Product novelty 22. September 2026
EMS high-performance polyamide replaces aluminium in ABS solenoid valve for commercial vehicles
Lower weight, reduced energy consumption and lower manufacturing costs: An ABS solenoid valve made of Grivory HT demonstrates the potential of EMS high-performance polymers for metal replacement in commercial vehicles. The high-performance polyamide replaces the previous aluminium version, reducing component weight by 33%, the CO₂ footprint by around 60% and manufacturing costs by around 30%.
The valve component is part of an ABS modulator for commercial vehicles. It regulates the air pressure to the brake cylinders, helping to prevent the wheels from locking and keeping the vehicle controllable even under heavy braking. Over its service life, the component must reliably withstand millions of braking cycles. It must also withstand temperatures from –40 °C to +80 °C and environmental influences. EMS high-performance polyamides meet these requirements with high mechanical and chemical resistance.
The change from aluminium to the EMS solution enabled a polymer-optimized component design to be specifically adapted to injection moulding. Pronounced ribbing provides the required stiffness, while complex geometries can be produced in a single manufacturing step, eliminating the extensive post-processing required for the aluminium version.
The solution also proved its durability in endurance testing. A minimum service life of one million braking cycles was required. The polymer component withstood more than seven million braking cycles, significantly exceeding the requirement.
Further benefits are achieved in production. The EMS solution is processed at around 340 °C, compared with approximately 650 °C for aluminium. The significantly lower processing temperature helps reduce energy consumption by up to 25%. The combination of material, polymers-opimized design and a coordinated manufacturing process thus combines safety and durability with resource efficiency and cost-effectiveness.
The valve component is part of an ABS modulator for commercial vehicles. It regulates the air pressure to the brake cylinders, helping to prevent the wheels from locking and keeping the vehicle controllable even under heavy braking. Over its service life, the component must reliably withstand millions of braking cycles. It must also withstand temperatures from –40 °C to +80 °C and environmental influences. EMS high-performance polyamides meet these requirements with high mechanical and chemical resistance.
The change from aluminium to the EMS solution enabled a polymer-optimized component design to be specifically adapted to injection moulding. Pronounced ribbing provides the required stiffness, while complex geometries can be produced in a single manufacturing step, eliminating the extensive post-processing required for the aluminium version.
The solution also proved its durability in endurance testing. A minimum service life of one million braking cycles was required. The polymer component withstood more than seven million braking cycles, significantly exceeding the requirement.
Further benefits are achieved in production. The EMS solution is processed at around 340 °C, compared with approximately 650 °C for aluminium. The significantly lower processing temperature helps reduce energy consumption by up to 25%. The combination of material, polymers-opimized design and a coordinated manufacturing process thus combines safety and durability with resource efficiency and cost-effectiveness.
EMS-CHEMIE AG
Contact
Ms. Jasmin Walt