Heuristic multi-corner performance monitoring of brake actuator output for decentralized vehicle brake systems

A non-transient, computer-readable medium storing instructions executable by a vehicle controller of a motor vehicle, the motor vehicle including multiple road wheels and a decentralized brake system with multiple brake actuators each operable to decelerate a respective one of the road wheels, the instructions, when executed, causing the vehicle controller to perform operations comprising:

• receiving, from each of multiple sensors operatively attached to the brake actuators, sensor data indicative of a measured actuator output of a respective one of the brake actuators;
• calculating, for each of the brake actuators, a normalized corner output using the measured actuator output and a respective commanded target actuator output for the brake actuator;
• determining a vehicle-calibrated weight value from a current vehicle speed and/or a current vehicle steering angle;
• calculating, for each of the brake actuators, a weighted average using the normalized corner output of the brake actuator and the vehicle-calibrated weight value;
• calculating an actuator error percentage as an absolute value of a mathematical difference between the weighted averages of the brake actuators;
• determining a vehicle-calibrated fault deviation threshold from the current vehicle speed and/or the current vehicle steering angle;
• detecting an actuator fault when the actuator error percentage is greater than the vehicle-calibrated fault deviation threshold;
• and
• commanding, responsive to determining the actuator error percentage is greater than the vehicle-calibrated fault deviation threshold, the decentralized brake system to execute a vehicle-calibrated brake action to remediate the actuator fault.

A motor vehicle, comprising:

• a vehicle body;
• a plurality of road wheels attached to the vehicle body;
• a prime mover attached to the vehicle body and configured to drive one or more of the road wheels to thereby propel the motor vehicle;
• a decentralized brake system attached to the vehicle body and including a plurality of brake actuators each independently operable to decelerate a respective one of the road wheels to thereby slow or stop the motor vehicle;
• a plurality of brake sensors each operatively attached to a respective one of the brake actuators;
• and
• a vehicle controller communicatively connected to the decentralized brake system and the brake sensors, the vehicle controller being programmed to:
• receive, from each of the brake sensors, sensor data indicative of a measured actuator output of a respective one of the brake actuators;
• calculate, for each of the brake actuators, a normalized corner output using the measured actuator output and a respective commanded target actuator output for the brake actuator;
• determine a vehicle-calibrated weight value from a current vehicle speed and/or a current vehicle steering angle
• calculate, for each of the brake actuators, a weighted average using the normalized corner output of the brake actuator and the vehicle-calibrated weight value;
• calculate an actuator error percentage as an absolute value of a mathematical difference between the weighted averages of the brake actuators;
• determine a vehicle-calibrated fault deviation threshold from the current vehicle speed and/or the current vehicle steering angle;
• detect an actuator fault when the actuator error percentage is greater than the vehicle-calibrated fault deviation threshold;
• and
• responsive to determining the actuator error percentage is greater than the vehicle-calibrated fault deviation threshold, command the decentralized brake system, a vehicle steering system, and/or a vehicle powertrain system to execute a vehicle-calibrated action to remediate the actuator fault.