A Study on TSC(Technical Safety Concept) design and verification in EMB(Brake By Wire) Systems

The Electro-Mechanical Brake (EMB) system, a dry-type Brake-by-Wire technology, eliminates hydraulic components by directly controlling friction braking through electrical actuators at each wheel. The architecture includes a Main Center Control Unit, a Backup Center Control Unit for redundancy, and four-Wheel Control Units, communicating via CAN FD. Compliance with ISO 26262 functional safety standards is critical due to the EMB system’s role in vehicle braking. As complexity increases, risks such as hardware failures and communication faults must be systematically addressed. This paper presents the design and verification of a Technical Safety Concept (TSC) for EMB systems in accordance with ISO 26262. Safety goals and Functional Safety Requirements derived from HARA analysis guide the System Architecture and TSC development. Key design principles include modularity, redundancy, fault detection, and fail-safe mechanisms. Verification is performed at both system and vehicle levels using EILS, HILS, and real-vehicle tests. Fault scenarios, including BCCU failure and CAN communication loss, are simulated using a custom LabVIEW-based fault injection tool. The study evaluates FTTI settings, error handling, and control handover strategies to ensure safe transitions under fault conditions. Results confirm that redundancy and local communication enable stable operation and smooth control transfer within the FTTI window, maintaining braking performance without driver awareness. This research demonstrates the robustness of the EMB architecture. Future work will focus on prognostics and maintenance strategies to support safe deployment in autonomous and electric vehicles.