Brembo will again be the supplier of brake systems for the Formula 1 World Championship which will have its first round this weekend in Bahrain. Over 48 seasons, F1 racing cars using Brembo brakes have won 27 Drivers’ World Championships, 32 Constructors’ World Championships and 485 GP races.
Over the past 20 years, Brembo has revolutionized the concept of discs used in F1 cars. In the early 2000s, Brembo carbon discs had a thickness of 28 mm with a maximum of 72 holes in a single row and a diameter that exceeded of 10 mm.
Today, the diameter has increased from 278 mm to 328 mm for the front axle carbon disc and from 266 mm to 280 mm for the rear one, with a thickness of 32 mm and a number of holes between 1,000 and 1,100 at the front, while 900 holes at the rear in the most extreme setup in terms of cooling. This year, the FIA has banned drilled pads.
Braking systems in today’s cars are no longer ‘dumb’ systems that perform only as well as the driver’s actions make them perform. Thanks to the integration of electronics and sensors, the operation of brakes is managed more by a computer working at lightning speeds to optimise stopping. The driver’s role is only to apply the pressure on the pedal, signalling the need to decelerate, and even that is now enhanced by features like Brake Assist which boosts braking pressure under certain conditions.
Brembo, a leading manufacturer of braking systems which also supplies to F1 teams, has developed a new pioneering intelligent braking system which uses artificial intelligence (AI) – SENSIFY. This system integrates current Brembo product portfolio of calipers, discs and friction materials with the most advanced software, digital technology and artificial intelligence. The result is a flexible and revolutionary platform that includes software, predictive algorithms and data management to control the brake system digitally.
Braking system becomes ecosystem
With SENSIFY, the braking system is no longer simply a sum of its parts but an ecosystem, where AI and software play an active role. Data collection is leveraged to improve the driver experience and allows the system to be constantly updated.
“By introducing SENSIFY, Brembo is pushing the boundaries of what is possible with a braking system, opening up entirely new opportunities to drivers to improve their experience on the road and customize brake response to their driving style. SENSIFY gives drivers the peace of mind they are looking for,” said Daniele Schillaci, Brembo’s Chief Executive Officer.
“SENSIFY fully embraces our vision – Turning Energy into Inspiration – and it’s another significant step forward in providing cutting-edge, innovative, intelligent and sustainable solutions to the automotive industry,” he added.
SENSE + SIMPLIFY
SENSIFY comes from the merging of two words: ‘SENSE’, a faculty by which a human perceives an external signal or stimulus, and ‘SIMPLIFY’ which means simplicity in installing at best the product in harmony with the vehicle.
Digital brain manages braking
The system is intuitive, responsive and smooth, providing the driver the expected performance when needed, combined with exceptional control. It has evolved naturally from Brembo’s heritage and know-how, combining the design of the best braking components with the integration of a digital brain and sensors that control each wheel independently. The result is more precise car handling, increased performance to give the driver more confidence.
Thanks to the optimized braking action on each wheel, combined with the absence of drag between pads and discs, emissions are minimized which is an environmental benefit.
SENSIFY also opens up opportunities in car design, offering great flexibility for carmakers and simplifying integration in any platform (electric and combustion engine) – from super sport to city car and, potentially, to the latest commercial vehicles. Brembo will offer it to the industry from the beginning of 2024.
At the 2021 Russian F1 Grand Prix over the weekend, brake manufacturer Brembo celebrated a historic milestone of its vital components having a presence for the 800th Formula 1 race. This milestone comes after 46 years when the company supplied a small number of cast iron discs to Scuderia Ferrari in 1975. At that time, Brembo, which had been founded in 1961, was still a small machine shop but it would grow and remain a supplier to the sportscar maker till today.
Brake supplier for almost all F1 teams
Over the decades, Brembo has supplied brake systems to almost every F1 team, from the most prestigious to the smallest. Initially, these were standardized parts but over time, the solutions have become increasingly customized to suit the design characteristics of the different single-seaters as they evolved (especially with regulation changes). Indeed, co-design activity today involves practically all components destined for the F1 customers, from the brake calipers to the Brake-by Wire (BBW) systems, resulting in very geometrically diverse products.
Brembo has long been well known for innovations in its field. For example, in 1982, it created the first radial mount brake caliper. In 1988, when it introduced the first monobloc caliper to racing, making a caliper from a single block of aluminium seemed like a feat verging on science fiction.
However, Brembo’s engineers managed to create the program and the tooling for the internal machining operations. The result helped write the history of motoring, initially only for competition cars, but later also transferred to road cars.
From discs to whole systems
After starting with brake discs (first cast iron and then carbonfibre), Brembo began to supply other related components – calipers, pads, disc housings, brake master cylinders and the development of complex braking systems. These include by wire technology, the electronically-controlled braking system that has been used for rear braking systems of F1 cars since 2014. Like many other technologies which originated in racing cars, wire technology is today available in many cars sold to the public.
During the 800 Grands Prix, cars equipped with Brembo brakes have driven on 56 tracks worldwide, most of them in Europe. However, the number of Asian events has increased since the 1990s, having first appeared on the calendar in 1976.
Stopping power needed, whatever the race
No two races are ever identical in course, weather conditions and competitors (constructors and drivers). The longest was the 1975 Swedish GP, a 321.44-km race won by Niki Lauda won with the Ferrari 312T. Last month’s Belgian GP was the shortest – just 3 official laps that were run behind the Safety Car due to the heavy rain. However, the next shortest was the 1991 Australian Grand Prix and there was actually some racing over the 52.92 kms.
Not every car used Brembo’s brakes but of the 800 races, 455 of them were won by cars with their brakes. The driver who won the most number of times in cars with Brembo brakes is Michael Schumacher – 91 times out of the 307 races he entered. All 7 of his world titles were won in cars that had Brembo brakes.
With all its twists and turns as well as tight corners, you would think that the street circuit for the 67th Monaco Grand Prix would be the toughest on brakes among all the circuits of the 2021 Formula 1 World Championship. However, it’s not and according to Brembo technicians, the Monaco Circuit falls into the category of tracks that present an average challenge for the brakes. On a difficulty index scale of 1 to 5, it is classified as a three, exactly the same as the tracks of the last three races.
The circuit stands out for its high aerodynamic load and the considerable percentage of braking time. The calipers and brake fluid reach high temperatures and vapour lock was a common phenomenon in the past, causing the lengthening of the brake pedal action.
Brembo carbon doesn’t melt at 3,000°C
Carbon discs began to be used in Formula 1 in the 1980s, and then spread into other motorsport competitions. Indeed, no other element offers that special combination of light weight, high thermal conductivity and absence of dilation, even at 1,000°C, a distinguishing feature of Brembo’s F1 discs.
The density of carbon is 1.7 grams per cubic centimetre, compared with 7.8 grams for steel and 7.3 grams for gray cast iron. Its thermal expansion coefficient is 1/15th that of steel and 1/11th that of cast iron. The melting point of carbon is higher than 3,000°C, compared with the 1,200°C of cast iron and 1,800°C of steel.
3 metres make all the difference
Carbon discs aren’t suitable for road use, mainly because the braking system doesn’t reach the minimum operating temperatures needed, but also due to their high consumption. Some of their benefits, however, can be found in the carbon ceramic discs of which Brembo is the main worldwide manufacturer.
Carbon ceramic discs allow a saving of 5 to 6 kgs in weight compared with traditional cast iron discs. What’s more, their lifespan may even equal that of the vehicle they’re mounted on, depending on how it’s driven. But, above all, carbon ceramic guarantees a reduction of about 3 metres in the braking distance from 100 km/h to 0 km/h compared with a traditional disc.
4.6g deceleration after the tunnel
Of the 11 braking sections of the Monaco Circuit, two are classified as very demanding on the brakes, another two are of medium difficulty, and the remaining 7 are light. The hardest for the braking system is the one that comes after the tunnel (Turn 10): the cars arrive at 307 km/h and have to get down to 90 km/h within just 121 metres. To do this, the drivers brake for 2.47 seconds, applying a load of 146 kgs on the pedal and experience a deceleration force of 4.6g.
870 braking points
Despite being the shortest World Championship track at just 3.337 kms, the Monaco Circuit has 11 braking points per lap (although only one of them is particularly intense). On 4 turns, the brakes need to be used for no more than 1.1 second. The drivers use their brakes for 18.7 seconds, corresponding to 27% of the total race time.
Notwithstanding the 7 braking points per lap where the load on the pedal is less than 90 kgs), the overall load exerted by each driver from the starting line to the checkered flag is more than 62 metric tons. Only in Singapore – also a street circuit – is the figure higher than this. It also has to be said that the braking system is used about 870 times on the Monaco track, from start to finish.
The 2021 Monaco Grand Prix will start at 3 pm in Monaco/9 pm in Malaysia tonight.