For six days and over a span of 3,300 kilometers through various climate zones to the Arctic Circle, a Bosch development team successfully tested its new hydraulic brake-by-wire system on public roads for the first time. The system eliminates the traditional mechanical link between the brake pedal and the braking mechanism. Instead, the driver’s braking command is transmitted purely via redundant electrical signal lines.

Developed at Bosch’s center in Abstatt near Heilbronn, the journey took the test team from southern Germany through Hamburg, Copenhagen, and Stockholm to the company’s winter test site in Arjeplog, Sweden. Bosch obtained public road approval for the test vehicle across multiple countries.

“Our hydraulic brake-by-wire system worked flawlessly throughout the trip,” said Hagen Kuckert, project manager for the by-wire brake actuator. “We gathered valuable real-world data during thousands of braking events, which will directly enhance further system development.”

Bosch’s hydraulic brake-by-wire solution consists of two independently functioning components: a by-wire brake actuator and an ESP (Electronic Stability Program). Unlike traditional systems that use mechanical connections to ensure backup in case of failure, this new solution assigns both hydraulic units to separate channels within the vehicle’s electrical system. Each unit can independently generate brake pressure at all four wheels in case of failure, ensuring redundancy and safety.

In addition to the hydraulic setup, Bosch is also developing a purely electromechanical version. Several automakers have already placed orders, and Bosch estimates that more than 5.5 million vehicles will feature brake-by-wire technology by 2030.

Eliminating the mechanical connection between brake pedal and system allows greater flexibility in component placement, improving crash safety, noise-vibration-harshness (NVH), and manufacturing efficiency. This also simplifies production, eliminating the need for separate left-hand and right-hand drive versions.

The by-wire system also enables shorter brake pedal travel, opening up opportunities for new interior designs. Built on proven braking technologies, Bosch’s system is reliable, adaptable, and designed for the future of automotive safety and electrification.