Overview

IP Portfolio B3 – Overview

During the innovation phase from late 2015 to mid-2016, IPGATE developed 22 independent inventions in four patent families (E147–E150) within just seven months.

Building on the foundations of portfolios A and B2 – in particular the MUX and piston pressure control PPC (E87), the highly dynamic pressure control systems HDS 1 and HDS 2 (E102, E141, E145, E146) and the self-monitoring braking system SMBS (E142) – portfolio B3 addresses four crucial key technologies that pave the way for the brake-by-wire system to reach series production: an innovative valve circuit for check valve-free, fault-tolerant pressure control; a double-stroke pressure supply (DAP) for simultaneous dual-circuit brake circuits pressure increase and pressure release; the physical integration of all components into a compact 1-box architecture; and sensor-based on-board diagnostics for predictively maintainable systems.

Structure

Four Technology Pillars

The portfolio is structured around four pillars that together cover the full technology stack from novel valve circuitry to predictive self-diagnosis, enabling series production of brake-by-wire systems.

Pillar 1 · Valve Circuitry (E147) Pillar 2 · DAP (E148) Pillar 3 · 1-Box Integration (E149) Pillar 4 · SMSD (E150)

Innovative valve circuitry: New safety architecture

With E147 (3 inventions), IPGATE introduced a fundamentally new valve circuit for brake-by-wire systems. The key innovation is that the anchor chamber of the inlet valve is hydraulically connected to the brake circuit, while the valve seat outlet leads to the wheel brake – a "reverse" connection compared to the state of the art since the introduction of ABS in 1978. For the first time, this architecture enables purely volume- and time-controlled pressure regulation during pressure build-up (bidirectional volume PWM), completely eliminating the need for check valves.

Any excess pressure trapped in the wheel brake during a power failure is automatically reduced by the valve seat pressure – a decisive safety gain. In addition, wheel brake pressures can be maintained in a targeted manner, even if the inlet pressure of the pressure supply is lower than the wheel brake pressure. This degree of freedom opens up new possibilities for torque vectoring, regenerative braking, and wheel-selective pressure control. Patents granted in EP, US, JP; proceedings pending in CN.

Patent Family E147

Check Valve-Free Fault-Tolerant Pressure Control

3 Core Innovations · 2015

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Double-stroke pressure supply: Simultaneous dual-circuit control

E148 (5 inventions) addresses the pressure supply side with a double-acting piston (dual-action piston, DAP). Two differently sized effective areas form two independent working chambers, which can simultaneously build up and release pressure via separate hydraulic circuits. Pressure build-up is controlled by piston stroke control based on pressure-volume characteristics. Switching valves allow targeted relief via working chambers or directly via outlet valves.

An optional connecting line between the working chambers enables pressure equalization and volume-based circuit coupling. A single compact double-stroke piston thus replaces two separate pressure sources – crucial for autonomous vehicle systems that require simultaneous, independent pressure control in multiple circuits. With 16 family members in 10 jurisdictions (EP, DE, FR, GB, NL, US, JP, KR, CN, IN), E148 is widely protected internationally.

Patent Family E148

DAP – Double-Acting Piston Pressure Supply

5 Core Innovations · 2015

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Integrated 1-box architecture: From concept to series production

While E147 and E148 optimized pressure control and supply as functional units, E149 (13 inventions) addresses the physical integration of all components into a single housing. The core idea is the parallel arrangement of the pressure supply (plunger or DAP) and the master brake cylinder in a compact, modular unit with integrated electronics and valve control. The family includes innovations on several levels: the Parallel Integrated Brake Pressure Unit (PIB) as the basic architecture, bevel gear sensor integration on the system board, an integrated clutch/transmission actuator, various connector geometries, and optimized ball screw drive units and continuous casting housing designs.

With 29 family members in 8 jurisdictions (DE, EP, US, CN, JP, KR, IN) and an additional 4 Chinese utility models, E149 is the most comprehensive family in the IPGATE portfolio.

Patent Family E149

PIB – Parallel Integrated Brake Pressure Unit

13 Core Innovations · 2015 / 2016

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System diagnostics: Multimodal self-monitoring (SMSD)

E150 (1 invention) completes the portfolio with sensor-based on-board diagnostics. Three alternative modes use the existing sensor technology of the electrohydraulic pressure supply: (a) measurement of piston movement at constant drive force, (b) measurement of pressure and/or motor current at a predetermined piston stroke, (c) measurement of the temporal pressure change dp/dt with the piston at a standstill. Without external test equipment and additional hardware, the tightness, flow resistance, and functionality of seals, valves, and lines are evaluated – during driving or after braking.

The invention is backed by three renowned inventors, including Dr. Anton van Zanten, who is internationally known as the co-inventor of ESP. Patents granted in US, CN, JP; DE application under review.

Patent Family E150

SMSD – Sensor-Based Multimodal Self-Diagnostics

1 Core Innovation · 2016

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Patent Families

Four Families · 22 Core Innovations

Each patent family covers a distinct layer of the brake-by-wire technology stack, from novel valve circuitry and pressure supply to physical integration and predictive self-diagnosis.

Pillar 1 · Valve Circuitry

Patent Family E147

Check Valve-Free Fault-Tolerant Pressure Control

Priority: 2015

Fundamentally new valve circuit for brake-by-wire systems enabling purely volume- and time-controlled pressure regulation via bidirectional volume PWM, completely eliminating check valves. Granted in EP, US, JP.

3 Core Innovations

See Patent Family

Pillar 2 · DAP

Patent Family E148

DAP – Double-Acting Piston Pressure Supply

Priority: 2015

Double-acting piston with two independent working chambers for simultaneous dual-circuit pressure control. 16 family members across 10 jurisdictions including EP, DE, FR, GB, NL, US, JP, KR, CN, IN.

5 Core Innovations

See Patent Family

Pillar 3 · 1-Box Integration

Patent Family E149

PIB – Parallel Integrated Brake Pressure Unit

Priority: 2015 / 2016

Physical integration of all BbW components into a single compact housing. The most comprehensive family in the IPGATE portfolio: 29 family members in 8 jurisdictions plus 4 Chinese utility models.

13 Core Innovations

See Patent Family

Pillar 4 · SMSD

Patent Family E150

SMSD – Sensor-Based Multimodal Self-Diagnostics

Priority: 2016

Three-mode on-board diagnostics using existing sensor technology to evaluate seal tightness, flow resistance, and valve functionality during driving or after braking – without external test equipment. Co-invented by Dr. Anton van Zanten (ESP co-inventor).

1 Core Innovation

See Patent Family

At a Glance

Patent Family Summary