Two-Box Brake Architecture With Redundant Pressure Generation
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Solution Overview
Problem
Existing brake systems for autonomous driving and electric vehicles face challenges in reducing weight and dimensions, increasing reliability, and meeting high safety requirements, while also ensuring optimal braking performance even in failure scenarios.
Innovation Solution
A two-box brake system design featuring an electric brake booster connected to a standard ESP unit via two hydraulic lines, with a compact and lightweight brake booster that decouples the main cylinder piston from the motor drive, providing redundant pressure generation and power supply, and incorporating a pedal travel simulator for consistent pedal feel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a redundant brake system with e-booster and ESP is implemented for autonomous driving, then safety and reliability are improved, but weight and system dimensions increase
Solution Approach 1:
The patent combines the e-booster and ESP units into a single integrated brake system, sharing common components such as the hydraulic circuit, control unit, and physical space, thereby reducing overall weight and dimensions while maintaining redundant functionality for safety
Solution Approach 2:
The control unit serves multiple functions by managing both the e-booster for brake pressure generation and the ESP for stability control, eliminating the need for separate control systems and reducing overall system weight
2Reliability
If a redundant brake system with e-booster and ESP is implemented for autonomous driving, then safety and reliability are improved, but system complexity increases
Solution Approach 1:
The patent merges the e-booster and ESP into a single integrated unit with shared hydraulic circuits and control mechanisms, reducing the number of separate components and connections while maintaining redundant safety functions
3Volume of moving object
If the main cylinder piston is decoupled from the motor drive, then compactness and responsiveness are improved, but mechanical complexity increases
Solution Approach 1:
The brake booster is divided into separate functional modules: the motor drive unit and the main cylinder unit, allowing independent optimization of each component and enabling a more compact overall design while maintaining functional integrity
Solution Approach 2:
A decoupling mechanism serves as an intermediary between the motor drive and main cylinder piston, enabling independent movement and optimization of each component while maintaining the necessary mechanical connection for force transmission
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 achieves a compact, lightweight, and highly reliable brake system with consistent pedal feel, enhanced safety through redundant systems, and improved braking performance even in failure scenarios, such as ESP motor failure.
Implementation Method 1
an electric brake booster (BKV), a so-called e-booster, and an ESP system (Electronic Stability Control System)
Data Source
AI summary
A brake system may include an actuation device that may actuate a first piston-cylinder unit to apply pressure medium to at least one brake circuit via a valve device, where a piston of the first piston-cylinder unit separate first and second working chambers; a second piston-cylinder unit, having an electromotive drive and a transmission to feed pressure medium to at least one of the brake circuits via a valve device; and a motor-pump unit having a valve device to feed pressure medium to the brake circuits. The motor of the electromotive drive of the second piston-cylinder unit and the motor of the motor-pump unit may be used jointly or independently of one another, under control of a control device. The motor-pump unit is connected via two hydraulic connections, one or both of which may incorporate separating valves, to the first and second working chambers of the first piston-cylinder unit.