In-Drive Brake: Mercedes-Benz's new, low-maintenance braking technology for electric cars

E-mobility Mercedes develops virtually maintenance-free brakes

2024-12-04 Source: sp-x | Translated by AI 2 min Reading Time

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The "In-Drive Brake" from Mercedes-Benz is designed to brake electric cars for the entire life of the car and is extremely low-maintenance and low-wear. It will probably be a few years before it is ready for series production.

The new In-Drive Brake in detail: the complete package is docked onto the engine-transmission unit.(Image: Mercedes-Benz AG) — The new In-Drive Brake in detail: the complete package is docked onto the engine-transmission unit.
(Image: Mercedes-Benz AG)

Modern electric cars perform up to 98 percent of all deceleration actions via recuperation. But when things get tight, the mechanical brakes have to be as powerful as ever, especially on a heavy electric vehicle. Is this only possible with the classic layout with four discs including brake callipers and pads in the rim? Or can the conflicting goals of safety, weight and operating costs be resolved differently? The developers at Mercedes-Benz have come up with a solution that may seem surprising at first glance: They push the brakes forcefully inwards.

The brake forms a unit with the drive train on the rear and/or front axle.(Image: Mercedes-Benz AG) — The brake forms a unit with the drive train on the rear and/or front axle.
(Image: Mercedes-Benz AG)

For this purpose, the mechanical stoppers are integrated into the closed electric motor/gearbox unit on the left and right. According to the technicians, finding the necessary installation space is not a problem. In vehicles without a front engine, the brakes are also located at the front in a corresponding housing almost in the middle of the axle. According to the current state of development, Mercedes is expecting a lot from the new In-Drive Brake. The brake systems should be extremely low-wear and practically maintenance-free.

The aim of the developers is for the pads and discs to survive the 15-year life cycle of an electric car without needing to be replaced - with the corresponding benefits in terms of operating costs. The problem of brake wear would also be solved. This is because the new system is closed and the brake dust ends up in a generously dimensioned collection container in the drive block.

Rust on the brake discs, an acute issue with electric cars due to their chronic underload, would no longer stand a chance with the in-drive brakes. And annoying braking noises would be a thing of the past. According to Mercedes, the stability of the water-cooled deceleration systems is beyond reproach: "The braking effect is easy to control and does not diminish even under high loads."

Less weight, more comfort

And the engineers have identified another advantage: without brakes, the wheel/tyre combinations are significantly lighter, which reduces the unsprung masses on the vehicle and improves ride comfort. In addition, the rim design can be rethought. Because cooling openings for the brake system no longer need to be installed, completely closed rims are also possible. This in turn improves aerodynamics.

The question remains: when can we expect market maturity and the start of series production? According to Mercedes, they are making good progress. But development will still take a few years.

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