Breaking New Ground: Brembo’s Innovative Brake Solution for Heavy EVs
With electric vehicles (EVs) tipping the scales at unprecedented weights, thanks largely to their hefty batteries, braking systems face new challenges. The Chevrolet Silverado EV and GMC Hummer EV, for instance, are prime examples of this trend, boasting weights upwards of 9,000 pounds and power exceeding 700 horsepower. These specifications demand innovative solutions in braking technology to manage the substantial force required to bring such mass to a halt.
Brembo, a leader in brake system engineering, has introduced Boldika, a novel brake caliper design aimed at addressing these challenges. The Boldika caliper represents a significant advancement in brake technology, combining stiffness with weight efficiency. It features a three-piece design: two aluminum halves joined by a cast-iron bridge. This design leverages Brembo’s expertise in high-performance aluminum calipers, akin to those found on sports cars like the Porsche 911 and Chevy Corvette.
Cloyd Reed, Brembo engineering supervisor, explains, “The forces that we would see from this application were exceeding the mechanical properties of aluminum, and in the compressional direction. The cast iron bridge was a solution to replace the areas where the aluminum was not sufficient.” This innovative approach allows the Boldika caliper to achieve approximately 6,296 pound-feet of braking torque, doubling the performance of Brembo’s next-best all-aluminum six-piston caliper.
The Boldika caliper weighs in at 32 pounds, significantly lighter than a fully cast-iron counterpart, which would tip the scales at about 53 pounds. The integration of the cast-iron bridge enhances torsional stiffness, resulting in improved pedal feel and a more rigid structure compared to traditional aluminum calipers. Reed notes, “Comparing stiffness, a fixed caliper like this one is going to have much less compliance than your standard sliding caliper.”
Corrosion concerns have also been addressed with advanced coatings that Brembo has developed to combat the effects of using dissimilar materials. Reed assures that these coatings meet stringent corrosion-resistant and appearance standards, effectively mitigating the risk of galvanic corrosion.
The Boldika caliper’s design process prioritized performance criteria, resulting in a robust and functional appearance. Reed describes the design as “an expression of this mechanical capability. It looks as the name is described… as bold and strong and robust.” The caliper also incorporates Brembo’s Enesys spring technology, enhancing pad life and efficiency by retracting the pad away from the rotor when not in use.
Currently, the Boldika caliper is compatible with 20-inch wheels, making it suitable for a wide range of heavy-duty EVs and off-road vehicles. The Chevrolet Silverado EV Stars and Steel special edition will be among the first to feature these cutting-edge brakes. As the demand for high-performance electric trucks grows, the Boldika caliper is poised to play a pivotal role in the evolving landscape of automotive engineering.
Original Story at www.roadandtrack.com