Axle Modulator Installation Verification via Wheel Speed Disturbance Analysis
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Solution Overview
Problem
In vehicles with multiple axles, structurally identical brake system modulators are often mixed up during installation, leading to incorrect activation and potential accidents, and existing solutions to prevent this result in high costs due to the need for numerous structurally different modulators.
Innovation Solution
A method that detects the axle assignment of pressure regulators by measuring abnormalities in wheel-related driving variables during operation, comparing these with reference sequences to determine correct or incorrect installation, and provides a status report for initiating countermeasures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coding plugs or structural differences are used to prevent incorrect installation of axle modulators, then installation correctness is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The system continuously monitors wheel speed signals from all axles and compares the disturbance patterns against expected patterns to detect incorrect modulator installation. The control unit receives feedback from speed sensors and automatically identifies mismatches between actual and expected installation configurations, enabling real-time detection without physical modification of the modulators.
Solution Approach 2:
The patent replaces mechanical prevention methods (coding plugs, structural differences) with an electronic/digital detection system. Instead of using physical features to prevent incorrect installation, the system uses software-based analysis of wheel speed disturbance patterns to identify incorrect installations, thereby eliminating the need for multiple modulator variants.
2Ease of manufacture
If identical axle modulators are used across all axles, then manufacturing costs are reduced, but the risk of incorrect installation increases
Solution Approach 1:
The control unit continuously receives wheel speed data from all axles and compares the disturbance patterns against stored reference patterns corresponding to correct installation configurations. This feedback mechanism enables the system to detect incorrect installations even when identical modulators are used, maintaining manufacturing simplicity while ensuring installation correctness through software-based verification.
Solution Approach 2:
The system enables the brake system itself to verify its own correct configuration by analyzing its own operational data. The control unit uses wheel speed signals generated during normal vehicle operation to automatically detect incorrect modulator installation, eliminating the need for external verification or specialized installation tools.
3Productivity
If axle modulators are installed without verification, then installation time is reduced, but incorrect activation leads to unsafe vehicle operation
Solution Approach 1:
The system performs preliminary verification of modulator installation by analyzing wheel speed disturbance patterns during the first drive cycles after installation. The control unit stores reference patterns and automatically compares actual patterns during normal operation, detecting incorrect installations before they lead to unsafe conditions. This allows rapid installation without manual verification while maintaining safety through automated detection.
Solution Approach 2:
The system provides continuous feedback during vehicle operation to detect incorrect installations. By monitoring wheel speed signals and comparing them against expected patterns, the system can identify incorrect modulator placement and alert operators, enabling fast installation while maintaining vehicle safety through automated monitoring.
Data Source
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AI summary
The invention relates to a method for detecting an axle association of at least one first pressure controller for a first brake cylinder and a second pressure controller for a second brake cylinder of an electronically controlled brake system of a vehicle, wherein the first pressure controller is associated with a first axle and the second pressure controller is associated with a second axle, and the first and second pressure controllers are structurally identical and the method comprises the following steps: detecting a temporal sequence of a first and second wheel-related driving manipulated variable of the vehicle during driving operation for at least one first wheel associated with the first axle and at least one second wheel associated with the second axle; comparing the temporal sequence of the first and second driving manipulated variables with a reference sequence in a vehicle electronic module connected to the first and second pressure controllers; evaluating the comparison in the vehicle electronic module in order to determine a deviation from the reference sequence; and associating the deviation with a status message of the vehicle. The invention further relates to an electronically controlled brake system and to a vehicle.