IPGATE AG · IP Portfolio B2 · IBS Gen2 – Part 2
IP Portfolio B2 –
Overview
2nd generation integrated braking systems (IBS2 – Part 2)
| Portfolio | IP Portfolio B2 |
| Technology | IBS Gen2 (IBS2) – Part 2 |
| Development Period | 2015 |
| Patent Families | E141 · E142 · E144 · E145 · E146 |
| Core Innovations | 36 independent inventions |
| Key Technologies | HDS 2 · SMBS · DAP · ECU Sensors |
Overview
IP Portfolio B2 – Overview
In 2015, IPGATE developed 36 independent inventions in five patent families (E141, E142, E144, E145, E146) within just twelve months.
Building on the foundations of portfolio A, in particular the MUX multiplexing process (E87) and the first-generation highly dynamic pressure control (HDS 1, E102), these inventions mark the evolutionary leap to the second generation of the 1-box electrohydraulic braking system (IBS2). Four pillars of innovation define this leap: the highly dynamic HDS 2 pressure control system for software-defined longitudinal and lateral dynamics control, including torque vectoring and wheel-specific recuperation; the self-monitoring brake system SMBS with continuous seal and valve diagnostics during operation; a radical reduction in valves through bidirectional inlet valves and central outlet valves, which significantly reduces costs, installation space, and weight; and ECU-integrated sensor solutions for compact, redundant pedal travel detection.
Structure
Four Technology Pillars
The portfolio is structured around four pillars that together define the evolutionary leap to second-generation 1-box electrohydraulic braking systems.
HDS 2: Second-generation highly dynamic pressure control
With HDS 2 (E141, 12 inventions), IPGATE introduced the second generation of highly dynamic pressure control, an extension of the HDS process defined in E102 (Portfolio A) to full degrees of freedom. While HDS 1 (E102) focused on finely metered pressure adjustment using a cascaded control structure with piston stroke and piston speed control via inlet valves (sequential, simultaneous, or partially simultaneous), HDS 2 expands the control concept to include additional time control or PWM control of the outlet valves. This second degree of freedom enables simultaneous pressure increase and decrease in different wheel brakes for the first time. The control architecture has also been extended to three types of delivery devices: plunger (HDS 2.1), double-stroke piston (HDS 2.2), and rotary pump (HDS 2.3).
E145 and E146 transfer the control system to complete brake systems: E145 as a floating piston BBW with integrated HDS 2, E146 as a double-stroke piston system with bidirectional pressure control via forward and reverse stroke, model-based pV control, and high-pressure relief ≥100 bar. Together, these three families form the foundation of a software-defined pressure architecture for torque vectoring and autonomous driving. Approximately 22 of the 36 inventions fall under this pillar.
Valve reduction: Cost-optimized system architecture
The extended degrees of freedom of HDS enable a radical reduction in the number of valves. To apply HDS 2 to the double-stroke piston (DAP), IPGATE reconfigured the DAP concept: solenoid valves release the pressure from one or two working chambers to the reservoir through precise volume control. E146 requires bidirectional inlet valves with only one outlet valve per brake circuit, a 50% reduction in outlet valves. Pressure build-up and release continue to be performed preferably via inlet valves in the closed brake circuit, but in special cases or for specific new functions (ABS on high-μ, braking with steering intervention), they can also be performed via outlet valves in certain cases, either time-controlled or finely dosed via PWM.
E145 also provides a solution where pressure is released via only one outlet valve for two wheel brakes of a brake circuit (front axle); pressure release then takes place with minimal effort from two wheel brakes (e.g., the front axle) via only one outlet valve. Approx. 3 inventions.
SMBS: Self-monitoring braking system
A central focus was on advanced system diagnostics during driving. Instead of pre-drive checks, the SMBS (E142, 5 inventions) checks the valve and seal integrity after each braking operation in three modes: BED (~5 bar, after each braking operation), CSD (10–20 bar, standstill) and PSD (up to 100 bar, parking state). Purely software-based, without additional hardware, this reduces the probability of failure to 10⁻⁸ to 10⁻¹⁰ per year.
E145 and E146 extend the diagnostics to include THZ floating piston tests during driving and parking, thus completely monitoring the mechanical fail-back level for the first time. Approx. 8 inventions.
Sensors: ECU-integrated sensor solutions
E144 (3 inventions) further develops the sensor technology fundamentals from IP portfolio A. The modular 1-box architecture with transverse arrangement of the master brake cylinder and pressure supply has become the standard principle of today's brake-by-wire systems. The ECU-integrated pedal travel and piston position sensors are located directly on the control unit circuit board: rack and pinion system with micrometer resolution and contactless flow guide variant. Separate measuring paths for the pedal and piston create redundancy for SAE L4/L5.
Patent Families
Five Families · 36 Core Innovations
Each patent family targets a distinct technical layer of the IBS2 system, providing layered protection across control architecture, diagnostics, sensor integration, and system-level actuation.
Pillar 1 · HDS 2
Second generation of highly dynamic pressure control, extending HDS 1 to full degrees of freedom. Covers plunger (HDS 2.1), double-stroke piston (HDS 2.2), and rotary pump (HDS 2.3) delivery devices.
Pillar 4 · Sensors
ECU-integrated pedal travel and piston position sensors located directly on the control unit circuit board, with separate measuring paths creating redundancy for SAE L4/L5.
Pillar 3 · SMBS
Three-mode diagnostics (BED / CSD / PSD) checking valve and seal integrity after each braking operation. Purely software-based, reducing failure probability to 10⁻⁸ to 10⁻¹⁰ per year.
Pillars 1 & 3
Floating piston Brake-by-Wire system with integrated HDS 2, single outlet valve solution for two wheel brakes, and THZ floating piston diagnostics during driving and parking.
Pillars 1 & 2
Double-stroke piston BbW with bidirectional pressure control, model-based pV control, high-pressure relief ≥100 bar, and 50% reduction in outlet valves through bidirectional inlet valves.
At a Glance
Patent Family Summary
| Family | Priority | Innovations | Cumulative | Pillar(s) | Jurisdictions |
|---|---|---|---|---|---|
| E141 | 03 / 2015 | 12 | 12 | 1 · HDS 2 | EP · DE · US · CN · JP |
| E144 | 03 / 2015 | 3 | 15 | 4 · Sensors | EP · DE · US · CN |
| E142 | 04 / 2015 | 5 | 20 | 3 · SMBS | EP · DE · US · CN |
| E145 | 03 / 2015 | 5 | 25 | 1 · HDS 2 3 · SMBS | EP · DE · US |
| E146 | 03 / 2015 | 11 | 36 | 1 · HDS 2 2 · Valve Reduction | EP · DE · US · CN · KR |
Strategic Significance
Strategic Importance
IPGATE has once again anticipated the future early on. Many of these concepts developed in 2015, in particular HDS 2 and SMBS, are now key elements of the second generation of 1-box systems from leading global Tier 1 suppliers. The portfolio addresses the central requirements of products that are produced in large quantities, where cost and reliability are paramount and autonomous driving from SAE Level 3 to 5 is being prepared. Low failure probability thanks to seamless self-diagnosis, new degrees of freedom in finely tuned pressure adjustment for torque vectoring and recuperation, cost efficiency through radical valve reduction, and integrated sensor technology for cost reduction and reliability. Patents granted in the most strategically important markets: USA, China, Europe, Japan, and Germany.
