Independent Axle Brake Verification for Rollback Prevention
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Solution Overview
Problem
Large off-highway vehicles face challenges in efficiently and reliably operating their braking systems, especially on grades and in wet conditions, due to the potential for rollbacks and the need for independent verification of brake functionality to ensure safe operation.
Innovation Solution
A control system that includes an electric drive system and a friction brake system, where the drive system control unit determines the functionality of the friction brakes on one set of wheels independently of the other, allowing for blended braking operations and automatic control of both systems to prevent rollbacks and ensure safe stopping and starting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the friction brake system operates independently on each axle, then the reliability of brake verification is improved, but the device complexity increases
Solution Approach 1:
The brake verification process is segmented into independent axle-level operations. The control system can verify front brakes and rear brakes separately by independently controlling friction brake units on each axle, allowing targeted verification without requiring complete system shutdown or complex coordinated testing of all brakes simultaneously.
Solution Approach 2:
The system implements local verification capability where each axle's brake units can be tested independently with localized control. The control unit can apply verification forces specifically to front or rear friction brake units based on operational needs, providing localized quality assurance rather than requiring uniform verification of the entire brake system.
2Productivity
If blended braking operation is implemented, then the productivity is improved, but the control complexity increases
Solution Approach 1:
The system merges electric retarding and friction braking into a unified blended braking operation. The control unit coordinates both braking mechanisms to work simultaneously or sequentially based on operational conditions, combining the advantages of electric retarding (energy recovery, smooth deceleration) and friction braking (reliable stopping force) to improve overall vehicle operation efficiency.
Solution Approach 2:
The blended braking system dynamically adjusts the contribution of electric retarding and friction braking based on real-time operational conditions. The control unit continuously monitors vehicle state and automatically optimizes the braking mix, transitioning between different braking modes as needed to maintain optimal productivity while managing control complexity through adaptive algorithms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively prevents rollbacks on grades by seamlessly transitioning between electric retarding and friction braking, ensuring the vehicle's stability and safety by verifying the functionality of the front brakes independently and adjusting torque and braking efforts accordingly.
Implementation Method 1
The electric drive system is associated with a first set of wheels (e.g., rear wheels) of the vehicle. The drive system control unit is configured to control the electric drive system to selectively provide electric motive power to the first set of wheels to propel the vehicle and electric retarding to slow the vehicle.
Implementation Method 2
The friction brake system includes a first friction brake unit associated with the first set of wheels and a second friction brake unit associated with a second set of wheels (e.g., front wheels) of the vehicle.
Data Source
AI summary
A control system for a vehicle includes an electric drive system, a drive system control unit, and a friction brake system. The electric drive system is associated with a first set of wheels of the vehicle. The drive system control unit is configured to control the electric drive system to selectively provide electric motive power to the first set of wheels to propel the vehicle and electric retarding to slow the vehicle. The friction brake system includes first and second friction brake units associated with the first and second sets of wheels, respectively. The drive system control unit is further configured to determine a functionality of the second friction brake unit, for a friction brake application to the second set of wheels, independent of operation of the first friction brake unit, and to control at least one vehicle system based on the determined functionality of the second friction brake unit.