Regenerative Air Brake Module Mechanical Override
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hybrid vehicles face challenges in maintaining the 'feel' of braking and incorporating mechanical safety features during regenerative braking, especially in commercial truck systems, where the blending of regenerative and foundation braking must be controlled effectively to ensure predictable operation and safety.
Innovation Solution
An air brake system that blends regenerative and foundation braking through a mechanical override mechanism, using a brake input member, sensor, controller, and control valves to manage air pressure, with a mechanical bypass for aggressive braking requests, ensuring a controlled delivery of air pressure to vehicle brakes and incorporating redundancy for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If regenerative braking is blended with foundation braking to improve vehicle operational efficiency, then energy recovery is improved, but braking feel predictability and operator control deteriorate
Solution Approach 1:
The patent introduces a mechanical override system with a bypass valve that acts as an intermediary between the electronic control system and the foundation braking system. When the operator applies aggressive braking (exceeding a threshold), the bypass valve mechanically overrides the electronic control, directly connecting the treadle circuit to the relay valve to provide full foundation braking. This mediator ensures that operator intent is always honored, maintaining predictable braking feel while allowing regenerative braking to operate during normal conditions.
2Productivity
If electronic control systems are used to manage regenerative braking blending, then energy recovery control is improved, but system reliability and safety deteriorate due to potential electronic failures
Solution Approach 1:
The patent implements a mechanical safety backup system that is预先 designed to compensate for potential electronic control failures. The bypass valve and mechanical override pathway are built into the system in advance, so that if the electronic control system fails or provides inadequate braking response, the mechanical system immediately takes over to ensure safe braking operation. This prior cushioning approach enhances reliability without compromising the efficiency of electronic regenerative braking control during normal operation.
3Speed
If mechanical override bypasses electronics for aggressive braking requests, then system response time is improved, but device complexity increases
Solution Approach 1:
The patent extracts the critical safety function from the complex electronic control system and places it in a simple mechanical override pathway. The bypass valve is designed to directly connect the treadle circuit to the relay valve when activated, bypassing all electronic components. This extraction of the essential braking function into a dedicated mechanical pathway reduces response time for aggressive braking while containing complexity to a specific, well-defined component rather than complicating the entire system.
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 system effectively blends braking forces during low deceleration conditions, maintains predictable operation, and ensures mechanical safety by bypassing electronics for aggressive braking, providing a reliable and safe braking experience.
Implementation Method 1
A control valve is configured to control a delivered air pressure level in a brake relay circuit based on the valve command
Implementation Method 2
A mechanical bypass valve is operable to directly communicate treadle pressure to the relay valve when the requested brake pressure is greater than an override limit
Implementation Method 3
An electronic pressure regulator is configured to communicate treadle pressure to the relay valve when in the first mode of operation and is configured to communicate an air pressure less than the treadle pressure when in the second mode of operation
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An air braking system (10) for a vehicle blends regenerative and foundation braking during low deceleration conditions in an effective and controlled manner. The braking system (10) also includes a mechanical override that bypasses system electronics in response to an aggressive brake request such that treadle circuit pressure is sent directly to a brake relay circuit to actuate vehicle brakes.