Trailer Control Module Redundancy for Brake System Electrical Failure

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Solution Overview

Problem

Electronically controllable brake systems that control service brakes on both vehicle axles via a central service brake control module fail to implement braking commands when there is an electrical failure, as they cannot convert service brake control signals into pressures, leading to limited deceleration performance and instability.

Innovation Solution

The system employs a trailer control module to control service brake pressures and parking brake pressures in case of a malfunction, using trailer brake pressure as a redundancy to actuate service brakes and parking brakes, ensuring both axles can be braked even if individual service brake circuits fail, through direct control or conversion of pressures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a central service brake control module is used to control service brakes on both vehicle axles, then device complexity is reduced, but reliability deteriorates because the system cannot implement braking commands when there is an electrical failure

Engineering Contradiction:

Improvebrake control system complexityVSAvoidbraking command implementation reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The brake control system is segmented into multiple independent control modules: a central service brake control module for normal operation, and additional service brake control modules for each service brake circuit that can operate independently when the central module fails. This segmentation allows the system to maintain braking functionality even when one control module fails, thus improving reliability while managing complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates redundant service brake control modules that are prepared in advance to take over control functions if the central service brake control module fails. This prior cushioning ensures that braking commands can still be implemented reliably even after an electrical failure, as the redundant modules are already positioned and configured to assume control immediately.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Ease of operation

If service brake circuits are controlled electrically via a service brake control module, then ease of operation is improved, but reliability deteriorates because electrical failures prevent braking command implementation

Engineering Contradiction:

Improvebraking command controlVSAvoidbraking command implementation

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system changes the operational parameter of the service brake control from purely electrical to a hybrid mode that can operate both electrically (via service brake control signals) and pneumatically (via service brake control pressures). This parameter change allows the system to maintain ease of electrical operation under normal conditions while gaining the reliability of pneumatic backup when electrical failures occur, as the service brakes can be actuated through either control signal or control pressure.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the parking brake circuit operates separately from service brake circuits, then reliability is improved through independent power supply, but device complexity increases

Engineering Contradiction:

Improvepower supply independenceVSAvoidbrake circuit configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The parking brake control module is designed with multi-functionality to serve dual purposes: it controls the parking brake circuit during normal operation and serves as a fallback control for service brake circuits when the central service brake control module fails. This universal design allows the system to maintain reliability through independent power supply for the parking brake circuit while reducing overall device complexity by eliminating the need for separate redundant service brake control modules in each circuit.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11511711B2Electronically controllable brake system and method of electronically controlling the brake system

Publication Date: 2022.11.29 ZF CV SYST EURO BV

AI summary

An electronically controllable pneumatic brake system includes a service brake control module for controlling a first and a second service brake circuit, and a trailer control module with a trailer brake pressure connection point for connection to a trailer brake pressure coupling head. The trailer control module outputs a trailer brake pressure via the trailer brake pressure connection point. Upon a malfunction of the first and/or second service brake circuit, the first service brake pressure is controlled depending on the trailer brake pressure; and the second service brake pressure is controlled depending on the trailer brake pressure specified by the trailer control module; and/or the parking brake pressure is controlled directly or depending on the trailer brake pressure specified by the trailer control module. Upon a malfunction of the trailer control module, the trailer brake pressure is controlled depending on the first service brake pressure.