Brake Control Unit PCB with Redundant Dual Power Paths
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Solution Overview
Problem
Existing electromechanical motor vehicle brakes lack a cost-effective redundant power supply system that ensures reliable operation in case of vehicle electrical system failures, compromising safety and functionality, especially in highly automated driving scenarios.
Innovation Solution
A brake control unit with a printed circuit board that integrates dual power supply connections from separate vehicle electrical systems, incorporating polarity reversal protection and voltage/current monitoring, allowing seamless switching to a functioning system in case of failure, and utilizing MOSFET transistors for efficient current management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a redundant power supply system is implemented for the brake control unit, then the reliability and safety of the brake system is improved, but the device complexity and cost increase
Solution Approach 1:
The patent merges two separate power supply paths into a single brake control unit by integrating multiple power supply connections (KL30_1, KL31_1 and KL30_2, KL31_2) and their associated polarity reversal protection circuits onto one printed circuit board. This consolidation achieves redundancy for reliability while avoiding the complexity of completely separate systems, as both power paths share common components and housing.
Solution Approach 2:
The printed circuit board is designed with universal power supply capabilities that can accept power from either vehicle electrical system independently. The polarity reversal protection circuits are configured to universally protect against polarity errors from either power source, and the system can automatically switch between power sources, making the single brake control unit capable of multiple power supply scenarios.
2Reliability
If polarity reversal protection circuits are provided for each power supply path, then the safety is improved, but the device complexity increases
Solution Approach 1:
Two polarity reversal protection circuits are integrated on a single printed circuit board rather than using separate physical components for each power path. The protection circuits share the same board real estate and can be controlled by a single control unit, reducing overall system complexity while maintaining dual protection capability.
Solution Approach 2:
The polarity reversal protection circuits automatically detect and respond to polarity errors without requiring external intervention. When a polarity reversal is detected on either power supply path, the corresponding protection circuit automatically prevents damage by blocking the faulty power path, providing self-protecting functionality that simplifies control requirements.
3Reliability
If seamless switching between power supply paths is implemented, then the operational continuity is improved, but the switching latency may increase
Solution Approach 1:
The control unit continuously monitors both power supply paths and pre-evaluates their availability status. When a failure is detected in one path, the switching decision is already prepared, and the control unit can immediately activate the standby power path without requiring time for detection and decision-making during the critical failure moment, thus minimizing switching latency.
Solution Approach 2:
The system implements continuous feedback monitoring of both power supply paths through voltage and current sensors. This real-time feedback allows the control unit to detect failures instantly and trigger the switching mechanism immediately, ensuring seamless transition with minimal latency while maintaining operational continuity.
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
Enhances operational reliability and safety by ensuring continuous brake functionality even in the event of electrical system failures, reducing latency and power loss, and maintaining vehicle control without additional components.
Implementation Method 1
a polarity reversal protection circuit (23, 33) is provided for each power supply path (20, 30)
Implementation Method 2
utilizing MOSFET transistors for efficient current management
Data Source
AI summary
The present embodiments relate to a brake control unit and a method for operating a motor vehicle brake using such a brake control unit. A brake control unit comprises at least one printed circuit board having an electronic circuit arrangement. A first set of electrical power supply connections of at least of a first type and second type are associated with a first vehicle electrical system and form a first power supply path. A second set of electrical power supply connections of at least of a first type and second type are associated with a second vehicle electrical system and form a second power supply path. A common output power supply connection is formed from outputs of the polarity reversal protection circuit for each power supply path brought together at a connection node at which a supply voltage can be provided in operation.