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Global market review of electronic braking systems - forecasts to 2010 2004 edition

by Matthew Beecham

October 2004

Published by

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This publication, nor any part of it, may be copied, reproduced, stored in a

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Page iii

Table of contents

Single-user licence edition............................................................................................................. ii Copyright statement .................................................................................................................. ii

Table of contents ........................................................................................................................... iii

List of tables .................................................................................................................................... v

List of figures ................................................................................................................................. vi

Acknowledgements ...................................................................................................................... vii

just-auto.com’s research portfolio .............................................................................................viii Incredible ROI for your budget - single and multi-user licences .............................................viii

just-auto.com membership ........................................................................................................... ix

Chapter 1 Introduction.................................................................................................................... 1 Throttling back on brake-by-wire...............................................................................................1 Report coverage........................................................................................................................ 2

Chapter 2 The market ..................................................................................................................... 3 Market players........................................................................................................................... 3 Market shares - global............................................................................................................... 4 Market shares - Europe............................................................................................................. 7 Market shares - North America ................................................................................................. 8 Market shares - Japan .............................................................................................................. 9 Market forecasts - electronic braking systems.......................................................................... 9 Market forecasts - anti-lock braking systems.......................................................................... 11 Market forecasts - electronic stability programme .................................................................. 13 Market forecasts - electric parking brake ................................................................................ 16

Chapter 3 Technical review.......................................................................................................... 19 Developments in braking systems .......................................................................................... 19 Brake pad developments ........................................................................................................ 20 Reducing brake squeal ........................................................................................................... 20 Fully automatic braking ........................................................................................................... 21 Continental’s MK25e............................................................................................................... 21 Brake-by-wire systems............................................................................................................ 22 Advantages of EHB................................................................................................................. 23 Bosch’s ESP program............................................................................................................. 23

Chapter 4 Manufacturers.............................................................................................................. 25 Advics...................................................................................................................................... 25 Robert Bosch GmbH............................................................................................................... 26


Page iv

Continental Teves ................................................................................................................... 28 Delphi Corporation .................................................................................................................. 31 TRW Automotive ..................................................................................................................... 31

Appendix 1 Glossary .................................................................................................................... 34

Online sources of information ..................................................................................................... 35 Free email newsletters ............................................................................................................ 35 Other research reports ............................................................................................................ 35 Global news and feature articles............................................................................................. 35 Search the web ....................................................................................................................... 35

Your feedback ............................................................................................................................... 36


Page v

List of tables

Table 1: Electronic brake system manufacturers: summary of business activities ........................... 3

Table 2: Electronic braking system equipment fitment rates in passenger cars and light trucks,

Western Europe, North America, Japan, 2000 - 2010.............................................. 10

Table 3: Electronic braking system equipment fitment volume in passenger cars and light trucks,


Table 4: Market value of electronic braking system equipment in passenger cars and light trucks,


Table 5: ABS equipment fitment rates in passenger cars and light trucks, Western Europe, North

America, Japan, 2000 - 2010 ................................................................................... 12

Table 6: ABS equipment fitment volume in passenger cars and light trucks, Western Europe, North

America, Japan, 2000 - 2010 ................................................................................... 12

Table 7: Market value of ABS equipment in passenger cars and light trucks, Western Europe,

North America, Japan, 2000 - 2010.......................................................................... 13

Table 8: ESP equipment fitment rates in passenger cars and light trucks, Western Europe, North

America, Japan, 2000 - 2010 ................................................................................... 15

Table 9: ESP equipment fitment volume in passenger cars and light trucks, Western Europe, North

America, Japan, 2000 - 2010 ................................................................................... 16

Table 10: Market value of ESP equipment in passenger cars and light trucks, Western Europe,

North America, Japan, 2000 - 2010.......................................................................... 16

Table 11: Electric parking brake equipment fitment rates in passenger cars and light trucks,

Western Europe and Japan, 2000 - 2010................................................................. 18

Table 12: Electric parking brake equipment fitment volume in passenger cars and light trucks,

Western Europe and Japan, 2000 - 2010................................................................. 18

Table 13: Market value of electric parking brake equipment in passenger cars and light trucks,

Western Europe Japan, 2000 - 2010........................................................................ 18

Table 14: Continental Automotive Systems’ brake manufacturing locations, and products made .29


Page vi

List of figures

Figure 1: Global market shares for electronic braking systems, 2003 .............................................. 5

Figure 2: Global market shares for anti-locking brake systems, 2003 .............................................. 7

Figure 3: European market for ESP systems, 2003.......................................................................... 8

Figure 4: Delphi’s Maximum Torque Brake..................................................................................... 19


Page vii

Acknowledgements

The publishers would especially like to thank Bosch, Delphi and TRW for their

assistance in compiling this report.


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Chapter 1 Introduction Page 1

Chapter 1 Introduction

Throttling back on brake-by-wire

Demands for more performance with minimal cost or weight penalties are

pressurising brake system designers to come up with new ideas. New

materials such as aluminium or ceramic discs have been closely studied, as

have the friction materials themselves, plus better caliper designs, and four-pot

calipers are now relatively commonplace. However, the main improvements in

braking in recent years have come from electronic control, firstly ABS (anti-

locking braking system), then EBA (emergency braking assistance). Technical

advances into the brake-by-wire arena, such as electro-hydraulic braking

(EHB) and electro-mechanical braking (EMB) are still in the early stages. It is

said that brake-by-wire will lead to more effective and safer braking,

eliminating bulky hydraulic technology, releasing space and reducing

maintenance.

The development push toward brake-by-wire by manufacturers has slowed

following the frustration by Bosch in rolling out its EHB solution. Bosch’s

concept for brake-by-wire, is the electro-hydraulic brake SBC (Sensotronic

Brake Control). The new Mercedes-Benz SL was the world's first production

car to use the electro-hydraulic brake-by-wire system. Developed by Bosch,

the system offers faster and more precise braking and allows functions such

as ABS and ESP to be built in. Despite the technical merits of the SBC system,

Bosch has not yet found other customers willing to use this technology.

Unlike Bosch, Delphi put its faith in EMB four years ago. Delphi’s EMB

replaces the conventional hydraulic braking system with electrically driven

actuators. Each EMB caliper integrates an electric motor, a gear reduction

stage and a ball screw into a package that is slightly larger than a conventional

caliper. A central processor provides control and a pedal feel emulator

provides driver feedback. An integrated parking brake operates on the rear

wheels. Delphi says the units can be supplied as ‘plug and play’ modules,

ready to bolt onto the vehicle.

In this second edition reviewing the key market drivers for electronic braking

systems, we consider these developments along with providing broader


Chapter 1 Introduction Page 2

market analysis, including installation, volume and market value forecasts of

anti-locking braking systems (ABS) and electronic stability programmes (ESP).

While ABS prevents the wheels from locking during braking, and Traction

Control System (TCS) stops the wheels from spinning on acceleration, ESP

goes one step beyond the functions of both these systems. It reduces, in

addition, the risk of skidding in all driving situations. ESP permanently monitors

the vehicle’s motion and compares it with the driver’s wishes (steering angle).

If the position of the steering wheel deviates from the actual direction in which

the vehicle is moving, this means that there is a risk of skidding. In this

situation ESP comes into play: By applying the brakes on individual wheels in

carefully measured doses so that the vehicle is stabilised and held more safely

on course.

Overall, we estimate that the Western European electronic braking system

market was worth about €3bn last year. Given the recent mandatory fitment of

ABS - from 1st July 2004, every new car produced for the West European

market is fitted with ABS - there is now pressure to fit ESP as standard. We

estimate that around one-third of newly registered cars in West Europe were

fitted with ESP in 2003. Installation rates could reach 45% by 2010. In North

America, we predict a booming market for ESP with fitment rates of just 6% in

2003 lifting to 16% by the end of the decade. The main reason for the disparity

in fitment rates of ESP in Western Europe and North America is the greater

competition between ESP suppliers in Europe, which has led to lower prices,

making it feasible to offer the technology on lower-end vehicles.

Report coverage

Chapter two sets out our forecast for product trends, fitment levels and market

wholesale values for ABS, ESP, electric parking brake and electronic braking

systems in Western Europe, North America and Japan through 2010. It also

identifies some shares for those supplying both ABS and ESP markets. All in

all, this report provides no less than 33 market volume and value forecasts by

region and technology through 2010. Chapter three sets out some recent

innovations and the forces driving those technical advances. Chapter four provides brief profiles of the major electronic brake system manufacturers,

namely Advics, Bosch, Continental Teves, Delphi and TRW.


Chapter 2 The marke Page 3

Chapter 2 The market

Market players

Following some intensive restructuring activity during the 1990s in the US and

Europe, opportunities for further consolidation in the light vehicle electronic

braking systems segment have largely dried up, with Bosch, Continental

Teves, Advics and TRW - dominating the market. Delphi is the 5th largest

supplier of electronic braking systems, enjoying 6% global market share.

Table 1: Electronic brake system manufacturers: summary of business activities

Manufacturer Electronic brake systems business activity

Advics

Bosch

Continental Teves

TRW Automotive

Source: just-auto.com

Market shares - global

The big four brake producers - Bosch, Continental Teves, Advics and TRW -

currently account for 90% of the global market.



Figure 1: Global market shares for electronic braking systems, 2003 (% of volume)

Manufacturer/Supplier 2003

Bosch

Continental Teves

TRW

Advics

Delphi

Others

Total 100

Source: just-auto.com

The two German groups, Robert Bosch and Continental still dominate the

global ABS market, collectively accounting for nearly 75% of the market.

ABS has been a spectacular success for Bosch since its launch 25 years ago.

The company produces about every third system worldwide (every second in

Europe) and recently celebrated the manufacture of its 100 millionth unit.

Further growth in Europe is likely to be modest however, as the technology

reaches saturation. “Market acceptability for even more sophisticated and

therefore more expensive systems appears to be currently in decline,” said

Guenther Plapp, director of development, chassis systems division of Bosch.

For that reason, Bosch has therefore pursued the idea of a scaleable product

range based on ESP. These technologies waiting in the wings include



electronic brake pre-fill, brake disc wiping, tyre pressure monitoring, hill hold

control, 'soft-stop', and adaptive cruise control (see Bosch profile for an

explanation of each). Beyond that, is Bosch's combined active and passive

safety system, CAPS, which networks the ESP, braking system, active

steering, driver assistance and restraint systems into an integrated whole. This

will be achieved mostly with conventional brake technology.

Germany’s Continental ranks in second place in the global electronic braking

system market. It also ranks second in the electronic braking system market in

North America and Europe. In the brake actuation sector, Continental Teves

also ranks in second place in South America and worldwide. The company

currently supplies electronic braking systems (ESP, ABS and TCS) for a range

of models, including the Porsche Cayenne, Lincoln Navigator, Ford Expedition,

Ford Explorer, Mercedes-Benz M-Class, Nissan Terrano, Volkswagen

Transporter, Mercedes-Benz C-Class/SLK, BMW 3-Series/Z4, Chrysler 300C,

VW Golf/Touran/Audi A3 and A2, Ford Focus/Fiesta, Opel Astra, Renault

Laguna/Espace/Vel Satis, Peugeot 206/Citroen Pluriel/C3/C5, and Honda CR-

V. Continental Teves introduced its first ABS unit in 1984. The company

produces an electronic braking system every two seconds. Each work day,

Continental Teves produces 45,000 electronic braking systems, 136,000 brake

callipers, 59,000 brake cylinders, 37,000 brake boosters, 17,000 brake power

controllers, and 130,000 brake hoses. During 2003, Continental Teves sold

more than 3m ESP units for the first time, representing a volume increase of

29%.


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