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The VW ID.4 Electromechanical Brake Servo (eBKV)
Self Study Program
Table of Contents:
Introduction
Design of the Electromechanical Brake Servo Module
How the Electromechanical Brake Servo Works
Brake Management
Service
Introduction
Due to the increasing number of electric vehicles and the low vacuum produced in the intake manifolds on modern combustion engines, a method to enhance braking force is needed.
The Electromechanical Brake Servo (eBKV) provides a solution to these concerns.
In addition to enhancing braking force, this system also reduces the total weight of the brake system, allowing further CO2 emission reduction for vehicles with combustion engines.
Technical features of the Electromechanical Brake Servo (eBKV):
• Parallel axis electric drive
• Weight-saving gear unit
• Weight saving control unit housing
• Vacuum-free brake force boosting
• No additional pressure accumulator
• Up to 5.3 kN power assistance
• Weight of approx. 9.7 lb (4.4 kg)
• Motor output 370 W
• Voltage range 9.8–16 V
• Maximum torque of 2.4 lb/ft (3.3 Nm)
Advantages of the eBKV
• Particularly fast brake pressure build-up for driver assist functions
• High safety advancement
• Reduced wheel brake drag torque
• Comfortable pedal feel
• CO2 savings due to weight reduction and omission of vacuum pump
• Long service life
• Redundant brake system for Electronic Stability Control (ESC)
Safety Increases due to the eBKV
The eBKV increases the effectiveness of driver assist systems, such as Front Assist, in potential accident conditions that require extremely high pressure braking increases.
This cannot be performed using conventional vacuum-based systems.
This results in a shorter stopping distances than conventional systems:
• A reduced emergency braking distance of up to 4.2 ft (1.3 m) with deceleration from 18.5 mph (30 km/h) to a stop
• Collision speeds can be reduced by approximately 1.8 mph (3 km/h) due to the shorter stopping distance
This also allows pedestrian accident avoidance to be improved by 10%.
Reducing collision speed decreases the energy that the body has to absorb during the impact, improving occupant protection.
What is Reduced Brake Drag Torque?
Brake drag torque occurs with disc brakes after a braking event. Brake drag torque leads to higher fuel consumption and increased CO2 emissions.
After a braking event, the brake pads retract to their starting position as brake pressure decreases.
Due to slight wobbling of the brake disc in relation to the brake caliper, combined with tight clearance, the whole brake pad does not immediately lose contact with the brake disc.
There is still transitional frictional contact between the brake disc and the brake pad.
By using a clip in the brake caliper, the pads can be mechanically retracted faster.
Conventional, Vacuum-based Brake Systems
Vacuum-based brake systems create vacuum using multiple methods:
• Intake manifold evacuation while the combustion engine is running
• A mechanical vacuum pump
• An electric vacuum pump
These methods have some partial disadvantages:
• Poor CO2 figures
• Heavy weight
• High production costs
Current Brake Systems for Electric Vehicles
This is the 1st Generation eBKV. It is used in high-voltage vehicles.
Its distinguishing feature is a special pressure accumulator for the brake system.
It stores brake fluid during recuperation, reducing the brake pressure in the system.
The disadvantages are:
• The space required
• The separate drive for the active accumulator
• Its weight
Electronic Brake Servo
The eBKV has an accumulator integrated into the ESC unit that holds brake fluid during recuperation, instead of an external brake system pressure accumulator.
The advantages of this system are:
• No additional space required for additional components
• Weight reduction
• Lower CO2 emissions
• Reduced costs
Self Study Program
Table of Contents:
Introduction
Design of the Electromechanical Brake Servo Module
How the Electromechanical Brake Servo Works
Brake Management
Service
Introduction
Due to the increasing number of electric vehicles and the low vacuum produced in the intake manifolds on modern combustion engines, a method to enhance braking force is needed.
The Electromechanical Brake Servo (eBKV) provides a solution to these concerns.
In addition to enhancing braking force, this system also reduces the total weight of the brake system, allowing further CO2 emission reduction for vehicles with combustion engines.
Technical features of the Electromechanical Brake Servo (eBKV):
• Parallel axis electric drive
• Weight-saving gear unit
• Weight saving control unit housing
• Vacuum-free brake force boosting
• No additional pressure accumulator
• Up to 5.3 kN power assistance
• Weight of approx. 9.7 lb (4.4 kg)
• Motor output 370 W
• Voltage range 9.8–16 V
• Maximum torque of 2.4 lb/ft (3.3 Nm)
Advantages of the eBKV
• Particularly fast brake pressure build-up for driver assist functions
• High safety advancement
• Reduced wheel brake drag torque
• Comfortable pedal feel
• CO2 savings due to weight reduction and omission of vacuum pump
• Long service life
• Redundant brake system for Electronic Stability Control (ESC)
Safety Increases due to the eBKV
The eBKV increases the effectiveness of driver assist systems, such as Front Assist, in potential accident conditions that require extremely high pressure braking increases.
This cannot be performed using conventional vacuum-based systems.
This results in a shorter stopping distances than conventional systems:
• A reduced emergency braking distance of up to 4.2 ft (1.3 m) with deceleration from 18.5 mph (30 km/h) to a stop
• Collision speeds can be reduced by approximately 1.8 mph (3 km/h) due to the shorter stopping distance
This also allows pedestrian accident avoidance to be improved by 10%.
Reducing collision speed decreases the energy that the body has to absorb during the impact, improving occupant protection.
What is Reduced Brake Drag Torque?
Brake drag torque occurs with disc brakes after a braking event. Brake drag torque leads to higher fuel consumption and increased CO2 emissions.
After a braking event, the brake pads retract to their starting position as brake pressure decreases.
Due to slight wobbling of the brake disc in relation to the brake caliper, combined with tight clearance, the whole brake pad does not immediately lose contact with the brake disc.
There is still transitional frictional contact between the brake disc and the brake pad.
By using a clip in the brake caliper, the pads can be mechanically retracted faster.
Conventional, Vacuum-based Brake Systems
Vacuum-based brake systems create vacuum using multiple methods:
• Intake manifold evacuation while the combustion engine is running
• A mechanical vacuum pump
• An electric vacuum pump
These methods have some partial disadvantages:
• Poor CO2 figures
• Heavy weight
• High production costs
Current Brake Systems for Electric Vehicles
This is the 1st Generation eBKV. It is used in high-voltage vehicles.
Its distinguishing feature is a special pressure accumulator for the brake system.
It stores brake fluid during recuperation, reducing the brake pressure in the system.
The disadvantages are:
• The space required
• The separate drive for the active accumulator
• Its weight
Electronic Brake Servo
The eBKV has an accumulator integrated into the ESC unit that holds brake fluid during recuperation, instead of an external brake system pressure accumulator.
The advantages of this system are:
• No additional space required for additional components
• Weight reduction
• Lower CO2 emissions
• Reduced costs
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