BrakeMaster: new hydraulic brake system for the next vehicle generation

At this year’s InnoTrans, HANNING & KAHL presented BrakeMaster, a new hydraulic brake system. The development follows a consistently modular system approach, with the mechanical and electronic components conceived and developed together from the outset. The result is a well-coordinated, integrated system that combines safety, energy efficiency and ease of maintenance and is designed for long-term use. By Berthold Fingerhut

One system, three key components

BrakeMaster comprises three central subsystems: the control unit ECU serving as the electrical interface to the vehicle, the hydraulic unit HCU generating the necessary brake pressure and the brake caliper HPC converting it into mechanical braking torque.

Thanks to the modular design, the individual components can be flexibly adapted to different vehicle architectures and installation conditions. At the same time, the generic system approach provides a common technical foundation for various projects and markets. The architecture is designed to ensure long-term availability for up to 30 years.

Safety and security from the outset

Current standards as well as the “Safety & Security by Design” principle were taken into account when developing BrakeMaster. The system supports safety functions up to SIL 2 and provides protection against tampering and incorrect wiring. The requirements of the Cyber Resilience Act (CRA) have also been incorporated into the system architecture.

BrakeMaster thus combines traditional functional safety with modern requirements for the digital security of rail vehicles.

ECU: the brake system’s digital interface

With the new control unit of the ECU series, HANNING & KAHL has introduced an upgrade to the existing HEYxPxG and HEY-C controllers. Supplied as a pre-assembled unit on a base plate, the ECU simplifies procurement, integration and commissioning.

The modular system enables flexible adaptation to different vehicle architectures. Ethernet, CAN and MVB are supported, along with conventional hard-wired systems. Decentralised placement of the modules is also possible, reducing the need for hard-wired connections.

An integrated web interface enables direct access to the controller, without additional software. Role-based user permissions, two-factor authentication and logging support current digital security requirements.

The ECU also plays a key role in diagnostics and condition monitoring. Advanced sensor technology and data storage provide information on the system condition and lay the groundwork for condition-based maintenance. Relevant data can also be accessed remotely via ConnAct®.

HCU: compact, efficient and flexible

The hydraulic unit of the HCU series adds the hydraulic component to the system. It is also based on a modular system and enables different requirements to be implemented with a generic manifold for each size.

The compact and lightweight housing requires less installation space. At the same time, the optimised hydraulic design and modern valve technology reduce system complexity and energy consumption.

Demand-based control of the motor and valves, combined with intelligent holding current reduction, further helps to improve energy efficiency and reduce the system’s thermal load.

Ease of maintenance and installation were also considered during development. Externally accessible pressure relief valves, a split housing design and flexible cable routing facilitate access and adjustment. Thanks to the mirror-image configuration, the HCU can also be adapted to different installation conditions.

A high-performance filtration system protects the hydraulic oil against particle contamination to support reliable operation of the brake calipers.

HPC: precise braking force and ease of maintenance

The brake caliper of the HPC series is an important part of the system. It combines proven mechanical principles with modern design features. The disc spring assembly and the tandem piston configuration for the service and auxiliary release circuits ensure precise and reliable braking force.

The brake caliper is designed for robust operating conditions to ensure a long service life. A high level of corrosion protection and a high IP protection class as well as the parallel guidance of the brake pads help to ensure even wear and minimise maintenance requirements.

The HPC also relies on simple solutions for manual operation: with the integrated quick auxiliary release device, the clamping force can be easily released via a Bowden cable. Following release, the hydraulic system automatically restores normal operating conditions. The modular bolted design also enables project-specific adaptations and simplifies servicing.

Future-ready brake technology

HANNING & KAHL is taking an integrated approach with BrakeMaster: the mechanical, hydraulic and electronic components are not considered in isolation, but are instead developed as part of a well-coordinated overall system. The modular design offers flexibility for different vehicle concepts, while digital features open up new diagnostics and predictive maintenance opportunities.

BrakeMaster combines the requirements of a modern brake system with the need for long-term availability, safety and ease of servicing – providing the basis for the next generation of hydraulic brake technology for rail vehicles.