24h Le Mans
As a key player in the field of braking technologies, Brembo is tackling a whole range of challenges in its quest to improve the efficiency and reliability of Hypercar brakes.
The brake systems fitted to the Hypercars competing in the 24 Hours of Le Mans call for specific materials that can withstand the demands of the race. While carbon-ceramic materials are used on sporty street-legal models, Hypercar brake discs are made of carbon. This element, specifically designed for racing, requires a temperature of at least 200°C for optimum performance, making it inappropriate for use on everyday vehicles. Carbon-ceramic discs, however, offer road cars an excellent compromise between light weight, heat resistance and efficiency, even at lower temperatures.
During a race like the 24 Hours of Le Mans, brake disc temperature fluctuates around 400°C on average, but can exceed 1000°C in heavy braking situations. Materials like carbon can withstand such extreme temperatures without compromising safety or braking performance.
As well as ensuring high levels of performance in its brake systems, Brembo is seeking to improve their durability throughout the 24 hours of racing. The Italian manufacturer is therefore working on developing friction materials offering lower wear rates and pioneering caliper concepts to reduce drag resistance. These innovations help maintain a high level of braking performance throughout the race, thus eliminating the need for frequent replacements and improving the car’s overall efficiency.
Brembo has integrated energy recovery systems (ERS) into the braking mechanism on hybrid Hypercars. On decelerating, an electric motor converts the vehicle’s kinetic energy into electricity which is then stored in batteries for reuse. However, the electric motor alone cannot supply all the braking force required. A conventional system based on brake-by-wire technology is therefore used to supplement the action of the electric motors. This system ensures precise control of the pressure applied and optimises braking performance in all situations.
The main challenge with hybrid systems lies in striking a balance between traditional hydraulic braking and regenerative braking as energy recovery is not constant throughout the race. It depends on several factors such as battery charge and the changing cell temperature. The brake system must therefore adapt to these variations to offer constant performance and optimum durability.
Hypercar aerodynamics have a significant impact on brake cooling. Although airflow is channelled through ducts towards the brakes, it generates extra drag that can affect the car’s top speed. The engineers must therefore find a compromise between efficient brake cooling and optimised aero performance to minimise air resistance without sacrificing braking efficiency.
To maximise brake performance throughout a stint, it is vital for drivers to be able to control disc and pad temperatures. Keeping the brakes within an optimum temperature window guarantees consistent performance and avoids the risk of overheating or failure. The drivers must also adapt their braking to race conditions and modulate the pressure to avoid premature wear and tear on the components.
The brake systems designed for Hypercars at the 24 Hours of Le Mans are a perfect illustration of the ingenuity and innovation that characterise motorsport. When it comes to managing extreme temperatures, improving energy recovery and resolving aerodynamic issues, Brembo constantly pushes the boundaries of technology in the quest for outstanding performance. These developments, honed through tackling the challenges of endurance racing, are finding their way into production vehicles, illustrating the direct impact of the sport on tomorrow’s motorcars.
