Vehicle Brake System Redundancy via Master Sub-Controller Segmentation
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Solution Overview
Problem
Existing vehicle brake systems with electric brakes lack cost-effectiveness and reliability due to the absence of redundancy in their control systems, making them vulnerable to failures in critical components like main microcomputers.
Innovation Solution
A vehicle brake system with multiple controllers, including a master controller and sub-controllers, that can independently control electric actuators on each wheel, ensuring redundancy and reliability by allowing either the master or sub-controller to take over in case of a breakdown, thereby reducing the need for multiple expensive master controllers and enhancing cost efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single main microcomputer is used to control the electric brake, then the device complexity is reduced, but the reliability deteriorates due to lack of redundancy
Solution Approach 1:
The control system is segmented into a master controller and multiple sub-controllers. Each sub-controller is assigned to control specific electric brakes on individual wheels, while the master controller coordinates overall brake control. This segmentation creates functional redundancy where multiple controllers can manage the braking system, improving reliability without requiring a completely complex dual-master architecture.
Solution Approach 2:
The sub-controllers are designed with multi-functionality to perform both wheel-specific brake control and participate in overall vehicle behavior control. Each sub-controller can independently manage its assigned electric brake while also contributing to coordinated braking operations, ABS, and TCS functions, reducing the need for multiple dedicated master controllers.
2Reliability
If multiple master controllers are installed to achieve redundancy, then the reliability is improved, but the cost increases
Solution Approach 1:
The control architecture employs an asymmetric structure with one master controller and multiple sub-controllers with different functional assignments. The master controller handles high-level coordination and vehicle behavior control, while sub-controllers handle wheel-specific control. This asymmetric design achieves redundancy and reliability without requiring multiple identical master controllers, reducing manufacturing costs.
Solution Approach 2:
Instead of copying the expensive master controller multiple times, the system uses simpler sub-controllers that replicate essential control functions for individual wheels. These sub-controllers copy the core brake control functionality needed for redundancy, while the master controller maintains overall system coordination, achieving cost-effective reliability.
3Ease of manufacture
If a single controller is used, then the cost is reduced, but the controllability deteriorates due to lack of redundancy
Solution Approach 1:
The control system is segmented into a master controller and multiple sub-controllers, where each sub-controller is assigned to control specific electric brakes on individual wheels. This segmentation enables independent control of each wheel's brake while maintaining overall system coordination, improving controllability and adaptability without requiring multiple expensive master controllers.
Solution Approach 2:
The control architecture is designed to be dynamic and adaptable, allowing the master controller to distribute control tasks to sub-controllers based on real-time vehicle conditions. The system can dynamically adjust which controller manages which brake, enabling flexible response to various driving scenarios, road conditions, and failure modes, thereby enhancing controllability.
Data Source
AI summary
A highly reliable vehicle brake system that includes an electric brake and achieves redundancy at low cost is provided.A vehicle brake system (1) is provided to a wheel (Wa) of a vehicle (VB), and includes an electric brake (16a) provided with a motor (80), a driver (60) that drives the motor (80), and a first control device (10) provided with a master controller (30) and a first sub-controller (40) connected to each other. The electric brake (16a) is controllable by both the master controller (30) and the first sub-controller (40).