Redundant Vehicle Brake Control with Triple Failover Circuits
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Solution Overview
Problem
Current brake systems for commercial vehicles lack redundancy in control circuits, making them unsuitable for autonomous driving scenarios where a driver is not present to intervene in case of electronic control circuit malfunctions.
Innovation Solution
A multiple redundant brake architecture combining intelligent foot brake module (iFBM) and electronic parking brake (EPB) architectures to create three independent electric brake control circuits, allowing automated switching between redundant parts, ensuring continued vehicle operation even in case of single circuit failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-circuit electronic brake control system is used, then the device complexity is reduced, but the reliability is insufficient for autonomous driving where driver intervention is not available
Solution Approach 1:
The brake control system is segmented into three independent control circuits: primary electronic brake control circuit, secondary intelligent foot brake module circuit, and tertiary electronic parking brake controller circuit. Each circuit can independently control the brake actuators, allowing the system to maintain functionality even if one circuit fails, thus resolving the contradiction between reliability and complexity by distributing control functions across multiple independent pathways.
Solution Approach 2:
The system implements beforehand cushioning by pre-configuring redundant control circuits that can take over in case of primary circuit failure. The secondary and tertiary circuits are designed to be ready-to-activate, providing a safety buffer that ensures brake functionality is maintained without requiring complex real-time decision-making, thereby improving reliability while managing complexity through predetermined failover mechanisms.
2Reliability
If redundant brake control circuits are implemented, then the reliability for autonomous driving is improved, but the device complexity increases
Solution Approach 1:
The brake actuators (axle pressure modulators and spring brake cylinders) are designed with multi-functionality to receive control signals from multiple different control circuits. The same physical brake components can be actuated by electronic signals, pneumatic signals from the intelligent foot brake module, or parking brake controller signals, universalizing the actuator interface and reducing overall system complexity despite having multiple control pathways.
Solution Approach 2:
The system introduces intermediary components such as the pressure control valve that can convert control signals between different types (electronic to pneumatic). This intermediary mechanism allows different control circuits with different signal types to control the same actuators, providing a bridging layer that manages complexity by standardizing interfaces between diverse control sources and common actuators.
3Ease of operation
If automated switching between redundant brake systems is implemented, then the ease of operation for autonomous vehicles is improved, but the device complexity increases
Solution Approach 1:
The brake control system implements self-service by automatically monitoring the status of primary, secondary, and tertiary control circuits and autonomously switching between them based on detected failures. The system includes self-diagnostic capabilities that detect circuit malfunctions and automatically activate alternative circuits without requiring external intervention or complex switching logic, thereby improving ease of operation while managing complexity through autonomous self-management.
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 solution provides reliable and redundant brake functionality, enabling autonomous vehicles to maintain operation and safety by activating secondary or tertiary control circuits in case of primary circuit malfunctions, thus ensuring continued mission capability.
Implementation Method 1
a pressure control valve, wherein the pressure control valve is configured to convert the second pneumatic parking brake signal into a first pneumatic parking brake signal for controlling the first axle pressure modulator
Data Source
AI summary
A brake system for a vehicle includes a first axle pressure modulator (APM) for service-brake-chambers for a first vehicle-axle, a second axle pressure modulator for spring-brake-cylinders for a second vehicle-axle, the second APM being connected to an electronic-brake-control-unit, which is configured to issue a first electric-control-signal for controlling the first APM and a second electric-control-signal for controlling the second APM, an intelligent foot brake module, which is configured to issue a first pneumatic-control-signal for controlling the first APM and a second pneumatic-control-signal for controlling the second APM, an electronic parking brake controller, which is configured to issue a second pneumatic parking brake signal for controlling the spring-brake-cylinders, and a pressure control valve, which is configured to convert the second pneumatic parking brake signal into a first pneumatic parking brake signal for controlling the first APM.