Redundant Brake Controller System for Heavy-Duty Vehicles
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Solution Overview
Problem
Heavy-duty vehicle braking systems face challenges in maintaining safe operation and stability when a brake controller fails, as existing redundancy solutions increase costs and complicate servicing without ensuring seamless transition to backup systems without affecting vehicle control.
Innovation Solution
A redundant braking system for heavy-duty vehicles with interconnected brake controllers that adjust wheel slip limits based on road friction conditions, allowing one controller to take over in case of failure, and utilizing trailer wheels as an anchor to maintain stability during front axle brake controller failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two or more independently controlled complete brake systems are arranged in parallel or in series to achieve redundancy, then braking reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges two brake controller functions into a single integrated controller unit. The controller is designed with dual capability to manage both primary and redundant brake systems through unified control logic, reducing the number of separate control units while maintaining redundancy functionality.
Solution Approach 2:
The single brake controller is designed as a multi-functional device that can operate in multiple modes: normal operation controlling the primary brake system, and fail-operational mode where it takes over control of the redundant brake system. This universal design eliminates the need for separate dedicated controllers for each system.
2Reliability
If two or more independently controlled complete brake systems are arranged in parallel or in series to achieve redundancy, then braking reliability is improved, but servicing complexity increases
Solution Approach 1:
By combining the control functions for both primary and redundant brake systems into a single controller, the patent reduces the number of components that require separate servicing. Maintenance personnel only need to service one integrated controller unit rather than multiple separate controllers.
3Reliability
If a back-up brake controller is used to assume control in case of failure, then braking reliability is improved, but vehicle stability control may be negatively affected
Solution Approach 1:
The controller is pre-configured with knowledge of both primary and redundant brake system characteristics during system design and initialization. This preliminary configuration includes storing control parameters, brake response characteristics, and coordination strategies that enable seamless transition between systems without compromising vehicle stability.
Solution Approach 2:
The controller continuously monitors the operational status of both primary and redundant brake systems, as well as vehicle dynamics parameters. This feedback mechanism allows the controller to detect failures and adjust control strategies in real-time to maintain vehicle stability during fail-operational mode transitions.
Data Source
Figure 1A~1C
Figure 2A~2B
Figure 3A~3B
AI summary
A braking system for a heavy duty vehicle, the braking system comprising a first brake controller arranged to control braking on a first wheel and a second brake controller arranged to control braking on a second wheel, based on a respective configured wheel slip limit and on a respective brake torque request, wherein the first and the second brake controllers are interconnected via a back-up connection arranged to allow one of the first and the second brake controller to assume braking control of the wheel of the other of the first and the second brake controller in case of brake controller failure, the braking system comprising a control unit arranged to, in response to brake controller failure, reduce (601) the configured wheel slip limit (λCON, 710) associated with the failed brake controller to a reduced wheel slip limit (λLOW, 730).