Redundant Brake Actuator Control via Multi-Functional Modules
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Solution Overview
Problem
Existing electronically controlled braking systems for towing vehicles with trailers face challenges in ensuring functional safety when only a single-channel pressure control module is present on an axle, as they lack redundancy to maintain operational wheel brakes in case of electrical faults.
Innovation Solution
The system incorporates a parking brake module and trailer control module to provide pressure control for wheel brakes in case of failures in either electrical brake circuit, allowing for flexible failure logic and maintaining functionality of all wheel brakes through electro-pneumatic or electro-hydraulic units, even if one electrical brake circuit fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-channel pressure control module is used on an axle, then device complexity is reduced, but reliability deteriorates because there is no redundancy to maintain operational wheel brakes in case of electrical faults
Solution Approach 1:
The patent makes the parking brake module and trailer control module multi-functional. The parking brake module can normally control parking brakes but also serves as a backup to control wheel brakes via pneumatic coupling when electrical circuits fail. The trailer control module can normally control trailer brakes but also serves as a backup to control wheel brakes when electrical circuits fail. This multi-functionality provides redundancy without adding dedicated backup components.
Solution Approach 2:
The system uses its own existing components (parking brake module and trailer control module) to provide backup functionality. Instead of introducing external backup systems, the patent enables these modules to control wheel brakes through pneumatic coupling when their primary functions are compromised, allowing the system to self-rescue from failure states.
2Reliability
If pneumatic or hydraulic lines are installed for redundant brake control, then reliability is improved, but device complexity and ease of manufacture deteriorate
Solution Approach 1:
The patent merges the backup control function into the existing electrical control architecture. The parking brake module and trailer control module are integrated into the electrical brake control system and communicate through existing electrical connections. The pneumatic coupling allows these electrical control modules to directly actuate wheel brakes without requiring separate pneumatic or hydraulic distribution lines, combining electrical control intelligence with pneumatic actuation.
Solution Approach 2:
The patent replaces a potentially complex mechanical pneumatic/hydraulic distribution system with a simpler direct pneumatic coupling mechanism. Instead of installing extensive pneumatic or hydraulic lines throughout the vehicle to provide redundant brake control, the system uses direct pneumatic connections between the multi-functional modules and wheel brakes, reducing manufacturing complexity while maintaining reliability.
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
This solution ensures high functional safety by enabling all wheel brakes to remain operational even if one electrical brake circuit fails, simplifying assembly by eliminating the need for pneumatic or hydraulic lines and allowing for easy integration of electrical components in the driver's cab.
Implementation Method 1
They convert the electrical control commands from the control units into pneumatic pressure. The implementation takes place with proportional solenoids or with a combination of inlet/outlet solenoid valves.
Implementation Method 2
pneumatic control pressures, for example, are generated in the foot brake module
Implementation Method 3
An integrated pressure sensor measures the brake pressure controlled by the pressure control module.
Data Source
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AI summary
The assembly (1) has a parking brake module (86) controlled by an electronic control device (10). The module controls combination cylinders (34) attached to a parking brake and a two channel electro-pneumatic pressure control module (30). The combination cylinders are controlled by the brake module, and a trailer control module (46) is controlled by a single-channel-pressure control module (60) or the brake module during malfunction of an electrical brake circuit. The module (60) is controlled by the trailer control module during malfunction of another electrical brake circuit.