Redundant Brake ECU Structure With Stacked Control Units
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Solution Overview
Problem
Existing brake systems, particularly integrated dynamic brake systems, face instability and failure risks due to the presence of many electronic devices, which can lead to serious accidents if they become inoperable during vehicle operation.
Innovation Solution
A dual control unit structure with redundant printed circuit boards and a stacked motor configuration, where the first and second control units are connected through a bus bar, allowing for continued operation even if one unit fails, with pressure sensors and a motor position sensor connected to both units to ensure stability and miniaturization of the brake system.
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 due to the presence of many electronic devices
Solution Approach 1:
The electronic control unit is divided into two separate control units (first control unit and second control unit) that are physically separated by a first cover. Each control unit has its own MCU and can independently operate, allowing the system to segment the electronic devices and reduce the risk of total system failure while maintaining the required braking functions
Solution Approach 2:
The patent applies local quality by creating physically separated zones for different control units within the same ECU housing. The first control unit and second control unit are positioned in different spaces divided by the first cover, allowing each region to have independent electronic devices with localized failure modes rather than system-wide failure
2Reliability
If a redundant control unit structure is implemented to ensure continued operation when one unit fails, then the system reliability is improved, but the device complexity and space requirement increase
Solution Approach 1:
The patent merges two control units into a single ECU housing structure, combining the first control unit and second control unit within the same overall assembly. This allows redundancy to be achieved while sharing common structural elements, mounting spaces, and connection interfaces, thereby reducing the increase in device complexity
Solution Approach 2:
The second control unit is positioned below the first cover which is below the first control unit, creating a nested arrangement within the ECU housing. This nested structure allows both control units to be compactly arranged in a vertical stack, minimizing the space requirement for the redundant system
3Reliability
If pressure sensors and motor position sensors are connected to both control units through bus bars to ensure stability, then the system stability is enhanced, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The bus bar structure serves multiple functions: it provides electrical connection between the first and second control units, supports the pressure sensor, and provides a common grounding path. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process despite the redundant connections
Data Source
AI summary
The present invention relates to an electronic control unit (ECU) structure of a brake system. An ECU of a brake system, according to the present invention, has a redundancy configuration in which a first control unit, a first cover, and a second control unit are sequentially stacked so that the first control unit and the second control unit are spatially separated by means of the first cover, and thus the second control unit can perform the function of the first control unit without being influenced when the first control unit malfunctions.