Modular Electrohydraulic Braking Redundancy for By-Wire Trucks

Solution Overview

Problem

Current heavy-duty passenger trucks lack fully by-wire braking systems, and existing electronic brake systems with hydro-boost modules are not redundant, leading to potential failures if one component fails.

Innovation Solution

A modular electrohydraulic braking system with independent first and second braking systems, each with its own control unit and low-pressure accumulator, allowing for redundant actuator operation and centralized domain control, ensuring continued braking performance even if one system fails.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single electronic brake system with hydro-boost module is used, then the device complexity is reduced, but the reliability deteriorates due to lack of redundancy

Engineering Contradiction:

Improvebraking system reliabilityVSAvoidbraking system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The braking system is divided into two independent electrohydraulic braking systems, each with its own control unit and low-pressure accumulator. This segmentation creates redundancy where each system can independently provide braking functionality, ensuring that if one system fails, the other can still operate to maintain vehicle safety.

Inventive Principle:

Principle #1Segmentation

2Reliability

If multiple independent braking systems are implemented, then the reliability is improved through redundancy, but the device complexity increases

Engineering Contradiction:

Improvebraking system redundancyVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The braking system is divided into two independent electrohydraulic braking systems, each with its own control unit and low-pressure accumulator. This segmentation creates redundancy where each system can independently provide braking functionality, ensuring that if one system fails, the other can still operate to maintain vehicle safety.

Inventive Principle:

Principle #1Segmentation

3Reliability

If a single hydro-boost module is used, then the ease of operation is maintained, but the reliability deteriorates due to potential component failure

Engineering Contradiction:

Improvebraking system failure resistanceVSAvoidbraking system operation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The braking system is divided into two independent electrohydraulic braking systems, each with its own control unit and low-pressure accumulator. This segmentation creates redundancy where each system can independently provide braking functionality, ensuring that if one system fails, the other can still operate to maintain vehicle safety.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If centralized domain control is implemented in a modular system, then the device complexity increases, but the adaptability improves

Engineering Contradiction:

Improvebraking system configuration flexibilityVSAvoidcontrol system integration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control units in each electrohydraulic braking system are designed to perform multiple functions including pressure regulation, fault detection, and communication with the domain controller. This multi-functionality allows the system to adapt to different operating conditions and failure modes while maintaining a modular architecture that can be configured for various vehicle applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The modular system provides redundancy and improved performance by allowing multiple actuators to operate independently, reducing hydraulic supply requirements and enabling faster brake pressure application, while maintaining braking functionality even if one actuator fails.

Implementation Method 1

a first low pressure accumulator connected to the first electrohydraulic braking system

Methodology Applied

Scientific EffectHydraulic Accumulator: Hydraulic Accumulator

Implementation Method 2

first electrohydraulic braking system with a first at least one hydraulically operated wheel brake

Methodology Applied

Scientific EffectElectrohydraulic conversion:

Data Source

PatentUS20260028006A1Modular braking system for a motor vehicle

Publication Date: 2026.01.29 CONTINENTAL AUTOMOTIVE SYSTEMS INC

AI summary

A braking system for a vehicle has a first electrohydraulic braking system that a first control unit, a first low pressure accumulator and with a first at least one hydraulically operated wheel brake. The braking system also includes a second electrohydraulic braking system with a second at least one hydraulically operated wheel brake, a second control unit and a second low pressure accumulator. The braking system also includes where the first electrohydraulic braking system is fluidly independent from the second electrohydraulic braking system.