicles, and autonomous (and semi-autonomous) vehicles.
• Electro-Mechanical Brakes: These brakes combine electronic controls with mechanical components to apply force. They use electric motors, solenoids, or other actuators to engage the brake pads or shoes directly or through a mechanical linkage. Applications include most on-road vehicles and heavy equipment.
• Brake Blending: Brake blending involves the integration of regenerative braking with traditional friction braking. Brake blending assures that the transition between regenerative and friction braking is smooth, providing a consistent braking experience for the driver.
• Regenerative Braking: This innovation converts kinetic energy generated during braking into electrical energy, which is stored in the vehicle’s battery. Regenerative braking is most common in electric and hybrid vehicles, but more non-passenger vehicles have adopted the technology.

As vehicles and their systems evolve, integrating advanced braking systems has become essential, not just as a technical requirement but as a fundamental part of vehicle design. The blend of electronic controls, intelligent algorithms, and mechanical precision is changing how vehicles perform, whether on daily commutes or in challenging off-road conditions. This shift calls for expertise that goes beyond the basics.

At Hayes, we understand that effective brake integration isn't just about connecting parts; it's about bringing together complex systems to build safer, more reliable, and more efficient vehicles. This requires a solid understanding of both new technologies and the details of vehicle architecture. Our focus on innovation means that every brake system we design works seamlessly with current technologies and is ready to adapt to future developments.