Global market review of foundation brakes forecasts to edition

Transcription

1 Global market review of foundation brakes forecasts to edition

2 Page i Global market review of foundation brakes forecasts to edition May 2010 by Matthew Beecham Published by Aroq Limited Seneca House Buntsford Park Road Bromsgrove Worcestershire B60 3DX United Kingdom Tel: +44 (0) Fax: +44 (0) Web: Registered in England no:

3 Page ii Single-user licence edition This report is provided for individual use only. If you would like to share this report with your colleagues, please order additional copies or sign up for a multi-user licence by contacting: Chris Clarke Research manager, just-auto.com Tel: +44 (0) chris.clarke@just-auto.com Copyright statement 2010 All content copyright Aroq Limited. All rights reserved. This publication, or any part of it, may not be copied, reproduced, stored in a retrieval system, or be transmitted in any form by any means electronic, mechanical, photocopying, recording or otherwise without the prior written permission of Aroq Limited. This report is the product of extensive research work. It is protected by copyright under the Copyright, Designs and Patents Act The authors of Aroq Limited s research reports are drawn from a wide range of professional and academic disciplines. The facts within this report are believed to be correct at the time of publication but cannot be guaranteed. All information within this study has been reasonably verified to the author s and publisher s ability, but neither accept responsibility for loss arising from decisions based on this report. Incredible ROI for your budget single and multi-user licences We understand the pressure your research budget is under and price our reports realistically. You won t find our reports with four, or even five-figure price tags, but you will find that they make some of the competition look expensive. Each title is available to you on a single-user basis, supplied on the strict understanding that each title is not to be copied or shared. Alternatively, titles can be shared within departments or entire corporations via a costeffective multi-user licence. Multi-user licences can also save you money by avoiding unnecessary order duplication. To further add value, all multi-user

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5 Page iv Contents Contents Single-user licence edition... ii Copyright statement... ii Incredible ROI for your budget single and multi-user licences... ii just-auto.com membership... iii Contents... iv List of figures... vi List of tables... vii Preface... viii Research methodology... viii Report coverage... ix The author... ix Chapter 1 Introduction... 1 Chapter 2 The market... 3 Market trends... 3 Market players... 4 Advics... 4 Akebono... 4 Bosch... 5 Brembo... 5 Q&A with Brembo... 5 Continental... 8 Q&A with Continental... 8 Mando Corp TRW Automotive Q&A with TRW Automotive TMD Friction Market shares World Europe North America Asia-Pacific Market forecasts Chapter 3 Technical review Defining the elements Recent innovations Q&A with IFR... 27

6 Page v Contents Chapter 4 Manufacturers Advics Akebono Bosch Continental Delphi TRW Appendix Glossary of terms... 40

7 Page vi List of figures List of figures Figure 1: World market shares of automotive foundation brake systems manufacturers, 2009 (% of volume) Figure 2: European market shares of automotive foundation brake systems manufacturers, 2009 (% of volume) Figure 3: North American market shares of automotive foundation brake systems manufacturers, 2009 (% of volume) Figure 4: Asia-Pacific market shares of automotive foundation brake systems manufacturers, 2009 (% of volume)... 19

8 Page vii List of tables List of tables Table 1: Market volume of OE disc brakes for passenger cars produced in North America, Europe and Japan, , expected, best and worst case scenarios (units 000s) Table 2: Market volume of OE drum brakes for passenger cars produced in North America, Europe and Japan, , expected, best and worst case scenarios (units 000s) Table 3: Market value of OE disc brakes for passenger cars produced in North America, Europe and Japan, , expected, best and worst case scenarios (EUR 000s) Table 4: Market value of OE drum brakes for passenger cars produced in North America, Europe and Japan, , expected, best and worst case scenarios (EUR 000s Note: data in some tables may not sum due to rounding.

9 Page viii Preface Preface Research methodology This report is intended to provide an overview of vehicle foundation braking systems, specifically providing market volume forecasts of disc and drum brakes through For the purposes of this report, we define foundation brakes as disc brake assemblies and components, including callipers, rotors and knuckles, drum brake assemblies and parts, including drum brakes, drums, drum-in-hat adapters, hubs and integral parking brakes. Our forecasts of disc and drum brakes are not extrapolative but dependent on the underlying drivers of supply and demand. Our forecasts are largely based on interviews with the author s extensive international network of industry contacts. This allows us to consider and explain the meaning and implications of industry events, rather than offer simple description based on incomplete data. Our approach is divided into two distinct methodologies: o qualitative interviews these are generally opinion-based, which aim to build knowledge about future braking market trends and company strategies; o quantitative interviews typically fact-based, focused on establishing market values, shares, and volumes. Our research typically concentrates on applications for light vehicles which include all cars, light trucks and the various cross-over vehicle styles such as sports utility vehicles and people carriers. These vehicles collectively account for about 96% of the global vehicle build. Our market forecasts are set out by major light vehicle-producing region, i.e. Europe, Japan and North America. For the purposes of this report, except where expressly stated, Europe includes Austria, Belgium, Bulgaria, the Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania, Luxembourg, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Switzerland, Sweden, Turkey and the UK. North America includes the US, Canada and Mexico.

10 Page ix Preface Report coverage In this, the second edition of this report, just-auto reviews the key market drivers for vehicle foundation braking. Following our market overview in Chapter 1, just-auto s product fitment forecasts in Chapter 2 predict in some detail how the OE market volume for brake disc and drums will evolve in Europe, Japan and North America from 2007 through to This chapter includes exclusive interviews with senior executives of Brembo, Continental, TRW and IFR Automotive. Chapter 3 sets out a review of recent innovations in this arena. This chapter includes exclusive interviews with senior executives of Bosch and Continental. Chapter 4 provides profiles of the major manufacturers, namely Advics, Akebono, Bosch, Brembo, Continental, Delphi and TRW. The author Matthew Beecham has more than 18 years experience of researching, writing and analysing market and technical trends in the global automotive components industry. Since 2000, he has served as an associate editor for just-auto. In addition to foundation brakes, he authors a range of global auto components market research reviews, including batteries, clutches, coatings, cockpits, driver assistance systems, door modules, electric motors, engine cooling systems, exhaust systems, front-end modules, fuel injection, fuel tanks, glazing systems, ignitions, interiors, lighting, mirrors, roof systems, shock absorbers, spark plugs, rotating electrics, tyres, tyre pressure monitoring systems, wheels and wipers. Matthew s freelance assignments have included working for AT Kearney, Belron, Bridgehead International, McKinsey, Kuwait Institute for Scientific Research, Motorsport Industry Association, Motor Industry Research Association and the Economist Intelligence Unit. He has also written for magazines including Car Graphic (Japan), JAMA (Japan) and Automotive Engineer (UK). He was awarded a PhD in automotive technology transfer from Cranfield University.

11 Page 1 Chapter 1 Introduction Chapter 1 Introduction The apparently simple issue of braking continues to be a major issue for engineers. Drivers are, of course, concerned that in an emergency, their vehicles should stop as quickly as possible. There is a practical limit to braking performance, set by the ability of the tyre contact patches to transmit the forces involved without sliding. However, advances in tyre design, soon to be complemented by the ability of electronically controlled braking systems to distribute effort according to wheel load (if, for example, the brakes are applied while the vehicle is cornering), mean that limit is now potentially very high, at least on dry road surfaces. This is throwing the onus very much back to the braking system developers. The main engineering challenges in any braking system are to withstand the extremely high temperatures involved, to remove the very large amount of heat generated during hard deceleration, and to minimise the weight of the braking units. Weight reduction is very important across the braking system, especially in the un-sprung area where it improves ride and handling as well as fuel consumption and CO 2 emissions. Consequently, brake manufacturers continue to focus on designs that improve brake feel and reduce engineering costs. Executives at Continental s hydraulic brake systems business told us: One means of saving weight when designing brake components is to replace the materials used so far, such as cast iron or steel, with lighter materials, such as aluminium, other light alloys or even plastic. However, the use of alternative materials is currently restricted to aluminium since extremely high demands are made of these materials. During its life, a brake will be operated several million times, subjecting it to great pressure; the material is also exposed to moisture and road salt and so far only cast iron, steel and aluminium have shown that they are able to cope with such demanding conditions. More efficient design techniques and intelligent lightweight construction can produce slimmed-down components without limiting their functionality. Specialised CAD software makes it possible to optimise component structures on the computer. Demands for more performance with minimal cost or weight penalties are also pressurising brake system designers to come up with new ideas.

12 Page 3 Chapter 2 The market Chapter 2 The market Market trends Akebono Brake Industry s most recently published 2009 annual report highlights some product development trends by conveying the observations and opinions of a number of their brake engineers. For example, in discussing the environmental performance of passenger cars, Daisuke Fujiwara, brake engineer for Akebono Brake Industry, said: These days, when the spotlight is on the environmental performance of passenger cars, brakes do more than simply stop forward motion; it is essential for them to provide an increased range of capabilities. Of particular note is the increasing demand for ever more lightweight brake systems to realise improved fuel efficiency... Specifically, one major trend is the replacement of traditional brake callipers with those made of more lightweight aluminium. One point in favour for aluminium is its recyclability, which means it can contribute to the environment from the standpoint of low energy and resource consumption. On the flipside, however, aluminium is a comparatively expensive material, and to gain acceptance for its use in mass-produced vehicles there is the issue of clearing the two conditions of lighter weight and reduction of cost. Shinya Kaneko, who is tasked with the development of proprietary brake pad technology for Akebono Brake Industry, pointed out the demand for a high level of brake quality, stating: With the development of friction materials, of course we prohibit the use of materials that severely impact the environment. While providing braking functions that operate safely and securely, it is also important to keep to a minimum any components that cause anxiety, such as those that cause noise or judder. Kaneko offered observations based on his work experience in Europe to detail the differing demands for brake performance from Japan, the US and Europe. In Japan, it is important not to have brake noise, drag or judder when the brakes are applied. Conversely, in Europe, where high-speed driving is common, the amount of effort it takes to put on the brakes from a high rate of speed is of concern. Furthermore, in North America, because of long-distance driving, durability and freedom from maintenance requirements take priority. Kaneko said: Of course, if we could develop a brake pad that was able to

13 Page 25 Chapter 3 Technical review Chapter 3 Technical review Defining the elements According to brake specialist PBR, the braking system is a means of converting the vehicle s momentum (called kinetic energy) into heat by creating friction in the wheel brakes. The heat is then dissipated into the air, and it is the ability to absorb and dissipate heat that prevents brake fade under severe conditions (downhill braking, for instance). The most common arrangement of a hydraulic brake system for a passenger car and light vehicle comprises a number of parts, namely the brake pedal, vacuum brake booster, master cylinder, a slave cylinder, brake rotor and/or brake drum, brake fluid reservoir and a warning system (to alert the driver of a failure of a brake circuit and loss of brake fluid). The master cylinder is connected to the brake pedal. It converts mechanical pressure into hydraulic pressure. Steel brake lines and brake hoses connect the master cylinder to the slave cylinders located at each wheel. The diameter and length of the master cylinder has a significant effect on the performance of the brake system. A large-diameter master cylinder delivers more hydraulic fluid to the slave cylinders, yet requires more brake pedal force and less brake pedal stroke to achieve a given deceleration. A smaller-diameter master cylinder has the opposite effect. A master cylinder may also use differing diameters between the two sections to allow for increased fluid volume to one set of slave cylinders or the other. The two most common arrangements of slave cylinders are a pair of opposed pistons which are forced apart by the fluid pressure (drum brake) and a single piston which is forced out of its housing (disc brake). The slave cylinder pistons then apply force to the brake linings (typically referred to as shoes for drum brakes and pads for disc brakes). The force applied to the linings causes them to be pushed against the drums and rotors. The friction between the linings and drum/rotor causes a braking torque to be generated, slowing the vehicle. While most large vehicles have disc brakes all round, small vehicles sometimes have drum brakes on the rear wheels.

14 Page 31 Chapter 4 Manufacturers Chapter 4 Manufacturers Advics Advics Co was formed in July 2001 by combining the brake operations of Denso, Aisin Seiki, and Sumitomo Electric Industries in Japan to develop new brake technologies and modules. Each partner holds an equity stake; Aisin Seik i has xx%, Denso and Sum itom o each have xx% and Toyota holds the rem aining xx%. Based in Aisin s headquarters in Kariya in Aichi prefecture, Advics operates four technical centres in Japan (two in Kariya and one each in Hyogo and Fujioka-cho). In addition, the company operates a number of subsidiaries overseas, as follows: o Advics North America Inc, Michigan, US research and development and sale of automotive brake systems and components. o Advics Manufacturing Ohio Inc manufacture of automotive brake components. o SAFA LLc, Georgia, US manufacture of automotive brake components. o Advics Asia Pacific Co Ltd, Thailand sale of automotive brake systems and components. Also oversees Advics business operations in the Asia-Pacific region. o PT Advics Indonesia sale of automotive brake systems and components. o Advics Tianjin Automobile Parts Co Ltd, Tianjin, China manufacture and sale of automotive brake systems and components. o Advics Guangzhou Automobile Parts Co Ltd, Guangzhou, China manufacture and sale of automotive brake components. Sale of automotive brake systems. o Advics Taiwan Automotive Parts Co Ltd, Taichung, Taiwan research and development and sale of automotive brake systems and components. o Advics Europe office, Braine L Alleud, Belgium research of the European market and establishment of business strategies. Advics designs and produces ABS, stability control systems, brake boosters, master cylinders, disc brakes, drum brakes and other related components. Its