FEATURE RACKS, CABINETS & ENCLOSURES
ADVANCED SEALING SOLUTION FOR MODERN BRAKING SYSTEMS
Dätwyler Mobilitydiscusses advances in sealing applications for electronics components S
ome might be tempted to argue that braking systems have changed
relatively little in the last 25 years. A combination of vacuum booster, callipers and brake fluids in place has been the standard, and therefore the requirements in terms of components have also remained consistent. Engineers were clear in the design parameters and geometries required and, although small changes have been implemented, the principles remained the same. Today, however, the technology has
evolved and will continue to do so without a doubt. The development of the electrohydraulic booster (EHB) means that not all partners along the supply chain have experience in handling the new, advanced sealing solutions that are now required. Of course, this evolution into EHB technology has largely been driven by the move towards the electrification of vehicles and the increasing amount of advanced driver assistance systems. Electric Vehicles (EVs) are projected to
account for 19% of the market by 2030 – with Full and Plug-in Hybrids accounting for 11% and Internal Combustion Engine (ICE) only and Mild Hybrid Vehicles the remaining 70% - and the EHB is a natural fit, particularly given there is no internal vacuum creation in EVs that is required for the vacuum booster. Continental’s EHB MK C1, where
Datwyler assists its partner with high- performance polymer components, is an important electrohydraulic brake system. While the vacuum booster has done a
stellar job of making global road users safer for decades, there are several advantages to the move into electrohydraulic alternatives. One is that electrohydraulic boosters are smaller and lighter, which means there is more space free within the engine compartment, while in EVs there are significant advantages where recuperation is concerned – bringing energy from the braking system back into the battery. There are also advantages in operating advanced driver assistance systems, as everything is electrically controlled. Moreover, advancements in sealing
20 MARCH 2021 | ELECTRONICS
applications enabled the use of sensors for streamlined production and tracking. The traceability of parts via smart sealings - for example with embedded sensor technology – could expedite a product recall if required, minimising the safety impact and potential reputational damage a brand could suffer. Sensors could also be used for predictive maintenance purposes in the future, along with providing solutions relating to authenticity that could combat counterfeiting and ensure parts are from the original manufacturer. Co-engineering helps to deliver the
safest possible braking systems Given the critical importance of reliable,
effective braking systems and the fundamental impact any fault could have in terms of safety, a wide range of factors must be carefully considered when developing system-critical components such as seals. With the EHB, a number of special requirements are imposed, such as abrasion resistance, cleanliness categories, and the precision of sealing solutions in
Figure 1:
Continental’s EHB MK C1
production. Among other things, the elastomer components in modern brake control systems must also be able to resist high-frequency, dynamic- mechanical loads under high pressure, and simultaneously guarantee safety over the lifetime of a vehicle. As seen in figure 2, elements such as
geometric design and functional performance optimisation can be supported by structural mechanics simulations, while virtual moulding simulations ensure best tool design, efficient production processes and top product quality. Sealing systems only achieve their optimum functionality if the designs of the sealing element and mounting space are a perfect match. Therefore successful co-engineering projects require cooperation very early in the development process, when there is still sufficient design freedom for the overall system to optimise both the sealing element and installation space. As an example for components
specifically designed according to customer requirements, the illustration shows a customer-specific O-ring seal for use in brake systems - a design perfectly matched to the installation space and operating conditions in combination with a tailor-made material makes the difference. This can even include the simulation of
Figure 2:
O-ring seal for use in brake systems
the flow behaviour of the compound - how it will behave when injected into a mould cavity, for example - and how the gating system can be designed to optimise the required tooling to ensure the most efficient production processes for manufacturing the highest quality products. Every design and processing detail can be simulated and checked ahead of time – meaning manufacturers can enter into production with the confidence required of their sealing solutions.
Datwyle
www.datwyler.com
/ ELECTRONICS
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