Redundant Electric Brake Power Module Switching for Lower Loss
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Solution Overview
Problem
Existing electric brake systems with three-phase dual winding motors experience unnecessary power loss due to constant operation of two power modules, reducing the travel distance of vehicles.
Innovation Solution
A control apparatus and method that includes a first and second power module, an input unit, calculation unit, determination unit, and control unit to minimize power loss by determining the state of each module and controlling their operation based on current thresholds and commands to reduce unnecessary power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two power modules operate constantly in a three-phase dual winding motor system, then system reliability is improved through redundancy, but power loss increases unnecessarily
Solution Approach 1:
The patent implements dynamic operation mode switching for the dual power module system. The control unit dynamically adjusts the operation state of the second power module based on real-time diagnostic information. When the first power module operates normally, the system switches to a single power module operation mode to reduce power loss. When a failure is detected, the system automatically transitions to dual power module operation or single power module failure mode, thereby dynamically optimizing both reliability and energy efficiency throughout the system lifecycle.
Solution Approach 2:
The patent changes the operational parameters of the power modules based on system state. By monitoring diagnostic information and changing the operation parameter (on/off state) of the second power module, the system adapts to different operational conditions. This parameter change allows the system to minimize power loss during normal operation while maintaining reliability through automatic failure response.
2Reliability
If two power modules are used for redundancy, then braking system reliability is improved, but fuel efficiency deteriorates due to increased power consumption
Solution Approach 1:
The system dynamically adjusts power module operation during vehicle operation. During normal braking operations, only one power module is activated, reducing energy consumption and improving fuel efficiency. The redundancy capability remains available but is not continuously consumed, creating a dynamic balance between reliability preparation and actual energy usage.
Solution Approach 2:
The patent extracts the second power module from active operation when it is not needed for redundancy. By taking out the second power module from the active state during normal operation, the system eliminates unnecessary power consumption while maintaining the capability to activate it when reliability is needed, thus improving fuel efficiency without compromising safety.
3Reliability
If diagnostic monitoring of power modules is implemented, then system reliability is improved through failure detection, but device complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where diagnostic information from the power modules is continuously monitored and fed back to the control unit. The control unit processes this feedback information to determine the operational state of each power module and automatically adjusts the system operation accordingly. This feedback loop enables reliable failure detection without requiring complex manual monitoring systems.
Solution Approach 2:
The power modules perform self-diagnosis and report their own status to the control unit. Each power module monitors its own operational parameters and communicates its health status, enabling the system to detect failures without external intervention. This self-service approach reduces the complexity of external monitoring equipment while maintaining high reliability through automated failure detection.
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
Reduces power loss by optimizing the operation of power modules, thereby improving vehicle fuel efficiency.
Implementation Method 1
An electric brake system may supply hydraulic pressure required for braking to wheel cylinders by advancing a master cylinder using a rotational force of the motor, which is generated by operating a motor based on a pedal effort of a brake pedal
Implementation Method 2
a power module may include a metal-oxide-semiconductor field-effect transistor (MOSFET)
Data Source
AI summary
An apparatus for power loss minimization in a redundancy electric brake system includes: first and second power modules receiving power from a battery and supplying a three-phase alternating current to first and second windings of a motor, respectively; an input unit receiving data from an input information detector, wherein the data includes first and second power modules diagnostic information, MOSFET specifications, diode specifications, and a current command for generating a required braking force; a calculation unit calculating current threshold of minimum power losses using the data; a determination unit determining states of the first and second power modules using the first and second power modules diagnostic information; and a control unit configured to, upon determining that both states of the first and second power modules are normal, perform a mode for control of power loss minimization based on the current command and the current threshold of minimum power losses.