Electro-Hydraulic Brake-by-Wire and Off-the-Shelf ABS Integration: Control Design and Hardware in the Loop Validation

This work presents the design of a control logic for an electro-hydraulic brake-by-wire in series with an off-the-shelf ABS unit for motorsport applications. Validation is performed through hardware-in-the-loop testing with a complete hydraulic layout, including the brake-by-wire actuator, the ABS module, and brake calipers. State-of-the-art electro-hydraulic brake-by-wire systems are increasingly adopted in top-level motorsport and are now transitioning to high-performance road vehicles, in combination with ABS and ESC. However, due to motorsport regulations, racing brake-by-wire systems do not incorporate ABS functionality. To combine the performance of motorsport grade actuators with the ease of use required for non professional drivers, a series configuration between brake-by-wire and ABS represents a natural solution. This architecture is also relevant for future road vehicle applications, offering additional redundancy for autonomous driving-ready systems. A dedicated hardware-in-the-loop test rig has been developed to perform experimental testing of the complete brake system. Wheel dynamics are simulated in real time using a single-axle vehicle model, and wheel speed signals are reproduced via a sensor emulator. Preliminary tests show that the original pressure-based brake-by-wire control strategy exhibits poor performance during ABS activation, as ABS operation significantly alters system behaviour. To address this issue, an improved control strategy is proposed, introducing a dedicated control mode activated during ABS operation, with a smooth transition back to nominal control once ABS activity ceases. Experimental results demonstrate that the proposed strategy maintains closed loop stability, avoids excessive pressure oscillations or piston end stop conditions, and, most important, does not interfere with ABS operation. Overall braking performance is fully preserved.