Brake Control Holder Failure Detection Using Internal Sensor Signals
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Solution Overview
Problem
Existing vehicle braking systems with a shared holder for primary and secondary brake control systems face challenges in detecting holder failures, such as breaking or loosened screw connections, which can lead to simultaneous system failures and safety risks.
Innovation Solution
A braking system with an evaluation unit that compares sensor signal curves from internal sensors to reference curves to detect holder damage, using internal and external sensors to differentiate between normal and faulty conditions, and generates a holder damage signal for notification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a common holder is used to attach both primary and secondary brake control systems to the vehicle body, then installation space requirement is minimized and component reduction is achieved, but the risk of simultaneous system failure increases if the holder breaks or screw connections loosen
Solution Approach 1:
The evaluation unit continuously monitors sensor signals from the holder and compares them against reference values before actual failure occurs. This preliminary detection allows the system to identify loosening or breaking of screw connections early, enabling preventive maintenance before simultaneous system failure can occur, thus resolving the reliability concern while maintaining the space-efficient common holder design
2Device complexity
If no detection system is implemented for holder damage, then the braking system remains simple and cost-effective, but holder failures such as breaking or loosened screw connections go undetected leading to safety risks
Solution Approach 1:
The brake control system uses its own existing internal sensors to monitor the holder condition without requiring separate external sensing systems. The evaluation unit processes signals already present in the brake control system, allowing the system to self-diagnose holder damage conditions. This self-service approach enables safety monitoring while minimizing additional complexity and cost
3Device complexity
If internal sensors are used for their primary function of monitoring brake control system operation, then the system remains compact and cost-effective, but these sensors must also serve the dual function of detecting holder failures
Solution Approach 1:
The internal sensors of the brake control system are designed to perform multiple functions: monitoring brake control system operation and detecting holder failures. The evaluation unit distinguishes between signals related to brake operation and those indicating holder damage by comparing sensor signals against reference values that account for normal operational variations. This multi-functionality approach maintains component compactness while enabling dual-purpose monitoring without compromising measurement precision for either function
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
Enables reliable detection of holder failures, preventing simultaneous system failures and ensuring timely remediation, applicable to both single and dual brake control systems, including brake-by-wire systems.
Implementation Method 1
an internal sensor, in particular an acceleration sensor, by means of which vibrations of the brake control system occur
Data Source
AI summary
A braking system of a vehicle, with at least one brake control system with a brake pressure regulator which, in case of a braking request, builds up a hydraulic brake pressure by which the vehicle wheel brakes can be actuated. The brake control system is attached to the vehicle body via a holder. For the detection of a holder failure, an evaluation unit is provided, which acquires a sensor signal curve from an internal sensor built into the brake control system. In the evaluation unit, a signal comparison occurs. The acquired sensor signal curve is compared to a reference signal curve. In case of a significant deviation of the acquired sensor signal curve from the reference signal curve, the evaluation unit generates a holder damage signal.