Innovation

Creating and innovating to improve together

Partnerships to improve the environmental impact of products

One of the prime objectives of Brembo product innovation is to reduce environmental impact, linked especially to the production of raw materials used, the generation of particulates during braking — harmful for human health — and greenhouse gas emissions caused by vehicles that can be reduced also by limiting the brake systems’ weight.

In a perspective of open-innovation, and to improve the effectiveness of research in these areas, the Group encourages collaboration, through networks and joint work projects, with other players in the automotive sector, Research Centres and Universities both at Italian level and at international level.

The main joint research projects in which Brembo participates 

LOWBRASYS: acronym for “Low Environmental Impact Braking System”, this three-year project began in the second half of 2015 as part of the Horizon 2020 scientific research and technological innovation programme. The project sees Brembo in the role of coordinator of a consortium of 10 partners from the industrial world — including Ford, Continental Teves, Federal Mogul and Flame Spray — and research institutions including: Ostrava Technical University, Stockholm’s Royal Institute of Technology, Trento University’s Department of Industrial Engineering, the European Commission’s Joint Research Center and the Mario Negri Institute for Pharmacological Research in Bergamo. The challenge is to develop a new generation of technologies, materials and measures to improve the impact of vehicles on health and the environment through an innovative braking system that can halve the emissions of micro and nano particles. To date, the first results of the project have highlighted the possible reduction of about 30% of particulate matter generated by braking systems, through the implementation of next generation discs and new friction materials. Similar results have been reached through the implementation of an in-vehicle smart dashboard designed to teach more sustainable braking styles to drivers. Lastly, the project has shown that it is possible to obtain a further 20% reduction of emissions by using the new Brake By Wire system. The project, which is a part of the European Union Horizon 2020 programme, came to an end in the first quarter of 2019, becoming a key element of the sustainability of Brembo’s products.

For further information: www.lowbrasys.eu/en

LIFE-CRAL: launched by the European Union in July 2016 and set to end in December 2019, this project is coordinated by Brembo and aims to develop a production line, in the pre-industrial phase, that will allow aluminium and magnesium components to be produced, starting with recycled or highly impure materials, whilst maintaining the product’s end quality. The use of secondary aluminium, i.e., arising on the recycling process, avoids the energy consumption required to prepare aluminium, by saving 97% of CO2, as well as the emissions of polluting gases released in the magnesium casting process. After the first pilot production line was created, a complete secondary aluminium caliper was then manufactured and validated according to Brembo’s standards. The entire project may be considered quite successful, in light of the successfully completed road durability test (2,000 km) and the use of the method concerned to make brake heads and levers for motorbikes from Eco-Magnesium.

For further information: www.cralproject.eu

AFFIDA: it represents the natural evolution of the European LIFE+ project known as COBRA. Continuing the collaboration with Istituto Mario Negri, AFFIDA aims to completely eliminate the phenolic binders commonly used in all friction materials and replace them with cement-based binders. The new materials must perform on a par with their traditional predecessors, while also meeting the high-performance standards required by the sporting applications and limiting fine particulate emissions and environmental impact. The considerable experience gained in COBRA made it possible to pursue more challenging objectives: AFFIDA pads are now meeting with great interest from various car and motorbike manufacturers, which are considering them for the future development of new applications. The prototype pre-industrialisation process, involving a mould created using ad hoc technology, would currently be sufficient to meet customer demand, and the process may be further improved through synergistic collaboration with each brand. The goal is to ensure that the product offers optimal performance and comfort, in a manner compatible with its mission. The introduction of the cement-based binder proved decisive in reducing volatile organic compound (VOC) emissions, with important positive repercussions for the environment.

LIBRA (Light Brake): Launched in 2015, this project aims to develop brake pads using a material capable of replacing steel in the composite material backing plate, reducing pad weight by 50%, by eliminating the steel backing plate in brake pads, replacing it with high-performance composite materials. In addition to the light weight, advantages include faster brake pad production times and a reduction in CO2 emissions. The results achieved in the first year of research and development have confirmed the validity and competitiveness of this approach: lighter pads and a consequent reduction in the overall weight of the brake system and in production times. A major US automotive brand requested the use of units developed with LIBRA in its parking systems and played a primarily role in intensive development, resulting in increasing recognition of the competitiveness and innovation introduced by LIBRA. In late 2018 and early 2019, a mould fully dedicated to the manufacture of these particular pads was installed to prepare for the imminent launch of manufacturing and mass production of the product. The important new goal pursued throughout 2019 was to transfer LIBRA technology to rear service pads as well, in order to continue to benefit even more thoroughly from the innovation and technology offered by this project.

ECOPADS: an evolution of the LOWBRASYS and REBRAKE projects, this is an international research project to develop new copper-free brake pads, with excellent brake performances and lower polluting emissions and a more effective recycling process. In this project Brembo works in partnership with the Trento University and the Stockholm Royal Institute of Technology (KTH). In 2019 a new pad formulation was implemented and tested, both in the laboratory and on the road, and then approved according to the European procedure for aftermarket products.

INPROVES: this is a pilot project aimed at creating brushless motors based on permanent magnets (PMM) for braking systems, traction and energy recovery. Brembo is the lead partner of the project in which other partners are Magneti Marelli, the Milan Polytechnic University, the Bergamo University and PMI members MD Quadro, eNovia, Peri, Mako-Shark and Utp Vision. The project is also aimed at integrating product and process innovation, by designing a new production line exploiting the potential of digitalization and IoT to produce future electrical motors. Brembo successfully completed the design of brake system motors and their production process, with an initial series of prototypes created and tested. The project was enriched by the installation at the plant in Stezzano (Italy) of a pilot flexible production line to demonstrate the efficacy of the Internet-of-Things and Industry 4.0 paradigm, applied to specialised production, planned for mid-2020.

MODALES (MOdify Drivers’ behaviour to Adapt for Lower EmissionS): this project is the clearest expression of Brembo’s commitment over the last eight years in the field of non-exhaust particulate emissions produced by brake systems through European Union projects of the calibre of Rebrake, COBRA and LOWBRASYS. This project involves analysing driver behaviour, not only as a consequence of the particulates emitted by brake use, but also with regard to tyres, exhaust systems and problems relating to maintenance and tampering. Once the behaviour that has a negative influence on overall emissions levels has been identified, a strategy will be developed to guide drivers’ behaviour to be more respectful of the environment around them, in addition to dedicated training activity.

For further information: http://modales-project.eu/

ENSEMBLE: the main goal of this project is to support the adoption of a multi-brand truck Platooning in Europe, by working on standardisation, universal communication projects and international legislation. ‘Platooning’ technology has made great progress in recent years: taking an integrated, multi-brand approach is the next step. By guiding up to six trucks of different brands in one (or more) platoons in real traffic conditions across national borders, it will already be possible to achieve benefits such as improved traffic security, productivity, fuel savings and, overall, a direct positive impact on total emissions.

For further information: https://platooningensemble.eu/

EVC1000: The EVC1000 project seeks to further increase user awareness and acceptance of electric vehicles (EVs) by developing components and systems independent of the brand using an integrated in-wheel propulsion architecture and proposing an approach to managing EVs implemented on second-generation electric vehicles. The goal of EVC1000 is to exceed the ERTRAC efficiency targets for EV2030+, demonstrating a range of 1,000 km with a maximum of 60-90 minutes of additional travel time thanks to faster recharging, while also reducing costs by at least 20%. This would also make it possible to achieve greater convenience and comfort in long-distance trips. Brembo will contribute to achieving these goals by developing and supplying a Brake By Wire system that will include brake mixing strategies and other advanced features developed with the consortium to optimise regeneration and residual resistance, thereby increasing the vehicle’s overall efficiency and range by 10% in real working conditions.

For further information: http://www.evc1000.eu/en/