ZF Highlights Brake By Wire System In Silverado, Sierra28
As high-efficiency engines fail to produce enough vacuum pressure to generate the ideal amount of stopping power, German supplier ZF has introduced its answer. The 2019 Chevrolet Silverado and 2019 GMC Sierra are some of the first vehicles to benefit.
It’s called Integrated Brake Control (IBC) and it replaces the vacuum booster and associated cables, sensors, switches, electronic controllers and vacuum pumps. According to a Wards Auto report last Thursday, the system works with a pedal simulator. Fluid in the master cylinder is displaced to an accumulator and the system measures pedal travel. A motor with a ball screw then pushes a plunger to deliver hydraulic fluid to the wheels.
According to ZF, the motor can do all of this and generate brake pressure measuring 1 g in just 150 milliseconds. Automatic emergency braking is also quicker with IBC; the system can deploy full stopping force in a quarter of the time compared to a traditional braking setup.
Another benefit of the system is the ability to incorporate the electronic stability control in the one module. Thus, the 2019 Silverado and 2019 Sierra feature one package for the braking and stability control system. It also saves 11 pounds over traditional components.
ZF added it has contracts in place to provide the IBC system to eight vehicle platforms between multiple companies by 2020. Several more automakers plan to tap ZF for the technology, and there’s a very good chance we’ll see IBC also make its way to the next-generation Chevrolet Tahoe, Suburban, GMC Yukon and Cadillac Escalade. The SUVs will share the new full-size pickups’ T1 platform.
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Having driven a couple of these trucks, the brakes are much more responsive over the current K2 trucks and older. Plus, the IBC works with those new 4 piston fixed front calipers they switched to, and the two pieces combined deliver some really nice braking.
This sounds really cool and it seems to make a lot of sense. However even more so then electronic steering, a system like this needs to be damn near 100% stone dead reliable. Don’t get me wrong, Hydra-boosts and vacuum boosts do go out but it is extremely rare, even after 100’s of thousands of miles and many years or service. Very exciting tech but scary at the same time lol
Dont panic. They do have push through. So if electronic assist is lost you still have manual backup.
Would be nice as an aftermarket upgrade to replace the older units.
If you lose engine and battery power, do you still retain manual brakes? This article doesn’t make it clear whether or not the brake pedal is physically attached to any sort of backup master cylinder directly connected to the brake’s hydraulic lines.
The image of the assembly at the beginning of the article shows a forked rod/piston input on aft side. Appears assembly may mount in conventional location with that forked rod as the manual reversion.
You could be right. Or, perhaps that is just the brake pedal position sensor and feedback device.
Yes, this takes place of vacuum/hydraulic brake booster. If the battery went dead, it would feel the same way as if your current car died while driving.
Yes, Bert. That actually raises a good point. However, rare for both battery and engine to die at same time. With the advent of electric steering and brakes, one would still maintain near normal steering and brake control during engine failure. And, hopefully reducing a portion of that panicky moment In the middle lane of a busy highway. So, in conclusion, avoid boosting a failed (as opposed to a drained) battery simply to drive somewhere unless it’s an emergency or to get to a service center.
Not true, when your alternator dies, so does the battery, so does the engine and it happens more often than you think. I’m a mechanic (certified)
Also, the fuse could blow to the thing, a wire could break, or it could simply malfunction. Point is, there needs to be a mechanical backup.
Hahahaha…certified???…hahahaha… I don’t think so. Any alternator that dies will have a BATTERY symbol illuminated on the instrument panel, indicating an electrical problem, typically a failed alternator, assuming anyone’s paying attention to it. 3 failed alternators in 20 years, been able to drive, traffic & highway, 45 minutes average, in daylight, each time, without the vehicle dying, to get replacements. All fuel injected vehicles. Not only that, on a vehicle with a serviceable alternator, once an engine is started, it can remain running without the battery connected. Done it, several times. As for MY qualifications, how about federally licensed aircraft maintenance engineer (AME), endorsed on Boeing 737 NG’s, 757, 767, 777, Airbus A310 through A330 and all things McDonnell Douglas. So I know a thing or 2 about alternators AND generators of every design and type. I also work on my own (and many other friends) trucks, cars, snowmobiles, dirt bikes, lawn tractors, etc. etc.
I wouldn’t advise removing your battery while your engine is running though, as you will get an initial spike in voltage possibly frying everything. Beyond that, the battery acts as a giant capacitor shorting any AC, spikes, transients, or ripple to ground and smoothing out the power. An alternator doesn’t provide a perfect direct current and with everything else in the circuit like relays and various electric motors, something has to keep things smooth. That is what a battery is for.
Loving the new technology with the braking . Things such as this will come into play when I purchase a new pickup.
I love how people always bring up the worst possible case in order to say this is something I wouldn’t want on my vehicle!
Guys embrace new technology! Dont be scared of it!
When my families life is on the line, I’m thinking of every bad situation possible.
Interesting…. Thanks for posting this, Sean.
Isn’t this the same company that just did a reall on a bunch of vehicles for not properly heat treating their brake pistons?
Oh good Lord . The drive by wire throttle body was horrible enough . Now the brakes ? A disaster waiting to happen .
Its got mechanical backup.
New technology? Mercedes had this in 2002 SL500 and 2003 E class.
Yes just what we need more expensive luxury pickup trucks to haul groceries around the city with. Technology costs money I think it’s getting out of hand. Keep buying overpriced plastic junk and throw your money out the window while your driving.
I am sure we can set you up with the horse and buggy, low and slow. And a good feed plan at the local feed store. Seriously, and while we’re at it, loses the dash cam and bring back window cranks???
I normally buy older used vehicles for myself and do all maintenance and repairs. I think I would steer clear of any vehicles with this system because of the cost of replacing this unit if it fails. At least until the technology proves its reliability for instance like multiport fuel injection has done over carburation. Besides, I hate abs and traction control with a passion .
I own a 2019 Silverado 1500, bought on 12/19/18, today while attempting to come to a stop at an intersection, the brake pedal became very spongy and I rolled into the intersection before I was able to fully compress the pedal almost to the floor, any owner of this truck know’s how responsive the brake system is and it only takes a slight touch to come to a full quick stop. This was not the case today, I drove it back to my shop and the entire 10 min. drive it repeated this failure. I got back to my shop and called chevy and they told me to bring it in to have it looked at. On the way to the dealership, I could not get it to reproduce this behavior, I hope they can find the issue, as I’m not sure I could trust the truck to not do this again.
You sound like a pilot that says he has a problem that cant be duplicated by a mechanic! The next time it happens ( if your so worried about it) drive the truck straight to the dealer and have a mechanic go around the block with you so you can show him.
Nothing is more frustrating than trying to fix a problem that doesn’t exist
Doesnt exist??? Dozens of people are having Brake-by-wire failures on these trucks now!! One guy rear-ended a car seconds after the warning message appeared in the dash.
Have a 2019 and the safety features do NOT work. My brakes completely failed without any warning, lights, or errors. I had virtually no brakes and fortunate got it stopped before rolling into a 4 lane. Diagnosed as a faulty master cylinder. GM has no parts. Been without my vehicle well over 70 days.