Brake Controller Redundancy With Fault Output Blocking
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Solution Overview
Problem
Existing vehicle brake systems lack reliability in monitoring and redundancy, particularly for antilock and antiskid functions, which can lead to failures in critical braking situations.
Innovation Solution
A vehicle brake system with at least three controllers connected to each other, where each controller includes a braking force calculation unit and a determination unit that compares results to identify normal or abnormal functioning, and an output block section to isolate non-functional controllers, ensuring redundancy and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single controller is used in the brake system, then the device complexity is reduced, but the reliability and redundancy of the system deteriorates
Solution Approach 1:
The brake control system is segmented into multiple independent controllers (first controller, second controller, third controller) that can operate autonomously. Each controller has its own driver control unit and braking force calculation unit, allowing the system to divide functionality across multiple units for improved reliability and fault tolerance.
Solution Approach 2:
The system implements predetermined determination units in each controller that continuously monitor and compare braking force calculation results before actual braking operations. This beforehand monitoring detects abnormalities in advance, allowing the system to switch to backup controllers or block faulty outputs before failures affect brake performance.
2Reliability
If multiple controllers are used without monitoring, then the system redundancy is improved, but the ability to detect and isolate failures deteriorates
Solution Approach 1:
Each determination unit continuously receives feedback from braking force calculation results of all controllers. The determination units compare these results in real-time, creating a feedback loop that automatically detects discrepancies and identifies abnormal controllers based on inconsistent braking force calculations.
Solution Approach 2:
The system monitors changes in braking force calculation parameters across different controllers. When a controller's calculation results deviate from the predetermined range or differ significantly from other controllers, the determination unit identifies this parameter change as an abnormality and blocks that controller's output.
3Productivity
If all controllers operate without output blocking, then the system productivity is maintained, but the harmful effects of abnormal controllers deteriorates
Solution Approach 1:
The determination units extract and isolate abnormal controllers from the system by blocking their outputs. When a controller is identified as abnormal through comparison of braking force calculation results, its output is separately blocked while other normal controllers continue to operate, effectively removing the harmful element without shutting down the entire system.
Solution Approach 2:
The output block sections are predetermined safety mechanisms that prevent abnormal controller outputs from affecting brake operation. By having these blocking mechanisms in place beforehand, the system cushions against the harmful effects of controller failures before they can impact braking performance or safety.
Data Source
AI summary
A vehicle brake system (1) includes a first control device (10) and a second control device (11) that respectively include a master controller (30), a first sub-controller (40), and a second sub-controller (41) that are connected to one another. Each of the master controller (30), the first sub-controller (40), and the second sub-controller (41) includes a braking force calculation unit that calculates braking force of electric brakes (16a to 16d), and a determination unit that compares braking force calculation results of the controllers to determine whether itself is normal. The determination unit includes an output block section that blocks, when the determination unit determines that any one of the controllers is not normal, an output of the controller that is determined to be not normal.