In modern vehicle electronics for commercial vehicles, EBS systems (Electronic Braking Systems) are the core of safety. The connection between EBS units (e.g. from Wabco, Knorr-Bremse or Haldex) and peripheral devices such as a CAN-Bridge for tire pressure monitoring systems (TPMS) places the highest demands on the cabling.
Why a “standard cable” cannot be used here and which clever detail makes mechanics’ lives easier when the chassis has been overpainted are explained in this article.
Waterproofing According to IP69K: A Must for Safety
Since the EBS directly controls the vehicle’s braking characteristics, fail-safe operation is the top priority. A short circuit caused by penetrating moisture must not occur under any circumstances.
High-quality EBS cables are characterized by the following features:
Complete sealing: Cables and connectors are not merely loosely connected, but firmly crimped together.
Encapsulation: In a multi-stage process, the connection point is overmolded with plastic.
IP69K standard: This design guarantees protection against high-pressure cleaning and permanent moisture.
This level of tightness is essential both at the connection to the EBS unit and at the CAN bridge.
Mechanical Durability:
Protection Against Vibration & Abrasion
Cables on the vehicle chassis are exposed to constant movement. They are secured with cable ties or clamps, but during driving, vibrations cause micro-movements at these mounting points.
A cable with a sheath not designed for this purpose would quickly fail. Therefore, cables for the commercial vehicle sector must meet specific requirements:Increased sheath thickness: More material protection against abrasion.
Abrasion resistance: The material must be designed so that it does not chafe through at the mounting points despite friction.
In addition, these cables are generally ADR-approved, allowing their use in vehicles for the transport of dangerous goods.
The “Hidden” Data Matrix Code: A Practical Solution
A problem that occasionally arises in workshop practice: A vehicle chassis is completely repainted – including the installed control units and cables. The result? Type plates and identification numbers disappear under a thick layer of paint and are no longer legible.
Our solution is a laser-engraved Data Matrix code located beneath the connector.
The principle: The code is positioned in a place that is concealed by the HDSCS connector (recognizable by the yellow release element) when plugged in.
The advantage: Even if the entire control unit has been painted over, all that is required is to disconnect the connector. The area underneath remains free of paint, and the code can be scanned to clearly identify the CAN bridge.
Compatibility: Wabco, Knorr-Bremse & Haldex
Vehicle architecture varies depending on the manufacturer and model. A well-designed cable portfolio therefore covers all common EBS manufacturers.
Available configurations include:
Direct connections: Simple cables for directly connecting the CAN bridge to the EBS unit.
Y-cables: For applications where additional devices, such as a display, are connected to the EBS unit alongside the CAN bridge.
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IMPORTANT FAQs
What Requirements Apply to EBS Cables in Trucks and Trailers?
EBS cables must be waterproof (IP69K) to prevent short circuits in the braking system. Mechanically, they must be highly resistant to abrasion caused by vibrations and have ADR approval for the transport of dangerous goods.
What Does IP69K Mean for EBS Cables in Trucks, and Why Is This Standard So Important?
IP69K is the highest protection rating against water and dirt. In trucks, trailers, and semi-trailers, this standard is essential, as EBS cables must withstand high-pressure cleaning, moisture, and dust. Without IP69K, the risk of short circuits and brake system failures increases.
Are All EBS Cables Automatically ADR-Approved for the Transport of Dangerous Goods?
No. Only specially certified cables meet the ADR requirements for vehicles carrying dangerous goods (e.g. tankers, chemical transport vehicles). ADR cables feature reinforced sheath materials, increased temperature resistance, and tested flame retardancy. We offer ADR-approved cables—please contact us for more information.
Why Is the Data Matrix Code on the TireCheck CAN Bridge Placed Under the Connector?
This protects the code from being painted over during chassis repainting. When the connector is plugged in, the code is covered; once the connector is disconnected, the identification remains readable, even if the control unit has been painted.
How Does the Hidden Data Matrix Code Help with Painted Control Units?
The Data Matrix code protected beneath the connector enables:
Fast identification of the CAN bridge after repainting
Clear assignment of serial numbers
This saves time in the workshop.
What Length Should EBS Cables Have in a Truck Chassis?
The optimal length depends on:
Chassis geometry
Installation position
Existing cable routing
Cables that are too long increase mechanical stress, while cables that are too short pose a safety risk. Vehicle manufacturers typically use lengths between 50 cm and 250 cm.
