Wired Braking

Electric Brake-by-Wire

Wired braking (Electric Wired Braking System, abbreviated as EWBS) is a highly advanced electronic control braking system that controls the brakes via electronic signals rather than traditional mechanical connections. On robot chassis, the wired braking system enables more precise and rapid braking responses, enhancing the safety and stability of the robot chassis. Additionally, by eliminating mechanical connections, it reduces the weight and complexity of the robot chassis, thereby improving its overall performance.

Wired braking converts brake signals into electrical signals, which are then processed by the motor controller to execute braking actions. The brake pedal functions similarly to a sensor, maintaining a relatively fixed position and not directly participating in the generation of braking force. A line control braking system typically includes components such as an electronic control unit (ECU), motor, brake, and various sensors.

The core difference between line control braking and traditional braking

Response speed and accuracy

Line control braking uses electrical signal transmission and electronic actuators, with a response time of <50 ms and a braking force error of <1%, supporting millimeter-level parking accuracy (e.g., warehouse robot shelf alignment deviation <5 mm); Traditional braking relies on mechanical linkage or hydraulic transmission, with a response time of approximately 100–200 ms and lower precision (error of approximately 5–10%), making it difficult to meet high-precision requirements.

System Complexity and Maintenance

Linear control braking eliminates components such as hydraulic lines and vacuum boosters, simplifying the structure and supporting intelligent diagnostics (e.g., real-time monitoring of motor temperature and signal anomaly warnings), reducing maintenance costs by 30%; Traditional braking systems require regular replacement of brake pads and replenishment of hydraulic fluid, and issues such as hydraulic leaks and mechanical wear frequently occur, resulting in higher maintenance costs.

Safety Redundancy and Energy Efficiency

Line control braking is equipped with a dual-controller + multi-power backup design, enabling emergency braking even in the event of a power outage or failure (e.g., firefighting robots rely on supercapacitor braking after a power outage) and supports energy recovery (e.g., braking energy recovery efficiency in electric vehicles improves by 20%-30%); Traditional braking relies on physical redundancy (e.g., mechanical handbrakes) and passive safety mechanisms (e.g., ABS requires pedal activation), resulting in low energy efficiency and limited functionality.

Advantages

1. Flexible Design

Eliminates hydraulic piping and mechanical linkage components, saving space and accommodating diverse structures such as hub motors and articulated brakes. Supports modular design for quick integration into industrial AGVs, robot chassis, special-purpose robot chassis, and other equipment.

2. Precise control

Response time <50ms, braking force error <1%, achieving millimeter-level parking precision (e.g., warehouse robot shelf alignment deviation <5mm), meeting high-precision operation requirements such as precise seeding in agricultural machinery and positioning detection in inspection robots. Dynamically adjusts braking torque to adapt to complex operating conditions such as high/low temperatures and slippery surfaces.

3. Intelligent Collaboration

Seamlessly integrates with navigation systems (such as lidar and SLAM) to automatically trigger emergency braking or energy recovery. In multi-robot collaboration scenarios (such as warehouse fleets), it supports synchronized braking command issuance to avoid collision risks and enhance safety.

4. Safety Redundancy

Dual controller + multi-power backup design ensures braking reliability in extreme scenarios. For example, after a firefighting robot's chassis loses power, it relies on a supercapacitor to perform emergency braking to prevent loss of control; real-time monitoring of motor temperature and communication status enables early fault warnings, reducing maintenance costs.

5. Strong Scenario Adaptability

Supports various chassis configurations (hub motors, Mecanum wheels) and can achieve stable braking in extreme environments (high temperatures, deep sea), such as special-purpose robots capable of withstanding 800°C high-temperature braking, expanding application boundaries.

Performance parameters

Serial number	Project Name	Unit	Parameter
1	Product Assembly Dimensions	mm	297219142
2	Assembly Weight	kg	6.1
3	Motor Rated Power	W	450
4	Motor Maximum Current	A	50
5	Rated Voltage	V	12
6	Main Cylinder Diameter	mm	25.4
7	Maximum Pressure	MPa	12
8	Brake Pressure Control Accuracy	MPa	0.2
9	Brake Response Delay Time	ms	<100
10	0-Maximum Brake Pressure Time	ms	<300
11	DBS Brake System Protection Rating		IP67 (excluding connectors)
12	Operating Temperature	℃	-40~105

Application Scenarios

Line control braking is suitable for high-precision, automated, and extreme environment scenarios, such as agricultural plant protection drones (precise braking on complex terrain), firefighting robots (heat resistance up to 800°C), and autonomous delivery vehicles (autonomous braking in conjunction with navigation systems). Traditional braking is more suitable for low-cost, non-intelligent applications, such as traditional industrial vehicles or agricultural machinery.

Agricultural Robots

Field operation robots must adapt to complex terrains such as muddy and sloped areas. The line control system achieves millimeter-level hovering braking through precise braking torque adjustment (response time < 50 ms), preventing slipping or crop damage.

For example, a robot chassis combining line control braking with GPS navigation can precisely execute complex terrain spraying tasks and rely on a backup power source for emergency braking in the event of a power outage, preventing runaway risks.

Manufacturing Robots

Factory AGVs rely on line control technology to achieve rapid start/stop and precise docking during high-frequency transportation, supporting a braking distance of <0.1m under loads exceeding 500kg.

Warehouse robot chassis utilize line control braking combined with laser navigation to achieve emergency stops within 0.3 seconds, preventing shelf collisions and enhancing assembly line efficiency.

Transportation and Warehouse Robots

Logistics sorting robot chassis utilizes line control, lightweight design (reducing weight by 10%-15%), and energy recovery functionality, increasing range by 15%.

Cold chain AGVs maintain stable braking at -30°C low temperatures, meeting the high-speed mobility and precise parking requirements of unmanned delivery vehicles and similar scenarios.

Inspection Robots

The substation inspection robot chassis employs an IP67-rated line-controlled braking system, offering dust and water resistance with standby power consumption <1W. Combined with infrared obstacle avoidance, it ensures stable operation in all weather conditions. 5G remote control functionality enables real-time emergency braking, ensuring safety in high-risk scenarios such as oil and gas pipelines.

Firefighting Robots

The chassis of firefighting robots must reliably brake in high-temperature and toxic environments. The line control system supports three power backups (main battery + supercapacitor + mechanical braking), withstands temperatures up to 800°C, and meets ATEX explosion-proof certification.

The chassis of firefighting robots achieves emergency braking within 10 seconds after power loss via line control braking, preventing loss of control in fire scenes.

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