Innovation

Creating and innovating to improve together

Partnerships to improve the environmental impact of products

For Brembo, innovation aims to ensure increasingly cutting-edge products able not only to anticipate and meet the new needs typical of the automotive industry, but that also allow to improve the environmental impact through:

► the design of products involving the use of low-impact materials and protections;
► the reduction of GHG emissions thanks to the use of lights alloys allowing to limit braking systems weight;
► the reduction of particulates during braking, harmful for human health thanks to the use of technical materials and solutions;
► the development of smart products such as mechatronic components;
► the implementation and improvement of structured Life Cycle Assessments, both on process and material level.

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 (including the Milan Polytechnic, the University of Padua, the University of Trento, the Mario Negri Pharmacological Research Institute) and at international level (where Brembo collaborates with the Lund University and continues to partner with the Royal Institute of Technology in Stockholm). Brembo subscribes to various coordinating organisations that promote industrial research in the automobile field, including AIRI (Italian Association for Industrial Research), ATA (Technical Automobile Association), Automotive SPIN Italia, CAAR (Automotive Cluster of Aragon Region), CLEPA (European Association of Automotive Suppliers) and the Lombardy Mobility Cluster.

In 2023, Brembo also continued to implement a series of European projects, two of which funded by the National Recovery and Resilience Plan (PNRR):

nPETS (nano Particle Emissions from the Transport Sector). The project, which is expected to end in June 2024, has received funding from the European Union’s Horizon 2020 Programme in order to understand and mitigate the effects of emerging emissions of unregulated nanoparticles generated by transport on public health and the new public policies. The goal is to monitor and sample with state-of-the-art instruments the sub 100 nm emissions generated by maritime, road, rail and air transport, both in the field and in controlled laboratory environments.

Emissions will be characterised in terms of size, morphology and chemical composition linked with specific emission sources, such as engines, brakes, clutches and tyres, to increase understanding of the mechanisms underlying the adverse risks posed by the different types and sources of identified sub 100 nm particles. The effects of nanoparticles from various modes of transport and fuels, as well as from specific emission sources, will be compared paying particular attention to markers significant for carcinogenesis and inflammation.

In addition, the goal is also to complete a comprehensive public database that collects all the chemical and toxicological information obtained to provide science-based suggestions for new policies specifically related to nanoparticulates.

For further information:nPETS | Just another WordPress site (npets-project.eu)

MODALES (MOdify Drivers’ behaviour to Adapt for Lower EmissionS). Launched in 2019, the MODALES project aimed to substantially reduce air pollution from petrol and diesel vehicles. The 18 project partners worked together for 45 months to bring this vision to life and propose an approach based on users and how their behaviour affects powertrain emissions, and brake and tyre wear. The MODALES vision is to reduce air pollution from all types of vehicles on the road by encouraging the adoption of low-emission driving behaviours and correct maintenance choices. The project, which ended in May 2023, researched, developed and tested a range of innovative and complementary solutions that include the driver, on-board diagnostics, periodic inspections and retrofits. MODALES was granted a nine-month extension since part of the project consisted of driving activities for data collection.

This extension was the result of delays caused by safety measures related to the COVID-19 pandemic.

For further information: Brembo | MODALES (modales-project.eu)

LIFE RE-BREATH.RE-BREATH is an ambitious project funded by European Commission’s LIFE programme in the field of sustainable urban mobility. Launched in August 2022, this project will continue until August 2025, as part of the control and technical countermeasures for particulate emissions (PM) of public transport vehicles. In recent years, there has been a greater awareness of pollutant emissions from braking systems and specific countermeasures are currently being developed for cars, but not an equal attention was given to the public transport area. In this scenario, the RE-BREATH project has 4 objectives:

1) to measure and demonstrate the reduction of PM10 emissions, related to the braking system of buses, at stops;

2) to support national authorities in the estimation of non-exhaust emissions to be calculated in the EMEP/EEA emission inventory, according to Directive (EU) 2016/2284;

3) to demonstrate the decrease in the brake wear rate, and the consequent increase in the life of the braking system compared to the traditional system, for a more sustainable economy;

4) to model a concentration map for pollutants emitted by brake wear and a map of the exposure risk to pedestrian health, in order to support the design of a "green intervention" along bus routes in Bergamo and Bratislava and the formulation of Guidelines for local administrations.

In practice, two fleets of 10 buses each will be implemented in two European cities, Bergamo and Bratislava, located in regions where the EEA has declared the highest concentrations of PM (2.5 and 10). During 2023, the first braking system retrofitting solution was designed, developed, tested and installed on a number of buses in Bergamo and Bratislava.

The RE-BREATH braking solution stems from the AM Beyond Greenance Kit solution, adapted for bus application with a dedicated friction formulation, designed for the vehicle’s specific mission.

During 2023, the first RE-BREATH solution was validated by performing performance and wear tests that were compared with the original components of the reference application. Compared to passenger cars and light commercial vehicles, as no test procedures exist for the assessment of bus emissions, specific activities were carried out to assess emissions behaviour.

In 2024, work will continue with the development of improved solutions and the definition of optimised procedures for measuring bus emissions.

For further information: https://www.brembo.com/en/company/news/re-breath

VERA: The VERA project is aimed at developing and optimising innovative tailpipe and brake retrofit solutions to tackle the issue of emissions associated with road transport. These solutions will be mainly dedicated to the fleet of circulating vehicles, which are obsolete in a high percentage, with particular reference to those that travel high mileages within cities (taxis, delivery vans, buses). On the brake side, retrofit solutions will include innovative discs and pads to reduce brake wear and an active filtration system to capture the particles generated. Environmental and health impacts will be analysed and a cost-benefit analysis will be conducted to assess the benefits of applying the new solutions. Finally, incentive and regulatory schemes will be considered to promote the retrofitting of existing vehicles. The project was launched in December 2022, and an analysis was conducted during 2023 to assess the global size of the retrofit market, examine existing retrofit solutions that aim to reduce exhaust or brake emissions, and finally highlight market gaps to guide the project's technical developments. In addition, the test procedures to be used for the validation of both exhaust and brake emissions have been defined, along with the methods used to perform the chemical and toxicological analysis of the emissions generated. Current activities focus on measuring baseline emissions and setting emission reduction targets. Retrofit solutions for the tailpipes and brakes are being developed, with the aim of carrying out validation tests scheduled for the end of 2024.

EMPOWER: The project stems from the European Commission Horizon Europe framework programme through the 2Zero Partnership and the call to develop a modular powertrain for heavy trucks, adaptable to different mission needs. It focuses on a modular vehicle for the IVECO platform (VECTO 9), designed for fuel cell electric vehicles (FCEVs) and battery electric vehicles (BEVs) for long distances and regional distribution. EMPOWER aims to reduce costs and improve energy efficiency, contributing to a total cost of ownership (TCO) equal to 2020 diesel trucks. The project involves the creation of digital models of the demonstrator vehicles and the operational demonstration of at least two prototypes in real mission conditions.

For further information: Home - PROJECT EMPOWER

METABRAKE:Over a period of 36 months, the MODALES consortium will monitor the variability of driving behaviour and recognise typical driving patterns and practices. Subsequently, based on this knowledge, MODALES will establish the link between real-world powertrain emissions and driving behaviour with measurement campaigns using portable emission measurement systems (PEMS) and laboratory tests. In addition, laboratory measurements for brake and tyre emissions will be conducted. In a second phase, MODALES will create low-emission driving training courses, which will be taught and validated in pilot exercises. Knowledge, experience and practices will be shared with other cities in China and Latin America. Aspects related to poor maintenance and tampering will be analysed with a fleet of cars whose emissions are intentionally affected by lack of maintenance and/or tampering, and MODALES will observe whether current OBDs and inspections are able to detect them. Finally, an assessment of the prospects and potential impacts of retrofits for light and heavy-duty road vehicles and non-road mobile machinery (NRMM) will be carried out, including the promotion of their application in selected pilot cities with significant pollution problems.

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

The two projects benefitting from the National Recovery and Resilience Plan (NRRP) funding are illustrated here below:

National Centre for Sustainable Mobility – MOST: In the next decades, the main challenge for tomorrow’s mobility will be to dramatically reduce emissions by reaching the maximum possible level of sustainability at global level. The MOST will be fully interconnected with the NextGenerationEU and, specifically, with the implementation of the National Recovery and Resilience Plan by Italy, which will encourage the spread of low and zero emission vehicles and renewable and low-carbon fuels for road, water, air and rail transport with specific measures on several levels: investing in green technologies, spreading greener vehicles and public transport and promoting equal opportunities nationwide, given the major geographical discrepancies existing in Italy.

Brembo S.p.A. is a founding partner of MOST with 25 Universities and Research Institutes, which in the three-year period 2023-2025, will be able to count on a structured staff of 696 researchers, including 574 newly-hired personnel and an investment capacity of €378 million. The MOST will provide a pivotal opportunity for the national scientific, industrial and economic system, addressing current and future scientific and social challenges related to the Sustainable Mobility paradigm. The ambition is to build a competent Italian leadership, strongly integrated into the local areas and local businesses, able to support the future development towards an inclusive, sustainable and decarbonised mobility.

“Made in Italy Circular and Sustainable”: the Brembo’s ambitious vision is to enable the design and production of Made in Italy closed-loop, self-sufficient, self-regenerative, reliable, safe and energy-aware products and services. The proposed expanded partnership will conduct the fundamental research underpinning the achievement of this vision. It thus proposes eight thematic areas on which to focus to address the challenges currently faced by our design, production, and consumption models, as well as the end-of-life of materials, products, production technologies and processes needed to move to greener, more circular pathways and models.

 Product innovation

The automotive market has embarked on one of the most important revolutions in its history, which could radically alter the concept of the car and its use. A profound transition as a mark of the new electric drive systems, autonomous driving and integration of different vehicle systems, where the car is increasingly more able to carry out independent actions and provide assistance to the driver in real time. In particular, over the next few years a sharp increase is expected in cars fitted with hybrid and electric motors in response to the new European regulations.

This is a revolution for which Brembo has been preparing for almost twenty years, due to an ever greater focus and investment spending on electric braking system and mechatronic product research and development, through the development of competences applied to systems such as Electric Parking Brake and SENSIFY™.

In all sectors of operation, each product is developed in accordance with the Group's vision and the following three guidelines: “low emission”, “high performance” and “best driving experience”. These products will thus be aimed at reducing the environmental impact, improving the performance and ensuring the best user experience.

The main example of the implementation of these three guidelines is SENSIFY™, officially presented in 2021 and representing the latest development in the research work on the braking system with by-wire technology. SENSIFY™ is an intelligent braking system that integrates the most advanced software based on artificial intelligence with the Company’s brake components. SENSIFY™ combines the current Brembo product portfolio of calipers, discs and friction materials with digital technology and artificial intelligence to create a flexible and revolutionary platform that includes software, predictive algorithms and data management to control the brake system digitally.

With SENSIFY™ the braking system is no longer simply a sum of its parts but an ecosystem, where artificial intelligence and software play an active role. Data collection is leveraged to improve the driver experience and allows the system to be constantly updated.

Its application development and industrialisation phases are currently ongoing, whereas launch into production will take place in 2025. Moreover, in keeping with Brembo’s strategic priorities, its promotional phase is underway for both Group clients and new players entering the electric vehicles market.

In addition to product quality, Brembo is also particularly committed to adapting to the tightest development times imposed by the market and accordingly is dedicating a large number of resources to perfecting advanced simulation methodologies in which artificial intelligence and virtual reality are increasingly applied. The Research and Development Centres operating in Italy, Poland, Denmark, Spain, North America, China and India play a key role in these developments.

At EICMA 2023, Brembo presented the new Hypure brake caliper, designed for high-performance motorbikes. The new Original Equipment brake caliper, that boasts unparalleled performance and a distinctive asymmetrical design, allows a 10% weight reduction compared to the reference caliper for the same application, making it the lightest component in its class.

The latest evolution of the Brembo GP4 family was also presented during the event: the GP4-MotoGP brake caliper, designed and developed to equip the most powerful latest-generation racing motorbikes. Brembo’s GP4-MotoGP is a brake caliper born from the racetrack for the road as it encompasses all the latest technologies, processes and the most innovative materials together with the know-how acquired by Brembo in its many years of experience in the racing world. Particular attention has been paid to the introduction of ventilation fins on the outer body and the new racing pistons, both characteristics which improve the braking system’s thermal exchange, contributing to cooling it.

EICMA also saw the presentation of the first high-performance braking system consisting of caliper and brake disc developed for SSVs (Side-by-Side Vehicles). Greatly increasing braking performance, the 4-piston SSV caliper provides driver confidence and easy maintenance, in addition to a weight reduction compared to the original parts. Designed to ensure robustness and safety, the Brembo SSV caliper combines the Group’s experience in road applications with its history in motorsport.

Finally, Brembo presented the new 16RCS Corsa Corta RR. The design of this new clutch master cylinder incorporates all the style features already adopted in the company’s RCS corsa corta RR family of products. That was also the reason why the brake master cylinder from the same range won the prestigious Red Dot design award in 2023. Developed especially for widely popular high-performance motorbikes, the new RCS corsa corta RR clutch master cylinder has a 16mm floating piston diameter to improve the feel and application effort on high volume engines.

The idle stroke setting is already set to minimum – like the master cylinders used in competitions – for greater precision in use.

Brembo has been recognised as "Top Innovator" in the "Green" category by the European Association of Automotive Component Manufacturers, thanks to its Brembo Beyond Greenance kit. This kit offers a more sustainable solution for light commercial vehicles, by reducing particulate emissions up to 83% in PM10 and 80% in PM2.5, ensuring savings over the life of the vehicle. The Greenance Kit, presented at Automechanika and now available in various light commercial vehicle models, ensures an increased durability of the brake discs, extended mileage and lower environmental impact.

OCTYMA is the latest addition to the Brembo stable, an 8-piston aluminum brake caliper that blends style, design and identity with functionality, performance and cutting-edge content. OCTYMA, from the Latin “octo”, indicates the number of pistons, but a figure of eight also symbolises infinity and a constant flow of energy and power that represents balance and harmony.

OCTYMA recalls the optimization of pad pressure distribution, made possible by the new cross layout for the pistons. This characteristic is highlighted in the caliper body design to convey the innovation and unique quality of the new braking system. OCTYMA is power and style.

Moving overseas, Brembo took part in AAPEX in the United States, where it presented the world premiere of the new Xtra brake pads for the aftermarket; while SEMA and PRI were the occasions to talk about the new CCM-R Plus brake disc for racing and supersport applications.