Redundant Brake ECU Assembly for Fault-Tolerant Control
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Solution Overview
Problem
Brake systems in vehicles, particularly in autonomous and electric vehicles, are prone to failure due to the integration of many electronic devices, which can lead to serious accidents when a part of the system becomes inoperable.
Innovation Solution
A redundant electronic control unit (ECU) assembly structure with symmetrical or asymmetrical control units, each equipped with microcontrollers, bus bars, and redundant components to ensure normal operation even if one unit fails, including dual winding motors, pedal sensors, and pressure sensors connected through specific bus bars and PCBs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrated dynamic brake system with multiple electronic devices is used to provide various functions and improve stability, then the braking power and stability are enhanced, but the risk of system failure increases
Solution Approach 1:
The brake control system is divided into multiple independent control units (first control unit and second control unit), each capable of independently controlling the brake motor. This segmentation allows the system to maintain functionality even when one control unit fails, thereby improving reliability without requiring a complete system redesign.
Solution Approach 2:
The patent implements a redundant control unit structure where the second control unit is prepared in advance as a backup for the first control unit. When the first control unit fails, the second control unit can immediately take over, ensuring continuous brake operation. This preliminary preparation of backup components prevents system failure before it occurs.
2Reliability
If redundant control units are implemented to ensure normal operation when one unit fails, then system reliability is improved, but the device complexity and component quantity increase
Solution Approach 1:
Multiple control units are integrated into a single housing with a unified structure. The first and second control units share the same housing, cover, and partition structure, and both connect to common components like the brake motor and pedal sensor. This merging approach reduces overall system complexity compared to having completely separate redundant systems.
Solution Approach 2:
The second control unit is designed to perform the same functions as the first control unit, making it a universal backup. Both control units can independently control the brake motor, and both can receive signals from the pedal sensor. This multi-functionality allows either unit to take over completely if the other fails, simplifying the redundancy design.
3Reliability
If control units are disposed in separated spaces with partition for redundancy, then system stability is improved through fault isolation, but the housing volume increases
Solution Approach 1:
The first and second control units are nested within a single housing structure, with each control unit occupying its own separated space defined by internal partitions. This nesting approach allows fault isolation between control units while maintaining a compact overall form factor, as both units share the same external housing boundaries rather than requiring separate housings.
Solution Approach 2:
The control units are arranged in a spatial configuration within the housing, utilizing internal volume efficiently through vertical or horizontal stacking with partitions. This dimensional arrangement isolates faults between units while minimizing the increase in external housing volume, as the separation occurs internally rather than through external expansion.
Data Source
AI summary
The present invention relates to an electronic control unit (ECU) structure of a brake system, and has an ECU board that is arranged, as an addition, in a symmetric or asymmetric structure in order to form redundancy in preparation for the breakdown of an ECU, and has sensors that are also arranged for implementation of the redundancy, and thus the brake system can be operated even if a part of the ECU breaks down.