Trailer Brake Redundancy Using Dual Pneumatic Circuits
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Solution Overview
Problem
Current trailer braking systems face issues with pneumatic and electrical failures leading to potential vehicle instability, loss of braking functionality, and increased risk of accidents due to lack of redundancy and efficient fault management.
Innovation Solution
A trailer braking system with first and second pneumatic circuits and a spring brake modulator valve arrangement that receives inputs from pneumatic circuits and control pressure from a trailer brake module, allowing for independent control of air flow to brakes and incorporating electrical signals from a second ECU for redundancy, utilizing existing spring brakes to ensure continuous brake functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single pneumatic circuit is used to supply air pressure to brake devices, then the system is simpler, but the reliability decreases due to potential single-point failures
Solution Approach 1:
The pneumatic supply system is divided into two independent pneumatic circuits (first and second circuits) that can independently supply air pressure to the brake devices. This segmentation ensures that a failure in one circuit does not affect the other, maintaining brake functionality and improving reliability while managing complexity through modular design
Solution Approach 2:
Different wheel ends are assigned to different pneumatic circuits based on their position (e.g., left side wheels on first circuit, right side wheels on second circuit). This local differentiation allows isolated failure management where only affected wheels lose braking capability while others remain functional, balancing reliability improvement with acceptable system complexity
2Reliability
If spring brakes are used with modulator valve arrangement, then continuous brake functionality is ensured, but the device complexity increases
Solution Approach 1:
The spring brake modulator valve arrangement is designed to perform multiple functions: it can receive control signals from either the first or second pneumatic circuit, modulate spring brake pressure accordingly, and maintain brake functionality even when one circuit fails. This multi-functionality ensures continuous operation while managing complexity through a unified control mechanism that can adapt to different operational scenarios
Solution Approach 2:
The modulator valve arrangement acts as an intermediary between the pneumatic circuits and the spring brakes. It receives control pressure from either circuit and translates it into appropriate spring brake pressure, providing a buffer that isolates the brake devices from direct circuit failures and ensures continuous functionality while managing the complexity of dual-circuit integration
3Reliability
If redundancy is implemented with second ECU and independent control, then safety is improved, but the system complexity and cost increase
Solution Approach 1:
The control system is segmented into two independent ECUs (first ECU connected to first pneumatic circuit, second ECU connected to second pneumatic circuit). Each ECU can independently control its associated circuit and spring brakes, providing redundancy so that if one ECU fails, the other can maintain brake functionality. This segmentation improves safety and availability while managing complexity through modular, independent control units
Solution Approach 2:
Each ECU is responsible for controlling specific local components (first ECU controls first circuit and associated brakes, second ECU controls second circuit and associated brakes). This local control approach provides distributed redundancy where failure of one control unit does not compromise the entire system, improving safety while managing complexity through localized control functions rather than centralized complex processing
Data Source
AI summary
A brake system is provided for a trailer vehicle having a plurality of axles, each of which has a wheel end on a respective side of the vehicle, the brake system including first and second pneumatic circuits for supplying air pressure to brake devices at the wheel ends. The system includes a spring brake modulator valve arrangement adapted to control pressure to spring brakes on the vehicle, which modulator valve arrangement receives an input from at least one of the pneumatic circuits and a control pressure from the trailer brake module. Flow of air to the brakes is controllable either by the trailer brake module or by the spring brake modulator valve arrangement to provide redundancy.