How Brembo brings AI-powered 4-wheel independent braking to masses

DAIKOJIMACHI, Japan — Brembo, the premium Italian brake-maker known for outfitting Ferrari and Lamborghini, plans to "democratize" high-performance, all-electric brake systems for mass-market brands with a new technology that harnesses the power of artificial intelligence.

The new setup, called Sensify, enables precise vehicle control by constantly applying different brake force to each of the four wheels independently. Brembo calls the development as revolutionary as the advent of antilock braking systems and wants to start production in 2025.

"Brembo is associated with high-end sports cars," Dino Maggioni, COO of Brembo's Global Business Unit, said during a demonstration at a proving ground here north of Tokyo last month.

"But with Sensify, we are presenting a solution that will democratize four-wheel independence," he said. "It's a revolutionary development in braking. It's opening a new era."

Brembo hopes Sensify sets an industry benchmark for next-generation braking, just as ABS did after it debuted decades ago and eventually became today's de facto must-have.

"Competition will be made on this standard in the future," Maggioni said. "We are very early movers, setting the new rules."

Sensify combines Brembo's portfolio of calipers, discs and friction materials with digital technology and artificial intelligence to create a flexible network that includes software, predictive algorithms and data management to control the brake system digitally.

Today's brake systems use hydraulic calipers that apply the same force to each wheel. When a wheel loses grip, the ABS opens that caliper to regain grip and then braking is resumed.

In Sensify, two control units, one for the front axle and one for the real axle, apply the desired braking force to each individual wheel. The braking process uses electromechanical actuators that have a faster reaction time than traditional hydraulic systems.

"It's independent four-wheel braking in all conditions in all times," Chief R&D Officer Alessandro Ciotti said. "It's designed to be scalable and fit-able to all major segments."

Brembo said the system can be used in a dry setup without hydraulic fluid for a completely electric system in anything from compact cars to large sedans and SUVs. It can also leverage a hydraulic system connected to the electronic backbone for added oomph in sports cars. And it can be deployed in vans, trucks and commercial vehicles, Brembo said.

Brembo is in talks with manufacturers to supply Sensify, executives said, though they declined to offer names. Top brass were in Japan to pitch the system to automakers here.

Nissan, Mazda and Toyota vehicles were among those depicted in a Brembo presentation touting the widespread, mass-market applicability of the upcoming Sensify system.

The supplier is still working to miniaturize the system and reduce costs before 2025. In particular, engineers intend to downsize the actuators and the central processing units.

Brembo predicts the new system will have special appeal in the age of electric vehicles because Sensify will make it easier for carmakers to differentiate the ride and handling of their vehicles through a software-controlled braking system that can be tailored to a brand's persona.

"One of the challenges for car manufacturers with EVs is the issue of personalization of the car," said Fabio Casablanca, general manager of Brembo Japan. "With Sensify, the OEM has a greater level of personalization of the braking system, of the performance and of the driving experience."

Brembo said delivering finely tuned braking to each wheel brings many advantages.

• Better stability: It prevents temporary losses of grip during ABS application.
• Better durability: When a single brake disc or caliper begins to overheat, braking force is decreased there and increased on the other three wheels.
• Lower total cost of ownership: The two control units exchange data on the status of the four calipers, applying the appropriate braking force to assure pressure is applied evenly, reducing wear on the caliper pads.
• Lower environmental impact: The software-controlled, electronic system reduces or eliminates pad fiction and the need for hydraulic fluids, thereby reducing emissions, particulate matter and brake drag that dents fuel economy.

Finally, the Sensify layout delivers safety benefits because it clears much of the braking hardware normally clustered in front of the driver, such as the master cylinder and electronic stability program. By moving smart actuators and brake control units to the wheels and axle areas, Brembo reckons it has removed 13 pounds of mass from the driver's crumple zone.