The Electronic Wedge Brake will be ready to go into series production in 2010. Automobile manufacturers will then be able to make the choice for new vehicle models to switch from hydraulic braking to brake-by-wire technology.

The brake of a car converts kinetic energy of the vehicle’s own momentum into frictional heat. To do this, brakes of varying size and with a wide range of different brake pads are used.

The Electronic Wedge Brake (EWB) entirely removes hydraulics from the braking equation. The EWB system electronically transmits signals throughout the car – hence the term “brake-by-wire”. This is similar to the technology used on modern aircraft, where the commands are electronically transmitted from the cockpit to the wings (“fly-by-wire”) to activate for example the landing airbrakes. The EWB exploits the self-energizing effect of a brake wedge to generate the needed stopping force from the kinetic energy of the vehicle’s motion. In this way, the braking force builds up quickly with very little energy expenditure. The driver’s brake signal is electronically transmitted to the brake module. The intelligent control electronics in the brake actuators ensure the wheels do not lock, even in full braking. This is achieved using a highly sensitive brake regulation system that monitors the position of the brake pad 1000 times per second. This allows the best possible brake engagement to be achieved at any given time. Tests by the German technical inspection authority DEKRA document at an average a 15 percent shorter overall stopping distance on ice for the prototype-stage EWB compared to modern hydraulic brakes.

1. Brake caliper: this spans the brake disk on either side.
2. Brake disk: this absorbs the kinetic energy and becomes hot as a result of the conversion of the vehicle’s kinetic energy into friction.
3. Brake pads: the brake disk is clamped on the one side by a stationary brake pad and on the other by a moving brake pad.
4. Electric Motor: this controls the position of the moving brake pad.
5. Wedge bearing mechanism: the self-energizing effect of the wedge brake is achieved by means of a special geometric shape. The wedge bearing mechanism provides the connection between the brake caliper and the moving brake pad.

The wedge bearing mechanism is the heart of the EWB. An electric motor controls a brake pad moving over a roller bearing. The roller bearing is like a miniature switchback with valleys and peaks. The “valleys” are the position where the metal rollers are at rest. When a brake signal is received, the electric motor moves the brake pad on the roller bearing in the vehicle’s respective direction of travel. The rollers climb toward the “peaks” in the roller bearing. As soon as the brake pad touches the brake disk, it is dragged along by the circumferential force. The friction between the brake disk and the brake pads converts the kinetic energy into heat and the car is braked. The electric motor holds the brake pad on the roller bearing in exactly the position necessary to build up the required braking force. The small, high-precision electric motor needs only a minimal amount of energy to reliably brake even heavy vehicles to a standstill from top speeds. The special design of the wedge bearing mechanism also enables braking force to be effectively generated at low speeds.

The power-assisted braking system provided in the Chrysler Crossfire is befitting to the performance level of the Chrysler. Undoubtedly, brakes and brake assistant system are important factors of a racing car like Crossfire. The brakes and brake assist system in the Chrysler Crossfire are appropriate for a racing car and for others in the motor industry.

Following are some of the salient features of brake assist system used in the Chrysler Crossfire. The brake system of the crossfire has large diameter ventilated front discs and solid rear discs. The system is backed up by the highly sophisticated electronic wizards of Brake Assist System and ANS anti-lock.

The front brakes of crossfire have ventilated discs of 300 X 28 mm measure with single piston floating calipers. The rear brake discs of crossfire measures 278 X 9mm. These rear discs have opposed-piston calipers. When any set of front pads becomes worn the wear sensors fitted in the system illuminate dashboard warning light. The power assistance is provided through tandem master cylinder and single=diaphragm vacuum booster.

The Chrysler Crossfire has state of the art ABS consisting of four-channel, four wheel anti-lock of standard quality. This brake system is considered most suiting for the crossfire.

When a driver applies heavy brakes, specifically on slippery surface, the system gets activated and applies and releases the brakes at high rate. The optimum brake applies and release rate is 30 times per second. Despite the higher rate of brake applying and release the system prevents wheel lock up and helps the driver in retaining steering control.

The Brake Assist System fitted in the Chrysler Crossfire anticipates the emergency application of brake by the driver and immediately releases optimum available power boost to help the driver gain control over the car without loosing steering control. The driver may have usual human tendency of not braking hard or not breaking soon enough. The Brake Assist System overcomes these problems.

Like other features of the Chrysler Crossfire, its brakes and brake assist system is reliable. The system is of high standard quality technology and produces excellent performance even in adverse conditions.

When, in an emergency, you apply the brake pedal quickly and with force but without really further increasing brake pressure, Dynamic Brake Control (DBC) instantly builds up maximum brake pressure, bringing your BMW more quickly to a halt.

Even when the driver fails to press on the brake pedal with adequate force, DBC ensures the braking distance will be a short as possible. The DBC control unit adjusts braking pressure to suit the current speed of the vehicle and the brake’s level of wear. Furthermore, the DBC computer is networked with the vehicle’s other chassis control systems, such as Dynamic Stability Control (DSC) and the anti-lock brake system (ABS), which work together to ensure the highest levels of driving safety.
Dynamic Brake Control (DBC) supports the driver actively and reliably when braking in an emergency. By electronically monitoring the speed and pressure with which the driver applies the brake pedal, it is able to recognise an emergency braking situation - and instantly ensures that full braking power is applied to the wheels. This automatically puts the brake force into the ABS range of control.
This process ensures that the stopping distance is not lengthened unnecessarily by abrupt braking. Whether the driver applies the brakes quickly or slowly, the system responds to the driver’s actions automatically and ends brake pressure buildup via DBC.