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A Brake By Wire (BBW) system is generally composed of electro-mechanical calipers at each wheel, a pedal simulator and a central controller. The brake demand is processed by the pedal and the central controller commands the brake distribution for each brake actuator. The highly responsive and independent brake actuators lead to enhanced controllability which should result in not only better basic braking performance, but also improvements in various active braking functions such as integrated chassis control, driver assistance systems, or cooperative regenerative braking. Although the BBW system has the potential for numerous advantages and innovations in braking, it has yet to be successfully introduced in series production mainly due to safety and cost concerns. Recent studies have been made to investigate the functional safety aspects and additional mechanical backup measures in this regard.

Wheel bearing seals are required to have strong sealing capabilities and low reaction forces because the bearing operates in extreme environments such as mud and water. And the design technology for wheel bearing seals is closely related to the efficiency and durability of the entire bearing. If the bearing seal performance can be estimated and used in the design procedure, more efficient and durable bearing seals can be produced. The bearing seal performance is strongly dependent on the shape of the bearing seal lip, so the optimization of the bearing seal design is more efficient if the design factors of the seal lip are known in advance. In this study, deformation patterns of seal lips are predicted by finite element analyses considering nonlinear characteristics of rubber material, and the shape is optimized using experimental design method applying parameters obtained from the analyses.