舍弗勒-后电驱集成制动器方案-2025-12-技术资料

SCHAEFFLER

E-AxleIntegratedBrakes

Pollutant-andMaintenance-FreeBrakesforElectricTractionSystems

Schaeffler/Public

.iS,Bierlinctisymposium

AUTOMOJIVEPOWERTRAINSYSTEMS

Wepioneermotion

工Drivers&Challenges

2MultiDiscWetBrakes

3KPIs&Results

Summary&Conclusion

4

1Drivers&Challenges

MultiDiscWetBrakes

2

3KPIs&Results

Summary&Conclusion

4

E·AXLEINTEGRATEDBRAKES

Overview-Pollutant-andMaintenanceFreeBrakesforElectricTractionSystems

SCHAEFFLER

BrakeParticleEmissions

EURO7

Councilofthe

EuropeanUnion

-PM10[mg/km]

35

30

20

Possible

measures

15

■Brakes

■Road

Exhaust

10

9,5

N1

7,2

5

M1

(PC<3.5t)

havehigh7regulation

shareofPM10emissions

limitstheparticleemissions

(LCV<3.5t)

·Brakes

·EURO

Source:

BremsenchneFeinstaubemissionen,DieinnovathveHybridbremseforNutzfahrzeugen.C.Kohle,eal2025QuantifizierungdesReibabriebsvonBremsenbeiPkwundlghtdutyvehicles,5.Hausberger,eaL,2021

PC.PassengerCars|LC:LightCommercialVehicles|PM:ParticulateMatter

Decembersrd,2025CTSymposlumBerlin|Dr,KlarashSabzewan|SchaefflerIPublke

Brakedisccoating

Cost

Emissions

Dragtorque

Drumbrakes

Active

filtering

Cost

Emissions

Dragtorque

Cost

Emissions

rato号rq驱ue动视界

ctisymposium

SCHAEFFLER

E·AXLEINTEGRATEDBRAKES

Stateoftheart-selecteddriversandchallenges

Maintenance

Regulations

EURO7

Councilofthe

EuropeanUnion

BrakeParticleEmissions

BEV:3mg/km,xHEV,ICE:7mg/km;

Updatein2030,3mg/kmallin2035

Efficiency

Drivers&Challenges

Residual

draglosses

ctisymposium

AUTOMOTVE·POWERTRAIN·SYSTiMS

公众号驱动视界

December3rd,2025CISymposlumBerlinDr,KlarashSabzewar|SchaefflerPuble

Stateoftheart

MultiDiscWetBrakes

3KPIs&Results

Summary&Conclusion

4

工乙

HAEFFLER

AJTOMOTVE·POWERTRAIN·SYSTIMS

Overview-Pollutant-andMaintenanceFreeBrakesforElectricTractionSystems

ATF:AutomateTransmissionFuid|AMS:Auto-Motor&Sport

December3rd,2025CISymposlumBerlin|Dr.KlarashSabzewari|SchaeflerIPuble

Baseline:

SchaefflerEMR4platform

Configuration:

Sideattachedsolution

Application:

C/Dsegmentvehicle-rearaxle

Performance:

1900Nm-1.2gdeceleration

Brakeprofilesvalidation:

Auto-Motor&Sport/Emergencybrake/Grossglockner

Cooling:

ATFcooledbrakes

Actuation:

hydraulicallyactuated

公众号·驱动视界

ctisymposium

SCHAEFFLER

INTEGRATEDBRAKE5-WIDERANGEOFAPPLICAT10N

Possiblepackagingconfiguration-highlyscalableandadaptable

Weight(max.)Maximumspeed

Braketorqueperwheel-rearaxle

EmergencyBrake

180km/h/620kJ

HCDirect

FrictionDisc

HOERB/GERCarbonDirect

2500kg250km/h

3500kg

250km/h

VehicleParameters2500kg

180km/h

1650Nm1800Nm2400Nm

+40mm

Scalingofbrakingtorquebasedonnumberandsizeoffrictiondiscspossible

EM:ElectricMachine|G:Gearbox[B:BrakeIR:Rim(whetlhub)

December3rd,2025CTISymposlumBerlinDr,KlarashSabzewar|SchaefflerIPuble

公众号·驱动视界

ctisymposium9

AUTOMoTVE·POWERTRAIN·5YSTiMS

SCHAEFFLER

ARCHITECTURESTUDY-BRAKEBYWIREFOR2WDAND4WDPOWERTRAINARCHITECTURE5

Variousarchitecturefeasibleformultidiscbrakes

Electrohydraulicactuation

MDB

MDB

actuator

MDBAxle

actuator

Parkingbrake

Brake

Brake

Control

Unit

Brake

Control

Unit

Brake

Brake

Booster

MDBstandaloneOil(ATF)

Control

Booster

Unit

Brakefluidelectrically

MDBMDB

actuator

公众号·驱动视界ctisymposium

AJTOMOTVE·POWERTRAIN·SYSTiMS

MDB:MuluiDiscBrakes,ATEAutomatictransmissionfuid

December3rd,2025CISymposlumBerlin|Dr,KlarashSabzewariISchaeffler|Publk

SCHAEFFLER

E·AXLEINTEGRATEDBRAKE5-BENEFITOFHEATING

Heatingusecasescoveredbybrakeswithheatingfunctionality

Function

Component

UseCase

whiledriving

recuperation)

multidiscbrakes

Reducer

December3rd,2025CTISymposlumBerlinDr,KlarashSabzewari|Schaeffler|Publk

Benefit

morecomfort

Highuseable

capacity,lessaging

Decrease

chargingtime

e-Axleefficiency

Increaseof

公众号·驱动视界ctisymposium

AUTOMoTVE·POWERTRAIN·SYSTIMS

工Stateoftheart

2Drivers&Challenges

3KPIs&Results

Summary&Conclusion

4

SCHAEFFLER

THERMALBEHAV1OR5ANDPERFORMANCE

NoBrakefadingduringperformancetest

2000

Highspeedfadingtest

Vehiclespeeed

180

(km/h/h)

Deceleration:6m/s²90%Vmax→90km/h

15times

DissTemperatureBraketorque

1500-

(N

1000

Samebrakingtorqueafter15events

→NObrakefading

350

240-

130-

Existingchallengeforconventionalbrakes!

、Thermalbehavior:

steadystate

6080100120140160180200220240260280

[s]

PASSED

AMEAutoMotorundSpoetTestIHE:HipeedFadingTet

December3rd,2025CTISymposlumBerlin|Dr.KlarashSabzewari|SchaeflerIPuble

公众号·驱动视界ctisymposium

13AJTOMOTVE·POWERTRAIN·5YSTiMS

SCHAEFFLER

DRAGTORQUE

"OilOnDemand"-Wetbrakesachievesverylowdragtorques

Impactonvehicleenergydemand

Dragtorque

-Casestudyforapassengercarlifetime

Stateoftheart:conventionaldiscanddrumbrakes1...2Nm

·Assumption:dragtorquereductionof0,5Nm/wheel

Drivingcyclemixture:

Condition:brakemoduletestontestrig

Mointain

10%

240tkm

Highway

30%

Urban

30%

City

30%

2

Stateoftheart

Discbrakes/drumbrakes

Req.:<1Nm

~0.5Nm

Dry

condition

500

Immediatelyafterbrake

10001500

Rotationspeed[rpm]

~320kWhenergysavingforvehiclelifetime~1%WLTCenergyconsumptionreduction

Results:

Directlyafterabrakingmaneuver,~1,5Nmduetorestoilbetweendiscs.Fordrycondition-alreadyaftersecondrun-dragtorqueis~0.5Nm

Alldragtorquereutsarecaloliaedconuidering>sboequeBOnpmsetoDNm

December3rd,2025CISymposlumBerlinDr,KiarashSabzewarn|SchaeflerIPuble

公众号驱动视界ctisymposium

ENCAPSULATEDWHEELS-ANALYSESBASEDONC·5EGMENT

Benefit:Reducedenergyconsumptionbyimprovedaerodynamics

SCHAEFFLER

VehicleEnergyDemandWLTC

100,0%

Te=Fo+F₁v+F₂v²53,7%

F₂=2*36

F1

[Wh/Km][Wh/Km]

32,7%

FO

[Wh/Km]

Inertia

[Wh/Km]

Total

[Wh/Km]

Assumption:closedwheelhousingimpactondragcoefficient(Ca)~0.0141

Thehigherthecycleaveragespeed,thehighersavingpotential

-2.5…-3.7%consumption&batterysizereductionfeasibledependingonthecycle

December3rd,2025CTSymposumBerlin|Dr.KiarashSabzewariISchsefflerIPublic

1)Soure:Paper"TheEfectsofwmee/DesgnontheAerodyamkDrago/Rassengervehicles"c公tiso动视界

AJTOMOTVE·POWERTRAIN·SYSTEMS

公众号·驱动视界

SCHAEFFLER

ConfirmationofFunctiononChassisDynoandTestTrack

Productiondrumbrakes

Tine-

Multidiscbrakes

Vehicledeceleration(m/s²)-Multidiscbrakes

-10

2,43,2

Drumbrakes

time

Testsonchassisdynoandtesttracksconfirmsverygoodresponseofmultidiscbrakes

December3rd,2025CISymposumBerlin|Dr,KlarashSabzewanISchaeffler|Publkctisymposium

AJTOMOTVE·POWERTRAIN·SYSTiMS

工Stateoftheart

2Drivers&Challenges

3KPIs&Results

Summary&Conclusion

4

E·AXLEINTEGRATEDBRAK