Automotive Braking Systems: A Review of Quality Precision Components

Aside from proper steering, braking systems are perhaps the most important safety component of any vehicle.  To the driver, they are a no-fail system which is expected to work without a second thought.  Yet to OEMs, braking systems are an intricate design of precision components which work together to bring vehicles to a complete and safe stop.

Have you ever wondered what happens when you press the brake pedal?  Or how you can ensure that the braking assembly is built to the highest-quality standards? Today on the CriticalPARTner, we review the precision components that are involved. 

The simple movement of pressing the brake pedal actually initiates a complex series of behind-the-scene mechanics. The central component of a brake assist system is the hydraulic control unit, which includes the ESC (electronic stability control) unit. Brake pressure sensors in the central hydraulic control unit and speed sensors on each wheel identify emergency driving situations in the brake assist system. In modern cars, they are also connected to sensors and cameras to assist the driver in critical driving maneuvers.

The tandem master cylinder, booster and hydraulic control module require critical high precision plastic components to ensure the vehicle comes to a smooth and timely stop. We like to refer to these components not as seals or seal rings, but small, high precision components which have critical functions such as guiding a piston, supporting a rubber seal, or even ensuring the proper performance of a high speed digital valve.  And most importantly, they are built to deliver safety even under the toughest conditions.

Given the critical requirement of these parts, 0 PPM must be delivered right from the box. Our partners depend on us to deliver this level of quality each time they place an order. Since they use fully-automated production lines of robots and cobots, our partners and customers simply don’t have the opportunities to detect irregularities on these critical parts. The final functional check may not occur until the entire assembly is completed. Only quality parts from a trusted supplier can deliver this level of confidence.

How do we ensure this quality precision? Through the following critical design engineering and manufacturing processes:

• Compounds – All precision braking parts are developed and tailor-made with engineered polymers to fit precise application needs. Components can be designed to resist extremes in temperatures, stress and wear to excel in all braking conditions.
• Processing and Tooling – Our process equipment and internal tool shops have also been custom-designed to our exact specifications so that we can offer you custom-built parts. Surface finish below Rz1, maximized and controlled mechanical properties and tolerances around 15µm are the products generated out of this combination. Need high volume, highly critical injection-molding components?  We have you covered!
• Future Technologies – As the industry trends move toward more autonomous driving and hybrid technology applications, the use of brake hydraulics and all of these related components are increased tremendously. Precise fit and lifetime confidence becomes even more important. Camera assist, lane-detection and other camera-assisted technology will continue to grow in the automotive industry. Read about braking in electrical car systems.

While the components and processes may be complicated; it is our responsibility to ensure that the same process is repeated each time to the same specifications and quality standards. We deliver over 150 million components each year in brake system applications and are committed to ensuring the quality of each one to provide your customers with enhanced safety.

Are you interested in learning more about our quality precision and control for braking or other automotive systems? Visit us at the 9^th International Chassis Tech Plus Symposium on June 12 and 13 in Munich, Germany, for a live demonstration or reach out to one of our experts!