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Trinova T-IBC(Onebox) Integrated line control system, leading the new era of intelligent driving!

Trinova T-IBC(Onebox) Integrated line control system, leading the new era of intelligent driving!

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  • Time of issue:2023-08-31 14:00
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(Summary description)

Trinova T-IBC(Onebox) Integrated line control system, leading the new era of intelligent driving!

(Summary description)

  • Categories:News  center
  • Author:
  • Origin:
  • Time of issue:2023-08-31 14:00
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Information

Introduction

          For intelligent new energy vehicles, the traditional vacuum booster + pump control hydraulic system (such as ESC, EPBi) can not solve the problem of vacuum source, with the shortcomings of pressure control fluctuations and slow response time can not meet the functional needs of intelligent new energy vehicles. At the same time, considering the limitation of the efficiency of the plunger pump, the pump-controlled hydraulic system is difficult to work for a long time. Trinova T-IBC(Onebox) integrated wire control dynamic system solution completely includes all functions of eBooster and EPBi, with advantages of high integration, fast braking response and high control accuracy, which meets the urgent needs of high-level automatic driving functions and is the core chassis component of intelligent new energy vehicles.

First, environment-driven acceleration line control is booming

          In order to promote the development of automobile power to automobile power, in line with the concept of green development, China has deployed the "Made in China 2025" action program, in which the intelligent connected vehicle technology roadmap clearly points out that it is necessary to develop domain controllers for specific intelligent functions to achieve integrated control of a number of driving assistance functions. Overcome the key technologies of accurate, reliable and coordinated control such as chassis braking, driving and steering. In recent years, China has issued the "New Energy Automobile Industry Development Plan (2021-2035)", which clearly proposes to overcome the core technology of automotive wire control execution system. The line control dynamic system has the characteristics of fast response speed, high control accuracy, higher energy recovery and meeting high-level intelligent driving performance requirements, which has been monopolized by foreign enterprises for a long time, and is the key problem of "jamming neck" of intelligent new energy vehicles in China. In terms of the market, intelligent new energy mass production models have entered L2 and above levels, and the line control industry will usher in a concentrated outbreak opportunity.

Ii. Trinova T-IBC system scheme

          Trinova T-IBC system is an electronic hydraulic line control system that integrates pedal push rod, motor, transmission mechanism, master cylinder, hydraulic module, redundant EPB, etc. In conventional braking, the hydraulic connection between brake pedal and wheel cylinder is cancelled, showing the typical characteristics of hydraulic decoupling, and an independent drive motor is used as a conventional braking source. The pressure building mode of the hollow shaft motor direct drive ball screw piston module makes the assembly mass of about 5.3kg and the pressure building efficiency of more than 90%, which meets the braking requirements of medium and large passenger cars. In addition, the T-IBC is equipped with a displacement sensor and a two-way pressure sensor assembly for monitoring the driver's braking intention and hydraulic model verification. The sensor redundancy scheme can provide a good basis for intention recognition, function degradation, redundancy control, and significantly improve system security and functionality.

TIBC assembly

          In normal working mode, the brake cylinder pressure is completely decoupled from the driver's pedal input, and the braking force of the vehicle is all provided by the motor. The hydraulic oil in the pedal master cylinder does not enter the wheel cylinder circuit when the driver presses the brake pedal, but is pumped into the foot sensation simulator composed of piston spring mechanism, which provides the driver with simulated foot sensation and travel feedback during the conventional braking process. The conventional braking process of the scheme can be summarized as follows: driver's pedal input → pedal displacement sensor signal → braking intention identification → motor action drives the electric master cylinder piston pressure building → brake fluid enters the wheel cylinder through the booster valve → braking force generation.

Hydraulic principle

3. T-IBC key technologies

3.1 Redundant electronic control architecture design

          Electric control scheme based on dual MCU and redundant EPB (as shown below), the whole scheme adopts dual independent external power supply, dual external CAN/CANFD communication and redundant EPB control. The motor drive unit, the motor position sensor, the power management unit and the main control MCU also adopt the redundant architecture of double backup. The main control MCU adopts a 32-bit chip with multi-core lock step and supports the highest ASIL-D functional safety level. Both MCUS CAN achieve complete EPB control and CAN communication functions, and assign master and slave roles by default after power-on initialization. If a single point of system failure occurs, the dual MCUS determine whether to switch the primary/secondary control of the EPB according to the fault diagnosis and processing mechanism, and switch from the system to the master control system if necessary.

ECU architecture

3.2 Series solenoid valve design

          The precise control of T-IBC hydraulic decoupling and wheel cylinder pressure depends on the joint action of 14 high-precision solenoid valves in 6 categories. The traditional ESC solenoid valve is difficult to meet the needs of T-IBC large flow rate and accurate wire control, which easily leads to problems such as large wheel cylinder pressure fluctuation, rough active braking, and loud noise from frequent opening and closing. The performance of the T-IBC system essentially depends on the design level and manufacturing capacity of the serialized solenoid valve. Based on the application experience of ESC million-level mass production, Trinova has spent two years developing six new types of solenoid valve structures and processes that fit the characteristics of T-IBC.

Serialized solenoid valve

3.3 Function design of the vehicle

          Since the driver's direct braking circuit is decoupled from the system's actual pressure building circuit, T-IBC is able to give the customer more design space in terms of vehicle functionality. The T-IBC system can determine the driver's braking intention according to the driver's opening and speed input to the brake pedal, and calculate the output torque of the motor to achieve the active/external pressure building function that meets the driver's intention. In this process, the algorithm compensation will be made for temperature, efficiency and friction.

Basic braking algorithm

          The T-IBC system not only provides basic brake control functions, but also incorporates an intelligent driver assistance system to support a number of additional, value-added functions. Through advanced sensors and intelligent control algorithms, T-IBC can sense the state of the vehicle and the driver's behavior in real time and make adjustments accordingly. For example, in the case of sideside or out of control of the vehicle, the system can help the driver stabilize the vehicle and improve driving safety through accurate braking force and wheel cylinder pressure control.

T-IBC software function definition

Iv. Conclusion

          The development of automobile electrification meets the requirements of environmental protection concept in the process of automobile operation, fits the strategic planning of China's energy development, and the production and sales of new energy models and the market share are rising year by year. The following characteristics of the integrated line control dynamic system have made it the core execution unit of the current intelligent new energy vehicle.

1, the mechanical master cylinder is embedded in the valve block and the vacuum pipe and part of the brake pipe are reduced, making the overall mass reduced and the volume smaller, which is more favorable for the space arrangement of the vehicle;

2. The pedal feeling simulator is added, the foot feeling simulation part is realized by the internal elastic damping element, and the dynamic and static pedal feeling can be customized to meet the needs of different customers.

3. Realize braking decoupling and recovery stability control, which can significantly improve the braking energy recovery efficiency of new energy vehicles;

4, hollow shaft motor direct drive scheme reduces the transmission efficiency loss, making the T-IBC system more rapid response, more accurate control, and smaller volume, lighter weight;

5. The T-IBC system can add redundant braking units to meet the backup braking requirements of automatic driving functions above L3 level.

 

          Compared with traditional brake system configurations, T-IBC requires a more complex system architecture and system redundancy to ensure vehicle safety, reliability and driving experience, and therefore has higher technical barriers. International leading suppliers have accumulated in this field for many years, domestic suppliers are also actively catching up, I believe that the future can provide consumers with more safe, reliable and comfortable products.

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