Front-Wheel Differential Limiting for Brake Failure Redundancy
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Solution Overview
Problem
Existing electric brake devices with dual motor systems for redundancy increase component costs and complexity, while maintaining effective braking functionality.
Innovation Solution
A vehicle control system with a differential device and a differential limiting mechanism, where a first electric brake mechanism and a second electric brake mechanism apply braking forces to respective drive wheels, and a controller assesses failures and required braking forces to adjust differential operation, allowing for redundancy without dual motor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dual motor system is provided for redundancy in the electric brake mechanism, then reliability is improved, but device complexity and component cost increase
Solution Approach 1:
The system divides the braking function across multiple wheels, with each wheel having its own electric brake mechanism. When one mechanism fails, the other wheels can still provide braking force, achieving redundancy without duplicating the entire motor system.
Solution Approach 2:
The differential limiting mechanism serves multiple functions: it limits differential rotation during normal operation and also enables redistribution of braking force when a failure occurs, allowing a single system to handle both normal and failure conditions.
2Reliability
If a dual motor system is provided for redundancy in the electric brake mechanism, then reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The system uses multiple individual electric brake mechanisms at different wheels rather than duplicating entire motor assemblies, reducing manufacturing complexity and component costs while maintaining redundancy.
Solution Approach 2:
The differential limiting mechanism acts as an intermediary that coordinates between the electric brake mechanisms and the drive system, enabling failure compensation through differential control rather than requiring redundant motors.
3Reliability
If the differential limiting mechanism limits differential operation, then reliability is improved through failure compensation, but productivity may be affected due to additional control operations
Solution Approach 1:
The control portion continuously monitors the operational state of electric brake mechanisms and automatically adjusts differential limiting control when failures are detected, providing real-time feedback-based reliability compensation without manual intervention.
Solution Approach 2:
The system prepares the differential limiting mechanism in advance to compensate for potential failures, so when a failure occurs, the compensation action is already positioned to activate quickly, minimizing the impact on productivity.
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
This configuration secures redundancy in the electric brake system while controlling component costs and ensuring sufficient braking force, even in the event of failures, by coordinating the differential device and electric brake mechanisms.
Implementation Method 1
The ball ramp mechanism converts the rotation of the motor into linear motion and transfers the linear motion to a piston
Implementation Method 2
presses brake pads against a disc rotor to generate a braking force
Data Source
AI summary
An electrically controlled differential gear is disposed between a right front wheel and a left front wheel of a vehicle. The electrically controlled differential gear includes a clutch mechanism that limits a differential operation of the electrically controlled differential gear. A second ECU (control portion) obtains information as to failure associated with actuation of a right front electric brake mechanism. The second ECU obtains a physical amount relating to a required braking force which is applied to the left front wheel and the right front wheel. The second ECU outputs a differential limiting control command for limiting the differential operation of the electrically controlled differential gear to the clutch mechanism (or more specifically, a differential ECU that controls the clutch mechanism) based on the information as to the failure and the physical amount relating to the required braking force.