Case Study: High-Reliability Silver Contact Spring for Integrated Brake Control (IBC)

The Integrated Brake Control (IBC) system developed by a long-time client combines brake actuation and control into a single compact unit, eliminating the need for vacuum boosters and hydraulic control modules. This system enhances response time and safety, particularly in vehicles with ADAS or full electrification.

One key component in the system is a silver contact spring manufactured by RPK Group, which guarantees electrical contact under dynamic conditions. This spring is the key part of the electrical contactor that enables the generation of hydraulic pressure sent to the brake calipers—ensuring reliable braking performance in disc brake systems.

Challenge: Secure electrical contact under dynamic vibration

The spring's primary function is to ensure a stable electrical signal within the contactor mechanism of the IBC actuator. It must:

• Perform consistently under vibration and mechanical stress
• Maintain contact pressure over time
• Be produced under clean, controlled conditions, ready for direct integration into a high-sensitivity braking module

Due to its critical role in safety, the spring is subject to stringent quality and cleanliness requirements.

Solution: Controlled coiling, coating, and cleanroom inspection

RPK Group developed a dedicated manufacturing process combining precision forming, surface treatment, and exhaustive quality control to meet these demands. The steps include:

• Coiling
• Heat Treatment

A thermal process is applied to stabilize the spring's mechanical properties and ensure long-term performance under load.

• Nickel and Silver Coating

A dual-layer Ni + Ag plating provides electrical conductivity and corrosion resistance, which are essential for reliable signal transmission in the contactor.

• Coating Thickness Control

The thickness of each metallic layer is verified to ensure performance and compatibility with downstream assembly.

• Cleaning and 100% Unit Control in Clean Room

Parts undergo a rigorous cleaning process before passing through automated inspection systems. Each spring is tested for:

- Load consistency

- Geometrical integrity via camera systems to detect any deformation

• Packaging in Clean Room

The fully verified components are packed in a clean environment to preserve surface quality and meet the cleanliness standards required by the braking system.

Outcome: Ready-to-integrate spring for safety-critical contactor systems

Thanks to tight process control and high-performance coatings, RPK delivered a spring that meets the electrical, mechanical, and cleanliness standards required for integration into the IBC module. The result is stable electrical contact under vibration and dynamic loads, directly contributing to braking reliability.