Mercedes-Benz is reimagining braking for electric vehicles, shifting mechanical brakes in-board to improve efficiency, handling, and durability.
A Radical Shift in Brake Design
Mercedes-Benz is working to revolutionize how braking systems operate in electric vehicles (EVs) by moving the brakes in-board, away from traditional wheel placement. Dubbed the “In-Drive” system, this innovative design integrates mechanical brakes directly into the motor transmission unit. This shift significantly reduces unsprung mass—the weight unsupported by the vehicle’s suspension—enhancing handling and overall performance. The system allows for fully enclosed wheels, which improve aerodynamics and boost EV range, a critical factor for consumers and automakers alike.
Optimized for Electric Power
With regenerative braking accounting for up to 98% of an EV’s deceleration needs, Mercedes sees minimal use for mechanical brakes under most driving conditions. The In-Drive system, however, ensures that mechanical brakes remain ready for emergency situations or when maximum stopping power is required. The design includes a circular brake pad attached to the driveshaft, with clamping discs applying pressure to slow the vehicle. Fully sealed within the motor unit, the system also captures brake dust, a feature that could enhance environmental benefits by reducing particulate emissions.
Engineering Innovations for Efficiency
A key engineering challenge for the in-board brake system is heat management, as the sealed design limits airflow. Mercedes engineers have turned to water cooling as a solution, experimenting with various cooling fluids to manage the heat generated during intense braking. The system’s durability is another highlight; Mercedes claims it could last the entire lifespan of the vehicle—estimated at 15 years or 186,400 miles. This longevity could significantly reduce maintenance and replacement costs, offering a practical advantage for EV owners.
Adapting to Different EV Architectures
The In-Drive system is versatile, accommodating both dual-motor and single-motor EV configurations. For rear-wheel-drive vehicles, the braking system can be mounted on the front axle, ensuring that the benefits of reduced unsprung mass and improved handling extend across different drivetrain setups. However, current costs remain a challenge, as the system is more expensive than traditional brakes. Mercedes is actively working to bring the price down to make the system viable for mass production.
What Lies Ahead
Despite its potential, the In-Drive system remains in the testing phase, and Mercedes-Benz has not yet committed to a production timeline. If successful, this innovative approach could redefine braking systems for EVs, making vehicles lighter, more efficient, and easier to maintain. “The brake of the future,” as Mercedes engineers describe it, is poised to bring meaningful advancements to EV technology. Whether this promise translates into widespread adoption depends on further testing, cost reductions, and market reception.
>>Join the conversation about this EV brake system design right here on MBWorld.org
For help with your maintenance and repair projects, please visit our How-to section in the forum.
Comments are closed