One Module — Two Protection Directions

Patent family E144 addresses two fundamental design challenges of modern brake-by-wire systems simultaneously: compact modular packaging (WO1) and ECU-integrated high-precision sensing (WO2).

Modern brake-by-wire systems have to solve two core design problems simultaneously: How can an electrohydraulic brake unit be designed to be so compact and modular that it functions as a scalable platform from fail-safe to fail-operational? And how can safety-critical operating variables — pedal travel, piston position, rotor movement — be measured with micrometer precision without requiring additional components and cabling outside the ECU?

E144WO1 — Modular 1-box architecture (packaging): Describes a design principle in which the piston-cylinder unit and pressure supply device are arranged with their longitudinal axes transverse to each other, and are integrated together with the valve arrangement, electric motor, and ECU in a vertical stacking direction to form a compact 1-box unit. This transverse arrangement in a stacked design enables a modular platform covering both fail-safe configurations (one pressure supply with a mechanical brake pedal) and fail-operational configurations (two pressure supplies in a common 1-box unit). Patents granted in the USA (US10,549,737 B2) and China (CN107635840B) secure this architectural principle in the two most strategically important markets.

E144WO2 — ECU-integrated sensor solutions (higher technical significance): Relates to innovative sensor concepts for high-precision detection of piston, brake pedal, and rotor movements, with sensor elements located directly on the ECU's system circuit board. The concept combines two sensor approaches: the main mechanical solution uses a rack-and-pinion shaft system to convert linear translational movement into rotational movement of a magnetized sensor target — implemented as a rotating button cell (N/S permanent magnet) that enables measurement resolution in the micrometer range. This mechanical solution has been granted in all three jurisdictions (US11,718,280 B2, CN107531225B, EP3271223B1) and represents the more commercially and technically relevant innovation.

In total, the E144 family comprises five granted patents (B2/B1 status) with five independent claims in three jurisdictions (US, CN, EP). All patents share the common filing date of 14 March 2016 and trace back to WO2016150746A1.