Brake Pressure Sensor Self-Diagnostics for Early Fault Detection
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Solution Overview
Problem
There is a need for self-diagnosing pressure sensors in vehicles to detect malfunctions and enable timely countermeasures, particularly in critical systems like brake systems, to prevent complete system or vehicle failure.
Innovation Solution
A pressure sensor with a data port, sensing element, pressure port, and data processing means that includes self-monitoring capabilities, temperature compensation, and diagnostic modes to ensure reliable operation and fault detection, using MEMS technology and ASICs for efficient data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If self-diagnosis functions are added to pressure sensors, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines the pressure sensing function and self-diagnosis function into a single integrated sensor device. The data processing means processes both measurement signals and self-test signals within the same device, merging multiple functions that could have been separate components. This integration improves reliability by ensuring both functions work together seamlessly while managing complexity through unified design.
Solution Approach 2:
The pressure sensor is designed with multi-functionality, serving both as a pressure measurement device and a self-diagnosis device. The data processing means can handle different types of signals (measurement signals and self-test signals) and perform multiple operations (processing and evaluating). This universal design allows one device to fulfill multiple roles, improving system reliability without requiring separate dedicated components for each function.
2Reliability
If self-monitoring capabilities are integrated into the pressure sensor, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process integrates the creation of sensing elements and data processing means into a unified production flow. The patent describes a single manufacturing process that produces both the pressure sensing element and the integrated circuit for data processing, rather than requiring separate assembly steps. This merging of manufacturing steps improves reliability through better integration while managing manufacturing complexity through process consolidation.
3Loss of information
If diagnostic information processing is added to the sensor, then information quality is improved, but data processing complexity increases
Solution Approach 1:
The data processing means is divided into specialized processing units that handle different types of information separately. The patent describes distinct processing paths for measurement signals and self-test signals, with dedicated evaluation logic for different failure modes. This segmentation allows comprehensive information processing and failure detection while managing complexity through modular, specialized processing blocks rather than a monolithic complex system.
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 early detection of sensor failures, enhances system reliability, and allows for proactive maintenance in brake systems, ensuring safe and efficient vehicle operation.
Implementation Method 1
The pressure supplied to the sensing element from the pressure port causes mechanical stress and/or deformation in the MEMS or in the bridge connection
Implementation Method 2
The sensing element may comprise a micro-electro-mechanic system (MEMS), in particular a resistively or a capacitively operating MEMS
Data Source
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AI summary
A pressure sensor (1) is disclosed. The pressure sensor (1) comprising - a data port (2) configured for providing sensor data, - a sensing element (3) configured for sensing a pressure measurement value based on a pressure supplied to the sensing element, - a pressure port (4) for receiving a pressure and for supplying the pressure to the sensing element (3), and - data processing means (5). Further, a method, a brake system (50), a vehicle (100) and the use of a pressure sensor (1) are disclosed.