Vehicle corner module and vehicle equipped with same

Abstract

To provide a vehicle corner module (VCM) 150 which is provided for regulating motion of a host vehicle including an onboard vehicle controller 102.SOLUTION: A VCM comprises: a sub-frame mountable to a reference frame of a host vehicle; a wheel-hub assembly; VCM-sub-systems mediating between the sub-frame and the wheel-hub assembly (e.g., a drive subsystem, a steering subsystem, a suspension subsystem and / or a braking subsystem); and a VCM-onboard VCM-controller comprising a computer-readable medium storing program instructions in one or more processors.SELECTED DRAWING: Figure 1A-1B

Description

[Technical Field]

[0001] The present invention relates to a vehicle corner module (VCM) for coordinating the operation of a host vehicle, and more particularly to a VCM incorporating mechanical and electrical subsystems. [Background technology]

[0002] Automotive systems have been developed and improved for over a century, resulting in sophisticated designs that integrate and centralize the management of various mechanical and electrical subsystems. Available control systems are limited to managing individual functions and do not integrate or combine the management of multiple subsystems.

[0003] Emerging vehicle platforms designed for electric propulsion can include modular axle-less wheel assemblies (Vehicle Corner Modules or VCMs) that require independent suspension, drivetrain, braking, and steering subsystems mounted to each individual wheel. These designs require new mechanical and electronic solutions to execute externally generated operational commands at each wheel with respect to the local subsystem. New control models are needed to manage not only the normal operation of the integrated wheel system, but also service, test, and management functions. Summary of the Invention [Problem to be solved by the invention]

[0004] [Means for solving the problem]

[0005] According to an embodiment of the present invention, a vehicle corner module (VCM) for coordinating operation of a host vehicle is disclosed, the vehicle including an on-board vehicle controller, the VCM including: (a) a subframe mountable to a reference frame of the host vehicle; (b) a wheel hub assembly having wheel hubs; (c) a plurality of subsystems interposed between the subframe and the wheel hub assembly and selected from the group of subsystems consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem; and (d) a VCM controller mounted on the VCM having one or more processors and a computer-readable medium storing program instructions that, when executed by the one or more processors, cause the one or more processors to perform the following steps: (i) establish a communication link with the vehicle controller, the establishment including electrically transferring information related to the VCM from the VCM controller to the vehicle controller; and (ii) perform a post-installation verification process in response to installation of the VCM on the vehicle, the verification process including verifying the plurality of subsystems and communicating results of the verification to the vehicle controller.

[0006] In some embodiments, the establishment of a communication link with the vehicle controller occurs prior to installation of the VCM.

[0007] In some embodiments, operation of the vehicle after installation of the VCM is conditioned on receiving a positive verification process result.

[0008] In some embodiments, the computer-readable medium further stores program instructions that, when executed by the one or more processors, cause the one or more processors to coordinate operation of at least one subsystem of the plurality of subsystems in response to an electrical signal input received from outside the VCM.

[0009] In some embodiments, the information about the VCM transferred from the VCM controller to the vehicle controller includes information about at least one of the plurality of subsystems.

[0010] In some embodiments, the communication link with the vehicle controller is a bidirectional link, and / or establishing the communication link further includes receiving information about the vehicle and / or another VCM attached to the vehicle.

[0011] In some embodiments, the computer-readable medium further stores program instructions that, when executed by the one or more processors, cause the one or more processors to exchange information with an on-board controller of another VCM attached to the vehicle.

[0012] In some embodiments, the information about the VCM includes the results of a self-diagnostic test performed prior to installation of the VCM.

[0013] In some embodiments, the information about the VCM includes at least one of an operational history and a maintenance history of the VCM.

[0014] In some embodiments, verifying the plurality of subsystems includes receiving information from one or more sensors mounted on the VCM.

[0015] In some embodiments, the computer-readable medium further stores program instructions that, when executed by the one or more processors, cause the one or more processors to determine an operational profile of the VCM based on data received from the vehicle controller.

[0016] In some embodiments, the selected plurality of subsystems comprises at least three subsystems. In some embodiments, the selected plurality of subsystems comprises four subsystems.

[0017] In some embodiments, the vehicle comprises (a) one or more opposing VCM pairs in any one of the VCMs described above, (b) a vehicle controller, and / or (c) a communication bus for electronic communication between the vehicle controller and the VCM controller of each VCM.

[0018] In some embodiments, a vehicle may include (a) one or more pairs of opposing VCMs in any one of the VCMs described above, (b) a vehicle controller, and (c) a communication bus for electronic communication between the VCM controllers of at least one of the one or more pairs of opposing VCMs. In some embodiments, the communication bus is for electronic communication between the VCM controllers of at least one of the one or more pairs of opposing VCMs.

[0019] In some embodiments, an apparatus for use in offline testing of a VCM when the VCM is mechanically decoupled from any vehicle can include: (a) a support element for at least partially supporting the weight of the subframe and limiting movement of the subframe; (b) at least one diagnostic device for measuring operational data of at least one of the plurality of subsystems; and (c) a computing device configured to communicate with the VCM controller and receive diagnostic information related to the offline testing from the VCM controller. The offline testing includes a functional test of at least one of the plurality of subsystems.

[0020] In some embodiments, a method of operating a vehicle according to any one of the above embodiments includes controlling, by a VCM controller, the operation of one or more of the plurality of subsystems of the VCM in response to an electrical input external to the VCM.

[0021] According to an embodiment, a method is disclosed for replacing a first vehicle corner module (VCM) with a second VCM, each of the first and second VCMs comprising a subframe mountable to a reference frame of a vehicle, a wheel hub assembly, a VCM controller mounted on the VCM, and a plurality of subsystems interfacing between the subframe and the wheel hub assembly and selected from the group of subsystems consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem. The method includes: (a) establishing an electronic communication link between each VCM controller of the second VCM and an on-board vehicle controller, the establishing including transferring information about the second VCM from each VCM controller to the vehicle controller; (b) completing a post-installation verification in response to and conditional on installation of the second VCM in the vehicle, the verification including verifying each of the plurality of subsystems of the second VCM and communicating results of the verification to the vehicle controller; and (c) using the communicated verification results to enable or disable operation of the vehicle after installation of the VCM.

[0022] In some embodiments, the method may further include transmitting information regarding the exchange of the first VCM and the second VCM to an authorization system of an external computer. In some embodiments, the method may further include receiving service subscription-based authorization from the authorization system and / or further includes receiving transaction-based authorization from the authorization system.

[0023] In some embodiments, the information transmitted to the authorization system includes at least two of: identification information for each of the first and second VCMs; usage information for one or more of the plurality of subsystems of the first VCM; and maintenance information for one or more of the plurality of subsystems of the first VCM.

[0024] In some embodiments, a value is assigned to the exchange based on at least one of: usage information of one or more of the plurality of subsystems of the first VCM, usage information of one or more of the plurality of subsystems of the second VCM, maintenance information of one or more of the plurality of subsystems of the first VCM, and maintenance information of one or more of the plurality of subsystems of the second VCM.

[0025] In some embodiments, the method includes determining an operating profile of the second VCM based on information received from the vehicle controller.

[0026] In some embodiments, an electronic communication link between a VCM controller of each of the second VCMs and the on-board vehicle controller is established prior to installation of the second VCMs.

[0027] In some embodiments, the electronic communications link with the vehicle controller is a bidirectional link, and / or establishing the electronic communications link further includes receiving information about the vehicle and / or another VCM attached to the vehicle.

[0028] In some embodiments, at least some of the information regarding the second VCM transferred from each of the VCM controllers to the vehicle controller includes a response to a query.

[0029] In some embodiments, the information about the second VCM includes the results of a self-diagnostic test performed prior to installation of the second VCM.

[0030] In some embodiments, the information about the second VCM includes at least one of an operational history and a maintenance history of the second VCM.

[0031] In some embodiments, verifying the plurality of subsystems includes receiving information from one or more sensors mounted on the second VCM.

[0032] According to an embodiment of the present invention, a vehicle-mountable vehicle corner module (VCM) for coordinating operation of a host vehicle comprises: (a) a plurality of mechanical subsystems fully mounted on the VCM for interfacing between a subframe and a wheel hub assembly, the subsystems being selected from a group of subsystems consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem; and (b) a VCM controller mounted on the VCM for actuating the plurality of mechanical subsystems in response to electrical signal inputs received from outside the VCM, the VCM controller having a communications module configured to establish a communications link with an onboard vehicle controller for exchanging information therebetween after the VCM is mounted on the host vehicle.

[0033] In some embodiments, the communications module is further configured to establish a communications link with the on-board vehicle controller to exchange information therebetween before the VCM is installed in the host vehicle.

[0034] In some embodiments, the information includes results of verification of the plurality of subsystems by the VCM controller.

[0035] In some embodiments, operation of the vehicle after installation of the VCM is conditioned on receiving a positive verification process result from the VCM controller.

[0036] In an embodiment, a method is disclosed for replacing a first vehicle corner module (VCM) of a host vehicle with a second VCM, each of the first and second VCMs comprising: (i) a plurality of mechanical subsystems fully mounted on the VCM to interface between a subframe and a wheel hub assembly, the subsystems being selected from the group of subsystems consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem; and (ii) a VCM controller mounted on the VCM for operating the plurality of mechanical subsystems in response to electrical signal inputs received from outside the VCM, the method comprising: (a) establishing an electronic communication link between each VCM controller of the second VCM and a vehicle controller mounted on the host vehicle; and (b) transferring information regarding the second VCM from each VCM controller to the vehicle controller.

[0037] In some embodiments, the communication link is established before the VCM is installed in the host vehicle.

[0038] In some embodiments, the transferred information includes results of verification of the plurality of subsystems by the VCM controller.

[0039] In some embodiments, operation of the vehicle after installation of the VCM is conditioned on receiving a positive verification process result from the VCM controller.

[0040] An embodiment of the present invention discloses an apparatus for use in offline testing of a vehicle corner module (VCM) when the VCM is mechanically decoupled from a vehicle, the VCM including a subframe mountable to a reference frame of the vehicle, a wheel hub assembly, a VCM controller mounted on the VCM, and a plurality of subsystems mounted on the VCM and interfacing between the subframe and the wheel hub assembly, the subsystems being selected from the group consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a brake subsystem. The apparatus includes: (a) a support element configured to at least partially support a weight of the subframe and limit movement of the subframe; (b) at least one diagnostic device configured to measure operational data of at least one of the plurality of subsystems; and (c) a computing device configured to communicate with the VCM controller and receive diagnostic information related to offline testing from the VCM controller, the offline testing including a functional test of at least one of the plurality of subsystems.

[0041] In some embodiments, the computing device is configured to (i) receive diagnostic information related to the test from at least one diagnostic device, and / or (ii) combine the diagnostic information received from the at least one diagnostic device with diagnostic information received from the VCM controller.

[0042] In some embodiments, at least one parameter of the test is selected by the VCM controller.

[0043] In some embodiments, the at least one diagnostic device comprises a chassis dynamometer.

[0044] In an embodiment of the present invention, a vehicle comprises: (a) an on-board vehicle controller; (b) one or more pairs of opposing vehicle corner modules (VCMs), each pair having a subframe attached to a reference frame of the vehicle, a wheel hub assembly, a VCM controller mounted on the VCM, and a plurality of subsystems interfacing between the subframe and the wheel hub assembly and selected from the group of subsystems consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem; and (c) a communication configuration enabling peer-to-peer data communication between the respective VCM controllers of at least one pair of the one or more opposing VCMs, each VCM controller being configured to exchange information therebetween.

[0045] In some embodiments, the exchanged information includes at least one of an operational history and an operational profile of the new or replaced VCM.

[0046] In some embodiments, the VCM controller is configured to reduce the computational load of the vehicle controller, either singly or in combination.

[0047] In some embodiments, the VCM controllers are configured to provide operational backup functionality to another VCM controller, either alone or in combination.

[0048] In some embodiments, the VCM controller is configured to provide operational backup functionality to the vehicle controller, either alone or in combination.

[0049] In some embodiments, the communication arrangement enables peer-to-peer data communication between respective VCM controllers of all of the VCMs of the vehicle.

[0050] In some embodiments, the plurality of subsystems selected in each VCM of a first pair of opposing VCMs are not the same as the plurality of subsystems selected in each VCM of a second pair of opposing VCMs.

[0051] In some embodiments, the plurality of subsystems selected in each VCM of a given pair of opposing VCMs includes at least three subsystems, hi some embodiments, the plurality of subsystems selected in each VCM of a given pair of opposing VCMs includes four subsystems.

[0052] In some embodiments, the vehicle includes exactly four VCMs. In some embodiments, the vehicle includes exactly two VCMs. [Brief explanation of the drawings]

[0053] The invention will now be further described, by way of example, with reference to the accompanying drawings in which dimensions of components and features shown have been chosen for convenience and clarity of presentation and are not necessarily drawn to scale. [Figure 1A] 1A-1C are diagrams illustrating various communication schemes between components associated with a vehicle equipped with a vehicle corner module (VCM) according to an embodiment of the present invention. [Figure 1B] 1A-1C are diagrams illustrating various communication schemes between components associated with a vehicle equipped with a vehicle corner module (VCM) according to an embodiment of the present invention. [Figure 1C] 1A-1C are diagrams illustrating various communication schemes between components associated with a vehicle equipped with a vehicle corner module (VCM) according to an embodiment of the present invention. [Figure 1D] 1A-1C are diagrams illustrating various communication schemes between components associated with a vehicle equipped with a vehicle corner module (VCM) according to an embodiment of the present invention. [Figure 2A] 1A-1D illustrate various embodiments of communication between a vehicle platform and one or more VCMs according to embodiments of the present invention. [Figure 2B] 1A-1D illustrate various embodiments of communication between a vehicle platform and one or more VCMs according to embodiments of the present invention. [Figure 2C] 1A-1D illustrate various embodiments of communication between a vehicle platform and one or more VCMs according to embodiments of the present invention. [Figure 2D] FIG. 1 is a schematic block diagram illustrating a high-level topology of a control unit in a VCM-based vehicle according to an embodiment of the present invention. [Figure 2E] FIG. 2 is a schematic high-level block diagram of software according to an embodiment of the present invention. [Figure 3A] 1A-1C illustrate various mechanical and electrical configurations of a VCM according to an embodiment of the present invention. [Figure 3B] 1A-1C illustrate various mechanical and electrical configurations of a VCM according to an embodiment of the present invention. [Figure 3C] 1A-1C illustrate various mechanical and electrical configurations of a VCM according to an embodiment of the present invention. [Figure 3D] 1A-1C illustrate various mechanical and electrical configurations of a VCM according to an embodiment of the present invention. [Figure 3E] 1A-1C illustrate various mechanical and electrical configurations of a VCM according to an embodiment of the present invention. [Figure 3F] 1A-1C illustrate various mechanical and electrical configurations of a VCM according to an embodiment of the present invention. [Figure 3G] 1A-1C illustrate various mechanical and electrical configurations of a VCM according to an embodiment of the present invention. [Figure 4A] FIG. 2 is a schematic 3D diagram of a VCM according to an embodiment of the present invention. [Figure 4B] FIG. 2 is a schematic 3D diagram of a VCM according to an embodiment of the present invention. [Figure 4C] FIG. 2 is a schematic block diagram of a storage device that stores a VCM according to an embodiment of the present invention. [Figure 5] FIG. 1 is a schematic flow diagram illustrating the steps involved in plugging a new VCM into a vehicle platform in accordance with an embodiment of the present invention. [Figure 6]1 is a chart detailing which elements of a system of one or more VCMs are involved in performing each of the specific operations that may occur during operation and maintenance of a vehicle having a VCM according to an embodiment of the present invention. [Figure 7A] FIG. 1 is a schematic flow diagram illustrating a process for matching a newly installed VCM with a vehicle platform and another VCM, and optional additional processes, according to an embodiment of the present invention. [Figure 7B] FIG. 1 is a schematic flow diagram illustrating a process for matching a newly installed VCM with a vehicle platform and another VCM, and optional additional processes, according to an embodiment of the present invention. [Figure 8] FIG. 10 is a schematic flow diagram illustrating a process for calibrating a newly installed VCM in accordance with an embodiment of the present invention. [Figure 9] FIG. 10 is a schematic flow diagram illustrating a process for calculating operating parameters of a newly installed VCM in accordance with an embodiment of the present invention. [Figure 10] FIG. 1 is a schematic flow diagram illustrating a process for adapting actual operating parameters based on predicted operating parameters in accordance with an embodiment of the present invention. [Figure 11] 4 is a flow diagram illustrating a process for replacing a malfunctioning VCM according to an embodiment of the present invention. [Figure 12A] 1 is a schematic block diagram illustrating communication and control flow between units of a vehicle in several exemplary situations according to an embodiment of the present invention. [Figure 12B] 1 is a schematic block diagram illustrating communication and control flow between units of a vehicle in several exemplary situations according to an embodiment of the present invention. [Figure 12C] 1 is a schematic block diagram illustrating communication and control flow between units of a vehicle in several exemplary situations according to an embodiment of the present invention. [Figure 13] FIG. 1 is a schematic flow diagram illustrating a process for operating a VCM and communicating operational data in accordance with an embodiment of the present invention. [Figure 14A] 1 is a schematic diagram of a vehicle including a communication bus and multiple VCMs according to an embodiment of the present invention. [Figure 14B] 1 is a schematic diagram of a vehicle including a communication bus and multiple VCMs according to an embodiment of the present invention. [Figure 14C] FIG. 1 is a schematic diagram of a vehicle consisting of a pair of opposing VCMs, according to an embodiment of the present invention. [Figure 14D] FIG. 1 is a schematic diagram of a vehicle consisting of a pair of opposing VCMs, according to an embodiment of the present invention. [Figure 15] FIG. 1 is a schematic diagram illustrating a VCM consisting of multiple subsystems according to an embodiment of the present invention. [Figure 16A] FIG. 1 is a schematic diagram illustrating a VCM consisting of multiple subsystems according to an embodiment of the present invention. [Figure 16B] FIG. 1 is a schematic diagram illustrating a VCM consisting of multiple subsystems according to an embodiment of the present invention. [Figure 17A] FIG. 1 is a schematic configuration diagram of a VCM controller according to an embodiment of the present invention. [Figure 17B] FIG. 1 is a schematic configuration diagram of a VCM controller according to an embodiment of the present invention. [Figure 17C] FIG. 1 is a schematic configuration diagram of a VCM controller according to an embodiment of the present invention. [Figure 18] 3 is a flowchart illustrating a method of operating a vehicle according to an embodiment of the present invention. [Figure 19A] 4 is a flowchart illustrating method steps for replacing a VCM in a vehicle according to an embodiment of the present invention. [Figure 19B] 4 is a flowchart illustrating method steps for replacing a VCM in a vehicle according to an embodiment of the present invention. [Figure 19C] 4 is a flowchart illustrating method steps for replacing a VCM in a vehicle according to an embodiment of the present invention. [Figure 20] 4 is a flowchart illustrating method steps for replacing a VCM in a vehicle according to an embodiment of the present invention. [Figure 21] 1 is a schematic configuration diagram of a VCM test device according to an embodiment of the present invention.

[0054] It will be understood that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. DETAILED DESCRIPTION OF THE INVENTION

[0055] The present invention will now be described, by way of example only, with reference to the accompanying drawings. Referring now in detail to the drawings, it is emphasized that the specific details shown are presented by way of example only, for the purpose of describing preferred embodiments of the invention, and for the purpose of providing what is believed to be the most useful and readily understandable explanation of the principles and conceptual aspects of the invention. In this regard, no attempt has been made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, and the description taken together with the drawings will make apparent to those skilled in the art how several forms of the invention may be embodied in practice. Throughout the drawings, like characters are generally used to designate similar elements.

[0056] NOTE: Throughout this disclosure, subscripted reference numbers (e.g., 101 or 10 A ) is used to designate multiple separate appearances of a single type of element, whether in a drawing or not. For example, 101 is a single appearance (of multiple appearances) of element 10. The same element may alternatively be referred to without a subscript (e.g., 10, not 101) when referring not to a specific one of multiple appearances, i.e., the type in general.

[0057] Various terms are presented herein for convenience. To the extent that definitions are provided, expressly or implicitly, here or elsewhere in this application, such definitions will be understood to be consistent with the use of the defined terms by those of ordinary skill in the relevant art. Moreover, such definitions are to be interpreted in the broadest sense consistent with such usage.

[0058] Unless otherwise indicated, as used herein, a "vehicle corner module" or "VCM" refers to an assembly for supporting vehicle wheels and coordinating vehicle operation according to any of the embodiments disclosed herein. The VCM assembly includes, but is not limited to, components such as a steering system, a suspension system, a braking system including a hydraulic subsystem, a gear assembly, a drive motor, a drive shaft, a wheel hub assembly, a controller, a communication arrangement, and electrical wiring. In some embodiments, the VCM includes wheels and tires. The VCM can be mounted to a vehicle's "reference frame," such as a chassis or similar vehicle frame or platform, but the mounting does not necessarily have to be "as a unit." When the VCM is described as being mounted to a vehicle, the VCM is mounted to the reference frame. The VCM may also include a "subframe" to which some or all of the VCM components are mounted or otherwise attached, providing an interface between the reference frame and various VCM components. The term "subframe" should be understood to mean any rigid frame or one or more structural elements in fixed combination. The prefix "sub" is intended to distinguish the subframe from the main frame or reference frame of the vehicle. The VCM may or may not include one or more electric motors and / or the wheels themselves (and tires).

[0059] As used herein and in the appended claims, the term "vehicle" is understood to refer to an electrically powered vehicle having one or more wheels. Non-limiting examples of vehicles according to this definition are vehicles having power provided by an onboard engine and "electric vehicles" that are powered when moving by one or more electric motors and onboard batteries or other energy storage devices. Batteries need not be associated with or attached to the vehicle except when the vehicle is in motion. The term "vehicle" should also be understood to encompass a "vehicle platform" consisting of at least a chassis (or other "frame of reference" to which a VCM can be mounted) and one or more wheels. A "vehicle platform" does not necessarily include all of the accessories, such as body components and interior trim, necessary for the transportation of passengers and / or cargo at the time the vehicle platform is provided.

[0060] As used herein, "communication arrangement" or similar terms such as "communication scheme" refer to any wired or wireless connection over which data communication can occur. Non-limiting and non-exhaustive examples of suitable technologies for providing communication arrangements include short-range point-to-point communication systems such as IrDA, Radio Frequency Identification (RFID), TransferJet, Wireless USB, and Dedicated Short Range Communications (DSRC); short-range wireless communications such as ZigBee, EnOcean, Wi-Fi, Bluetooth, TransferJet, and Ultra-wideband; wireless networks (including sensor networks); and wired communication bus technologies such as Controller Area Network (CAN) bus, Fieldbus, FireWire, HyperTransport, and InfiniBand. As used herein, "establishing a communication link" refers to initiating and / or maintaining data communication between two or more processing units (e.g., controllers, computers, processors, etc.) according to any of the communication protocols supported by the two or more communicating nodes.

[0061] As used throughout this disclosure and the appended claims, "electrical signal" or similar terms such as "electrical input" mean electrical and / or electronic and include the transmission of electrical current, either direct or alternating current, electronic information, or any combination of electrical and electronic signals and information.

[0062] As used herein, the term "controller" refers to a computing device configured to monitor, control, regulate, and / or operate one or more components, systems, or subsystems. A controller is understood to include, but is not limited to, one or more processors, one or more computer-readable media, e.g., transient and / or non-transitory storage media, communications arrangements, power sources and / or connections to power sources, and firmware and / or software. When used herein in hyphenated terms such as vehicle-controller or VCM-controller, the terms refer to a controller for controlling a vehicle and / or vehicle components and / or subsystems, or a controller for controlling a VCM and / or VCM components and / or subsystems, respectively. Unless otherwise specified, a controller is located in a controlled element (e.g., vehicle, VCM), and a "control unit" is similar to a controller but is not located in a controlled element. For example, a VCM-controller is located in or on the VCM, while a VCM control unit may instead be located elsewhere on the vehicle, such as on a chassis unit. The controller (and control unit) may be pre-programmed, for example, by having program instructions stored on a computer-readable medium for execution by one or more processors of the controller. Thus, a controller being "configured" to perform a function is, as used herein, equivalent to the controller being programmed to perform, i.e., having access to stored program instructions to perform, that function.

[0063] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, steps, and components have not been described in detail so as not to obscure the present invention.

[0064] A vehicle corner module (VCM) system is disclosed that includes a subframe for interfacing between the VCM and a vehicle platform, a wheel interface for coupling wheels to the VCM, one or more VCM modules including mechanical assemblies and electrical units for steering the wheels when assembled to a vehicle, and one or more electrical interfaces for exchanging signals and data between the VCM module and the vehicle platform.

[0065] In some embodiments, the VCM further comprises one or more sensors for measuring operational data of one or more VCM modules, and a VCM controller electrically connected to one or more electrical interfaces and one or more electrical units of the VCM modules.

[0066] In some embodiments, the VCM further comprises one or more of a suspension module, a wheel drive module, a steering module, and a control module, and the wheel drive module comprises one or more of an electric motor unit, a transmission unit, and a brake unit.

[0067] In some embodiments, one or more VCM modules are disposed between the wheel interface and the subframe.

[0068] In some embodiments, one or more of the electrical units comprises a VCM module controller, which comprises an integrated circuit having hardware and software for controlling two or more VCM modules.

[0069] A vehicle is disclosed that includes one or more of the vehicle corner modules described above.

[0070] In some embodiments, the vehicle includes a VCM control unit (CSCU) and a platform-VCM bus for communicating between the vehicle and one or more electrical circuits located in the VCM.

[0071] In some vehicle embodiments, the VCMs are in direct electrical communication and can exchange data between themselves without going through the VCM control unit (CSCU).

[0072] A method for operating a vehicle corner module (VCM) includes mounting the VCM on a vehicle platform, setting a VCM motion profile, and operating the VCM with the VCM motion profile.

[0073] In some embodiments, the method further includes reconciling an operational profile of the VCM with the vehicle platform, and setting the VCM operational profile is reconciling the operational profile of the VCM.

[0074] In some embodiments, the method further includes reconciling an operational profile of the VCM with an operational profile of another VCM coupled to the vehicle platform, and setting the operational profile of the one or more VCMs coupled to the vehicle platform according to the reconciliation of the operational profiles of the one or more VCMs.

[0075] In some embodiments, the method further includes receiving an operating plan defined for the VCM and setting a VCM operating profile according to the operating plan.

[0076] A method for servicing a vehicle having one or more vehicle corner modules (VCMs) is disclosed that includes receiving an indication that a system located in the VCM requires maintenance, removing the vehicle from operation, disconnecting the VCM from the vehicle, installing a replacement VCM on the vehicle, and resuming operation of the vehicle.

[0077] According to an embodiment of the present invention, a vehicle corner module (VCM) is disclosed, which is adapted to connect a wheel of a vehicle to a vehicle platform to provide one or more of the following functions to the wheel: turning force, braking, steering, and suspension.

[0078] The VCM can operate the vehicle's drive system by communicating operational data related to the drive system disposed in the VCM between the VCM and the vehicle platform. The VCM may include a subframe for connecting the VCM to the vehicle platform, a wheel interface for attaching the vehicle's wheels to the VCM, mechanical and electrical drive systems for driving the vehicle platform, sensors for measuring VCM operational data and reflecting the operational data to a VCM controller and optionally a vehicle controller, and a transceiver unit for exchanging data with the vehicle controller.

[0079] Control of the drive systems of the VCM may be performed by a control unit connected to one or more drive systems. A control unit may be associated with each drive system. In some embodiments, two or more control units of the VCM system may be embodied in a common control unit, which is associated with multiple drive systems. Thus, a single controller may be associated with multiple VCMs, thereby becoming an integrated unit as opposed to a distributed unit.

[0080] The VCM may be comprised of one or more modules from the list consisting of a suspension module, a wheel drive module, a steering module, and a control module. The drive module may be comprised of one or more units selected from an electric motor unit, a transmission unit, and a brake unit. The steering unit may be comprised of a local steering actuator or a mechanical steering connector adapted to receive steering control from outside the VCM, and an optional steering transmission unit. The control module may be adapted to control all operational aspects of the VCM, such as wheel motorization parameters (momentum, speed, direction, etc.), suspension damping dynamics, braking action, and steering action.

[0081] According to embodiments of the present invention, the VCM can be adapted to mechanically and electrically interface with the vehicle and to interface with vehicle control signals. For example, the VCM may be connected to the vehicle platform and optionally adapted to mechanically interface with steering control provided by a module on the vehicle platform. According to some embodiments, the VCM may further be mechanically coupled to rotational power provided by a module on the vehicle platform.

[0082] In some embodiments, the VCM can be adapted to receive electrical power provided by an electrical module on the vehicle platform and convert the electrical power into rotational power provided to the wheels, for example, by an electric motor configured in the VCM. The provided electrical power may further be utilized to generate steering control to the VCM using an electric steering module, for example, an electric motor, an electric linear motor with or without a steering transmission, or the like.

[0083] In some embodiments, the VCM may be adapted to interface with a vehicle control module located on the vehicle platform to exchange data and control commands for controlling wheel rotation, braking, steering, and / or suspension. In some embodiments, the VCM may be configurable to interface with a given type of vehicle simply through data interaction between the vehicle controller and the VCM controller, at least with respect to control of instantaneous drive force demand, braking profile, damping profile, etc. According to some embodiments, plugging the VCM into or unplugging the VCM from the vehicle may be communicated to an external control unit.

[0084] The VCM module may be coupled to the vehicle platform by mechanical, power, and control means. The coupling may be configured to operate by plug-in / plug-out means to allow for quick and accurate installation / removal of the VCM unit. Installing the VCM unit on the vehicle results in one or more of coupling the wheel transmission to the vehicle platform, coupling the brake system to the vehicle platform, coupling the suspension system to the vehicle platform, coupling the steering system to the vehicle platform, and coupling the wheel motors to the vehicle platform.

[0085] According to embodiments of the present invention, the installation of a VCM to a vehicle platform brings the vehicle and VCM into mechanical and electrical operation, including any necessary adjustments and adaptations, such as adapting the dynamics of the just-installed VCM (instantaneous driving moments, steering alignment, suspension coordination, etc.) to the other VCMs of the vehicle and vehicle platform. In some embodiments, the performance parameters of the VCM itself may be transmitted to the vehicle platform to enable the installed VCM to fully coordinate with the other systems of the vehicle.

[0086] Upon installation of the VCM in a vehicle, the VCM may perform an acknowledgement process with a controller on the vehicle platform. In some embodiments, the acknowledgement process includes exchanging data with another VCM on the vehicle. In some embodiments, the acknowledgement process may include communication with an external computing unit located remotely from the vehicle (e.g., an external computer, connection to a remote computing unit via a cloud service, etc.).

[0087] Once the VCM is installed, the vehicle platform's control system can communicate with the connected corner module and exchange data and / or power with the corner module to operate it with systems such as steer-by-wire, torque vectoring, brake-by-wire, and yaw stability control systems (such as ESP systems).

[0088] Data exchanged between the computing unit on the vehicle platform and the VCM can include data representative of operational status monitoring and data related to preventive maintenance.

[0089] Data exchanged between the compute unit on the vehicle platform and the VCM may include a VCM module identification number (ID) to uniquely identify the VCM, VCM model, VCM system, and VCM capabilities / specifications. Data exchanged may also include critical sensor readings (errors and current life status of components such as bearings, seals, oil levels, brake pads, air pressure, etc.).

[0090] One aspect of the present invention relates to the calibration of a VCM. Calibration can be performed after the VCM is mounted on a vehicle platform. Calibration can be performed as a scheduled process. Calibration can also be performed according to updated operating parameters in the vehicle and / or the VCM. Calibration can include measuring, diagnosing, and updating one or more of the following parameters: orientation (caver, caster, toe angles) of wheels mounted on the VCM, braking performance in response to a predetermined braking input, and vibration of one or more assemblies of the VCM.

[0091] According to embodiments of the present invention, the operation of the VCM may be adaptively performed based on the lifecycle of the VCM, data received from the VCM, and operator settings.

[0092] In some embodiments, the actuators included in the VCM may be electric and / or hydraulic. One or more electric motors that power the wheel drive systems may be located in the VCM. The power source may be located within the VCM or external to the VCM. If the hydraulic power source is external to the VCM, the VCM may include a hydraulic control / power actuator / transmission to operate the drive system and / or steering system. If the hydraulic power source is internal to the VCM, located inboard of the wheels, a drive transmission may be smaller or may not be needed at all.

[0093] In some embodiments, the computational load associated with a vehicle equipped with at least one VCM may optionally be split between the vehicle platform's computing units and the computing units included in the VCM unit (if the VCM includes computing units) to ensure sufficient collective computing power. The minimum computational duties of the VCM's computing units may be to collect sensor data from the VCM's various sensors, provide pre-processed data to the vehicle platform's computing units, and also receive a flow of control signals provided by the vehicle platform's computing units and distribute the control signals to the various actuators.

[0094] In some embodiments, following connection (or assembly) of the VCM to the vehicle platform, a data connection may be established between the parties to recognize and operationalize the newly installed VCM autonomously, without the need for human intervention. Embodiments involving relatively high computing power on the VCM side allow for a high ability to upgrade the VCM's operational capabilities without overloading the vehicle platform's computing unit. In some embodiments, the vehicle's operational profile may be managed by the VCM's computing unit. Furthermore, the high computing power of the VCM's computing unit allows for the production of the VCM without impacting the production of the vehicle platform.

[0095] In some embodiments, a VCM may actively communicate with at least one other VCM as well as the vehicle platform. This is referred to as an interconnected VCM. The VCMs on a vehicle may all be the same type, or the front of the vehicle may have the same type and the rear may have a different type. In other embodiments, the VCMs on one side may be the same type and the VCM on the other side may be a different type. For example, in a particular type of vehicle, the front VCM may be capable of steering and motoring, while the rear VCM may not have steering or motoring capabilities. In another example, VCMs may differ from each other based on the sensors they contain. In such embodiments, VCMs with more sensors may communicate relevant data to VCMs lacking these sensors.

[0096] In some embodiments, the vehicle may be fully controlled over all aspects of vehicle operation, with all computational tasks performed by one or more computing units in the VCM, and no computing units may be present on the vehicle platform. In some embodiments, the vehicle may be fully or partially remotely controlled, such as an airborne autonomous vehicle.

[0097] Vehicles equipped with VCMs also reduce the time and cost of routine inspections and breakdowns by replacing traditional maintenance routines, including maintenance of submodules (e.g., brakes, steering, etc.), with the replacement of a malfunctioning VCM with a fully functional VCM. The fully functional VCM may be selected to mechanically match the vehicle type, and all other aspects of its operation may be tailored to fit the vehicle using data exchange between the newly installed VCM and the entire vehicle and its associated VCMs. This process may take anywhere from a few seconds to a few minutes, minimizing the vehicle's downtime in the garage and allowing a malfunctioning VCM to remain in place even after the vehicle leaves the garage. The simplicity associated with disassembling / assembling a VCM from / to the vehicle platform allows for the use of robotic equipment to perform the process, further expediting the process and reducing labor hours. According to this embodiment, maintenance does not require training or expertise and can even be performed by the vehicle operator in their home garage. Furthermore, vehicles can be upgraded by upgrading the VCM without modifying the vehicle platform. Additionally, vehicle insurance can be changed from a full vehicle model to a VCM-based insurance model.

[0098] In this type of embodiment, replacing the VCM may involve unsecuring the VCM from the vehicle platform, disconnecting any electrical / communication connections, positioning and securing the replacement VCM to the vehicle platform, reconnecting the electrical / communication connections, and autonomously completing the installation process with the newly installed VCM connecting to another VCM and / or the vehicle platform's computing unit. This replacement process may be performed by a mechanic, an untrained operator, or a robotic system.

[0099] VCMs stored on a shelf awaiting use in a vehicle may be tested for proper operation periodically or on demand. The stored VCM may be connected to a test fixture that closely mimics the VCM being tested being fully connected to an operational vehicle, injecting test signals into the VCM being tested and monitoring received signals from either sensors within the VCM or external sensors that are part of the test fixture. The test step may end with a run / abort of the VCM being tested, or may include a test summary that is provided to the operator and stored in the VCM being tested's computational unit to allow for faster and more accurate tuning of the VCM once it is installed in the vehicle.

[0100] The test steps may be adapted to perform one or more of the following test steps: testing a single system of the VCM, testing multiple systems of the VCM, testing two or more VCM systems in an operating scenario involving combined system behavior (e.g., steering while changing speed), repeated testing multiple times and / or at varying speeds, and testing the VCM with a predetermined driving profile.

[0101] The VCM usage fee may be used for business transactions such as vehicle rental, corner module rental, service plans, and subscription services. Examples of operational parameters include mileage, usage time, and acceleration (maximum, frequency), which can be correlated to the wear rate of the VCM. The operational data may be compared to operational plan values. The plan values may be part of a business plan established for the VCM and / or vehicle, such as when purchasing the VCM, renting the VCM, or purchasing / subscribing to a service plan for the VCM. The financial data may relate to information used for insurance plans. The insurance plans may be related to the corner module and / or the vehicle. The cost of the insurance plan may be based on historical data for the VCM. According to some embodiments, the operation of the VCM may be controlled according to the financial data. In some embodiments, the VCM's performance (operational profile) is selected as a dependency of the selected plan. In some embodiments, the VCM's performance (operational profile) is selected as a dependency of actual VCM data on the preceding plan. The operational profile may be configured to decrease / increase.

[0102] Several embodiments of a VCM, applications of a VCM, a VCM as part of a vehicle, etc. are described herein with respect to the following drawings:

[0103] Reference is now made to FIGS. 1A-1D, which schematically illustrate various communication schemes between components associated with a vehicle equipped with a VCM according to embodiments of the present invention. FIG. 1A illustrates a basic communication scheme between the VCM 150 and the vehicle platform 102, which allows for the exchange of power and signals related to the operation of the VCM motors, steering, brakes, suspension, and VCM computing units. The signals consist of control and data signals. FIG. 1B illustrates a basic communication scheme between the VCM 150, the vehicle platform 102, and an external computing unit 106. The signals and power exchanged between the vehicle platform 102 and the VCM 150 may be similar to those described above with respect to FIG. 1A. Additionally, the VCM 150 and the vehicle platform 102 may exchange data with the external computing unit 106, for example, to store data for later use, to receive stored data, or to utilize additional computing power.

[0104] 1C illustrates a basic communication scheme between VCM 150, vehicle platform 102, external computing unit 106, and one or more additional VCMs 108. Signals and power exchanged between vehicle platform 102, VCM 150, and external computing unit 106 may be the same as those described above with respect to FIG. 1B. Additionally, one or more other VCMs 108 that are in active communication with vehicle platform 102, like VCM 150, may optionally communicate with VCM 150 (i.e., VCM-to-VCM communication) and / or with external computing unit 106.

[0105] FIG. 1D illustrates a basic communication scheme between the VCM 150, the vehicle platform 102, the external computing unit 106, and the service station 110. The signals and power exchanged between the vehicle platform 102 and the VCM 150 may be similar to those described above with respect to FIG. 1A. Additionally, the service station 110 may establish active communication with any one of the vehicle platform 102, the VCM 150, and / or the external computing unit 106. The signals exchanged between the service station 110 and any one of the vehicle platform 102, the VCM 150, and the external computing unit 106 may comprise VCM-related data, vehicle-related data, and other types of data related to the vehicle platform and the VCM. Such data may be useful for repairing a faulty VCM, updating the operational status record of a repaired VCM, efficiently tuning the VCM to a particular vehicle, etc.

[0106] 2A-2C illustrate various embodiments of communication between a vehicle platform and one or more VCMs according to embodiments of the present invention.

[0107] 2A, which is a schematic electrical diagram illustrating the connections between units on a vehicle platform 202 and the VCM 150. A power supply 202A may be located on the vehicle platform 202 and / or within the VCM 150, adapted to supply power to consumers on the vehicle platform 202. A VCM control unit (CSCU) 202B may be located on the vehicle platform 202 and may comprise a VCM data processor 202B1 and a VCM system controller 202B2. The VCM 150 may comprise one or more control units from a group 204A consisting of a suspension control unit (SCU) 204A1, a brake control unit (BCU) 204A2, a transmission control unit (TCU) 204A3, and a steering control unit (STU) 204A4. The VCM 150 may further include a VCM controller 50 adapted to communicate with all other VCM subsystem control units and with the VCM sensors 204B. The VCM controller 50 may be in active communication with the VCM system control unit 202B. This scheme allows for control and data flow between the vehicle platform 202 and the VCM 150.

[0108] In some embodiments, one or more control units 204A are designed to have merged components and functions. In some embodiments, the merging of control units is due to the sharing of processing algorithms with shared operating parameters (e.g., rotational speed). In some embodiments, the merged control units share a power source. In some embodiments, the merged control units receive input from a common set of sensors (e.g., sensors included in 204B). In some embodiments, the merged control units are housed within a common mechanical compartment. In some embodiments, merging control units reduces the size of the control units disposed within VCM 150.

[0109] In some embodiments, one or more of the control units 204A are positioned on the VCM 150 using potting techniques so that the control units do not require an external housing other than being supported by the mechanical structure of the system on the VCM 150.

[0110] Refer to FIG. 2B, which shows a schematic electrical diagram of the connections between units on the vehicle platform 202 and two or more VCMs 150. The power supply 202A of the vehicle platform 202 may be the same as or similar to that of FIG. 2A. The VCM control unit (CSCU) 212B may include an I / O unit 212B3 and data storage 212B4 in addition to a processor 212B1, which may be the same as the processor 202B1 of FIG. 2A. The I / O unit 212B3 may be adapted to communicate via a platform-VCM bus 213. Each VCM unit 150 may further include a controller (CCU) 50 and a sensor unit 204B, which may function similarly to the controller 50 and sensor unit 204B of FIG. 2A. Additionally, the VCM 150 may include data storage 204D. This scheme enables control and data flow between the vehicle platform 202 and two or more VCMs 150, and also enables control and data flow directly between the VCMs. In some embodiments, two or more of the control units of each VCM 150 may be embodied in a single computing unit.

[0111] Refer to FIG. 2C, which shows a schematic electrical diagram of the connections between units on the vehicle platform 202 and multiple VCMs 150 using separate communication buses 213, 223. The control units on the vehicle platform 202 may be identical to the corresponding units in FIG. 2B, and the control units of each VCM 150 may be identical to the respective control units of the VCMs 150 in FIG. 2B. In contrast to the communication scheme of FIG. 2B, here another communication bus is used: a VCM-to-VCM bus 223, which allows direct communication between two or more VCMs without the involvement of the platform's VCM control unit (CSCU) 212B. Each of the VCMs may be connected to the platform-to-VCM bus 213 and the VCM-to-VCM bus 223 via connector 214E. This scheme allows control and data flow between the vehicle platform 202 and two or more VCMs 150, as well as direct control and data flow between the VCMs 150.

[0112] Reference is now made to Figure 2D, which is a schematic block diagram illustrating a high-level topology of control units in a VCM-based vehicle 100 in accordance with an embodiment of the present invention. Vehicle 100 has four VCMs mounted on its vehicle platform: left VCM 150; L1 , 150 L2 and the VCM150 on the right R1 , 150 R2 Each controller 50 of each VCM 150 may be in active communication with a vehicle controller 115, which includes a VCM control unit (CSCU), either as a separate unit or as an added / integrated function. Communication between each of the VCMs and the vehicle controller 115 may be adapted to exchange data, control signals, and to reflect errors that occur during the VCM's operational phases and the state of the VCM.

[0113] 2D may be an autonomous vehicle. In this embodiment, the main autonomous computer 233 is in active communication with a vehicle controller 115 installed in the vehicle and adapted to exchange control, error, and status signals. In some embodiments, the vehicle may be driven by a human, and the main autonomous computer 233 may be included as a driver assistance system.

[0114] In the configuration shown in Figure 2D, there is no direct communication between the VCMs. A potential advantage of having VCMs that do not communicate with each other is that control is via the vehicle controller 115. In some cases, this simplifies preventing the transmission of conflicting signals, such as conflicting steering angles.

[0115] However, in some embodiments, an inter-VCM bus (such as VCM-VCM bus 223 in FIG. 2C) may be provided to allow for faster data exchange, improved levels of redundancy, and / or distribution of computational overload between processors.

[0116] Reference is now made to FIG. 2E, which is a schematic block diagram of a software (SW) high-level scheme according to an embodiment of the present invention. The SW scheme illustrates the division of SW allocations among SW modules of a vehicle comprising one or more physical modules, at least one of which is controlled by a dedicated SW module. In the SW scheme of FIG. 2E, each of the physical modules—steering module, power module, powertrain module, thermal / cooling module, and brake module—has an associated SW module adapted to provide control signals to control the operation of the associated physical module and to receive sensor readings from the module that monitor the operation of the physical module. Thus, steering SW module 241, power SW module 242, powertrain SW module 243, suspension SW module 244, thermal / cooling SW module 245, and brake SW module 246 are each adapted to provide control signals to their respective physical modules and to receive sensor signals from their respective physical modules that reflect the operation of the associated physical module.

[0117] Each of the SW modules may actively communicate with a central SW module 248, which is adapted to receive and store control, status, and error data from each of the SW modules and process the received data according to program lines optionally stored in non-volatile memory (not shown). The central SW module 248 may actively communicate with a vehicle control unit (not shown), for example, according to one or more control schemes described elsewhere herein. The central SW module 248 is adapted to receive control signals from an external control entity (not shown), such as an autonomous control unit (not shown). In some embodiments, each of the SW modules may operate on a dedicated computing device (not shown) located on or near the physical module it is adapted to control. In this manner, each HW / SW module is completely replaceable by simply removing the associated module and replacing it with another such module. In other embodiments, two or more SW modules may be embodied on a single HW platform, for example, located on the vehicle platform. In some embodiments, the HW modules of the physical modules may be identical to each other and may differ only by the SW package loaded into the HW module. Such an arrangement can save costs, reduce the number of off-the-shelf spare modules, and reduce the time required for removal, installation, and SW loading and adjustment.

[0118] 3A-3G show various mechanical and electrical configurations of a VCM according to embodiments of the present invention. The following examples show various partial combinations of units of a VCM.

[0119] 3A, which shows a schematic isometric view of a mounted wheel VCM 150. The VCM 150 comprises an electric motor 304A that drives a suspension unit, which in turn has a drivetrain unit 304B adapted to rotate the wheel. Furthermore, in this embodiment, a rotation sensor 306 may be installed in the wheel bearing to reflect the rotational speed of the wheel. The electric motor 304A may be connected to a power source via a power connection 304A1.

[0120] 3B, which schematically illustrates an isometric view of the VCM 150 installed within a wheel. The VCM 150 includes a steering assembly 310A, a suspension assembly 310B, and a brake assembly 310C, all of which are at least partially enclosed within the wheel rim. According to this embodiment, the steering assembly 310A may include a steering rod 310A1, a steering motor 310A2, and a steering control unit 310A3. The steering assembly 310A is adapted to receive steering control signals from the steering control unit 310A3. In some embodiments, the steering control unit 310A3 receives steering control signals from a central controller on the vehicle platform or from the VCM. The suspension assembly 310B is depicted as a system that enables movement of the wheel relative to the vehicle platform. The suspension assembly 310B may include a subframe 310B2 along which rails 310B1 are movable. The suspension assembly 310B may further include a sensor (not shown) adapted to measure suspension expansion / compression.

[0121] Figures 3C and 3D are front and side cross-sectional views, respectively, of the VCM of the embodiment of Figure 3B. Figure 3C shows details of brake assembly 310C, including brake actuator 310C1 and brake control interface 310C2, while Figure 3D shows another view of subframe 310B2 and rail 310B1 of suspension assembly 310B.

[0122] 3E, which illustrates a top cross-sectional view of a VCM 150 mounted at least partially within the rim of a wheel in accordance with an embodiment of the present invention. The VCM 150 may include a motor 320A having a control unit 320A1 and a motor electrical connection 320A2 for receiving power from the vehicle platform. The VCM 150 further includes a power transmission 320D that provides rotational drive to a wheel interface 320C and a steering assembly 320B. The wheel interface 320C may include a rotation sensor (not shown) that provides data indicative of rotational speed. An electrical and communication cable 320A2 may provide necessary connections to the vehicle platform and / or another VCM. In some embodiments, a VCM controller 50 may be installed as part of the VCM 150 system. The electrical and control connections of the steering assembly 320B may be connected to the VCM controller 50.

[0123] Reference is now made to FIG. 3F, which illustrates a schematic cross-sectional side view of a VCM 150 mounted at least partially within the rim of a wheel, according to an embodiment of the present invention. FIG. 3F illustrates an embodiment of a VCM 150 including a combined drivetrain and suspension 330B adapted to rotate a wheel via a drive shaft 330B1. Electrical and communication cables 330D may provide necessary connections to the vehicle platform and / or another VCM. In some embodiments, a VCM controller 50 may be installed as part of the VCM 150 system. If steering functionality (not shown) is included in the embodiment, its electrical and control cables may be connected to the VCM controller 50. Reference is now made to FIG. 3G, which illustrates a schematic side view of a VCM 150 mounted at least partially within the rim of a wheel, according to an embodiment of the present invention. The VCM 150 includes a motor 340A, a suspension assembly 340B, a VCM controller 50, a brake actuator 340D connected to the VCM controller 50 via connection 340D1, and a rotation sensor 340E, which may be located in the wheel bearing, and may be mechanically connected to the vehicle platform via an interface module 342. Any one of the motor 340A, the rotation sensor 340E, the brake actuator 340D, and the suspension assembly 340B may be connected to and controlled by the VCM controller 50. In some embodiments, any one of the motor 340A, the rotation sensor 340E, the brake actuator 340D, and the suspension assembly 340B is connected to a predetermined control unit that is connected to and controlled by the VCM controller 50.

[0124] 4A , which illustrates a schematic 3D diagram of one embodiment of a VCM 150 in accordance with an embodiment of the present invention. The VCM 150 includes a motor and motor control unit 400A, a powertrain 400B, a suspension assembly 400C, a steering control unit and steering actuator combination 400D, a brake unit 400E, and a wheel interface 400F, with at least a portion of the VCM 150 adapted to be configured within the rim of a vehicle when attached to the wheel interface 400F. Any one of the motor and motor control unit 400A, sensors (not shown), brake unit 400E, and suspension assembly 400C may be connected to and controlled by a VCM control unit (not shown). In some embodiments, any one of the motor, brake, and suspension assembly may be connected to a designated control unit, which may be connected to and controlled by a VCM controller (not shown).

[0125] 4B, which is a schematic 3D diagram of a VCM 150 according to an embodiment of the present invention, the VCM 150 represents an in-wheel unit for mounting on two wheels. The VCM 150 includes a motor and motor electrical connections 410A adapted to drive two wheel interfaces 410D via a drive train 410C. The VCM 150 further includes a suspension assembly 410B comprised of a suspension control unit 410B1, a suspension motion sensor 410B2, and a suspension spring damper 410B3. The VCM 150 may be connected to the wheels via the wheel interfaces 410D and may be mechanically connected to the vehicle platform via interface 412. The VCM 150 may be controlled by a VCM controller 50. Either the motor 410A or the suspension assembly 410B may be connected to and controlled by the VCM controller 50. In some embodiments, either the motor 410A or the suspension assembly 410B is connected to a designated control unit (such as suspension control unit 410B1) that is connected to and controlled by the VCM controller 50.

[0126] 4C, which is a schematic block diagram of a storage unit 452 storing a VCM 454 according to an embodiment of the present invention. The VCM 454 may be similar to any one of the VCMs described above, such as the VCM 150 described in FIG. 2A, and includes a sensor unit 454A and a VCM controller 50 in active communication with the following active systems: a suspension control unit (SCU) 454B1, a brake control unit (BCU) 454B2, a steering control unit (STU) 454B3, and a wheel drive control unit 454B4.

[0127] The VCM 454 may be adapted to be attached to the storage unit 452 via one or more mechanical mounts 452A and at least one electrical and control connector 452B. Any one of the mounts 452A may be adapted to support the weight of the VCM 454 within the storage unit 452, and in some embodiments, one or more of the mounts 452A include electrical circuitry.

[0128] In some embodiments, the storage unit 452 may include a controller and control program (not shown) adapted to perform operational tests on the VCM 454 stored within the storage unit 452, as described hereinabove. The storage unit 452 may further include a local output device 452C (e.g., a display, a wireless transmitter / receiver, etc.) that provides VCM test results and allows for control of test parameters. One or more mounts 452A may include or consist of one or more forms of sensors, such as vibration sensors, mechanical load sensors, mechanical moment sensors, etc. Tests may be performed by activating one or more VCM systems according to a test scheme. Test results may be recorded by the VCM sensors 454A and / or sensors included in the mounts 452A.

[0129] The storage unit 452 may be a container having multiple walls 450a, 450b, 450c, 450d. The storage unit 452 may be shaped to fit the VCM 454 or may be designed to be adjustable (e.g., via adjustable mounts 452A) to fit multiple VCM types. The storage unit 452 may be shaped and sized to accommodate multiple VCMs 454 at once. The storage unit 452 may be stationary or adapted to be movable.

[0130] Reference is now made to FIG. 5, which is a schematic flow diagram illustrating the steps involved in plugging a VCM into a vehicle platform in accordance with embodiments of the present invention. In step 502, a VCM is plugged into a vehicle platform. In some embodiments, the VCM plugged in at step 502 is a new VCM that has not been previously installed on the vehicle platform. In some embodiments, the VCM plugged in at step 502 is a VCM that has been previously installed on the vehicle platform. In some embodiments, the VCM is plugged in by a human operator (e.g., technician, driver, professional military), and in some embodiments, the VCM is plugged in by a robotic system. In step 504, VCM operation profile data is received by the platform.

[0131] In step 506, the version of the VCM is checked. If the VCM verification fails, a notification (failure notification) is issued in step 504a. The failure notification may be provided to an operator and may be visual or audible. The failure notification may be an output sent to another device. The failure notification may be provided by the VCM and / or the vehicle platform and / or devices connected to the VCM. In some embodiments, if the version of the VCM needs to be updated, the update is performed in step 506a.

[0132] The VCM profile and platform profile are matched in step 508, and any failure to match is reported in step 508a. In some embodiments, step 508a (reporting) follows the unplugging of the VCM and the completion of the VCM plugging process into the vehicle platform. Step 508a (reporting) may be to an operator and may be visual or audible. Step 508a (reporting) may be an output sent to another device. Step 508a (reporting) may be provided by the VCM and / or the vehicle platform and / or devices connected to the VCM.

[0133] In step 510, the newly installed VCM is activated using a profile that matches the vehicle's profile. According to some embodiments, the profile is selected from a profile database stored on the VCM. In some embodiments, the profile database is stored on the vehicle platform. In some embodiments, the profile database is stored on a remote storage device (device, computer, cloud). According to some embodiments, the selected operational profile includes activation / deactivation of systems related to steering and / or braking and / or driving of the VCM. According to some embodiments, the profile includes operational parameters that match the vehicle's performance. In some embodiments, the profile includes operational parameters that match the driver's profile. In some embodiments, the profile includes predictive operational parameters that depend on the vehicle's planned operation (e.g., time, distance, speed, weather, road conditions).

[0134] VCM historical data may optionally be read in step 512. In some embodiments, the historical data may be vehicle platform operational data. In some embodiments, the historical data may be VCM operational data. In some embodiments, the historical data may be planned vehicle operations. In some embodiments, following the reading of the historical data (step 512), an analysis of the historical data occurs (step 513). In some embodiments, if the results of the analysis (step 513) are inconsistent with the expected behavior of the VCM and / or vehicle platform (e.g., if there is not enough time for maintenance to enable the expected behavior), a warning is provided.

[0135] After a VCM is activated, its profile is matched with the profile of another VCM in the vehicle in step 514. According to some embodiments, if a mismatch is found, it is reported in step 514a (the reporting method may be similar to that listed above).

[0136] In step 516, the profile of the new VCM is adjusted to the profile of another VCM in the vehicle.

[0137] In step 518, the profile of the other VCM is adjusted to the profile of the new VCM, creating a closed loop of adjustments until all necessary adjustments are completed. Once all VCMs have been adjusted successfully, in step 520, the newly installed VCM is enabled for operation.

[0138] Reference is now made to FIG. 6, which is a chart detailing which elements of a system of one or more VCMs according to an embodiment of the present invention are involved in performing each specific operation performed during operation and maintenance of a vehicle having a VCM.

[0139] 7A and 7B, which are schematic flow diagrams illustrating a process for matching a newly installed VCM with a vehicle platform and another VCM, as well as optional additional processes, according to an embodiment of the present invention. The new VCM is connected to the vehicle platform in step 702, and the control units in the VCM are started in step 704. In step 706, the VCM is verified by either a remote / external computer, a vehicle platform controller, or a remote, in-cloud service. In step 708, the VCM's information is sent to the vehicle platform controller, and then to another VCM in the vehicle in step 710, completing the process.

[0140] The following steps 712-716 are optional. Step 712 receives data from another VCM, and step 714 configures the operating profile of the newly installed VCM based on the data from the other VCM. If historical information about the new VCM is needed to optimize the results (configuration) achieved in step 714, that historical information may be read in step 714a. Finally, in step 716, the VCM's operating parameters are calibrated to match its operation with the vehicle system.

[0141] Reference is now made to Figure 8, which is a simplified flow diagram illustrating a process for updating an operational VCM installed on a vehicle platform in accordance with an embodiment of the present invention. Once the VCM is installed and activated, the vehicle's operating parameters are updated (step 802). The update in step 802 may be performed while the vehicle is in operation, for example, during changes in speed and / or steering. The update may be part of a maintenance process.

[0142] Following the update (step 802), one or more systems of one or more VCMs that support the vehicle's operating parameters that require updating are identified (step 804).

[0143] Parameters to be updated are calculated for the identified VCM systems (step 806). This calculation may be performed by a computing unit on the vehicle platform or in the VCM, as the case may be. Following the calculation process (step 806), operational parameters are updated to operate one or more systems in one or more VCMs (step 808). After the update process (step 808), the VCM system is activated (step 810), and acknowledgement of successful operation of the VCM system is provided to the vehicle platform and / or another VCM (step 812).

[0144] One or more of the steps of the identification process (804), the update process (808), the activation process (810), and the approval process (812) may involve data exchange between the VCM and the VCM system control unit, and are described elsewhere above.

[0145] Reference is now made to Figure 9, which is a simplified flow diagram illustrating a process for updating the operating parameters of an attached VCM, in accordance with an embodiment of the present invention.

[0146] A target operating profile setting is received from a vehicle operator, step 902. The target operating profile may be provided during one or more of vehicle operation, maintenance procedures, and initial start-up.

[0147] Following setting of the target profile (step 902), a current operating profile of the vehicle is received from one or more control units of the vehicle platform controller and / or one or more VCMs (step 904).

[0148] Based on the target VCM operating parameters and the current operating profile, target operating profile parameters are calculated (step 906). The calculations (step 906) may be performed by a computing unit located on the vehicle platform, the VCM, and / or a remote computing unit.

[0149] The calculated operating parameters are distributed to one or more control units of one or more VCMs (step 908). The control units may send updated actuation signals to the VCM's systems according to the target parameter values.

[0150] Reference is now made to Figure 10, which is a simplified flow diagram illustrating a process for adapting actual operating parameters based on predicted operating parameters in accordance with an embodiment of the present invention. The process begins by receiving data indicative of VCM performance requirements (step 1002) and continues with estimating predicted VCM performance (step 1004).

[0151] Next, based on the previous steps, it is determined whether the VCM can achieve the predicted performance (step 1006). In this step, operating parameters to be updated to achieve the predicted data may be calculated (step 1006a), and, optionally, the predicted data may be updated accordingly (step 1006b).

[0152] Start-up commands based on the calculated updated prediction data are sent to one or more VCMs (step 1008), and in step 1006, it is determined again in a closed loop whether the VCMs can achieve the predicted performance. If the calculation of the operating parameters in step 1006a fails to provide the updated operating parameters, a failure is provided. One or more of the steps of the determining process (step 1006) and the calculating process (step 1006a) may be performed by a computing unit located on one or more of the vehicle platform, the VCMs, and / or a remote computing unit.

[0153] Reference is now made to Figure 11, which is a flow diagram illustrating a process for replacing a VCM according to an embodiment of the present invention.

[0154] A VCM is determined to require replacement when, for example, a mismatch between the VCM's target operating parameters and its actual operating parameters is detected that exceeds a predetermined threshold (step 1102A), when the VCM's expiration date is detected (step 1102B), or when a change in the planned service program is detected (step 1102C).

[0155] If it is determined that the VCM needs to be replaced, a signal indicating "replacement is required" is issued (step 1104), and the vehicle operation mode is set to service mode (step 1106).

[0156] The non-functional VCM is removed from the vehicle platform (step 1108) and, depending on its actual condition, is either discarded (step 1110A) or serviced (step 1110B).

[0157] Regardless of the actual state of the removed VCM, a replacement VCM is installed on the vehicle platform and activated (step 1112), and vehicle operation is resumed (step 1114).

[0158] Reference is now made to Figures 12A-12C, which are schematic block diagrams illustrating communication and control flow between units of a vehicle in several exemplary scenarios according to embodiments of the present invention. In all three examples, the vehicle platform may include at least a power supply and a VCM system controller, where the system controller may be disconnected from other units, as in the following examples. Each VCM module in the following examples may include at least one or more from the list consisting of a motor unit, a steering unit, a brake unit, a suspension unit, and a VCM controller. In all the following examples, communication between the vehicle platform controller and the VCM control unit may be disconnected. Other communication lines may also be disconnected. In the following examples, disconnected communication lines are marked with a cross.

[0159] FIG. 12A shows a basic communications arrangement in which the vehicle platform communicates with the VCM through an external or remote computer, bypassing any broken direct lines between the two.

[0160] 12B shows a configuration including a vehicle platform with multiple VCMs and an external / remote computer, where direct communication lines between the single VCM and the platform and between the platform and the multiple VCMs are broken. This configuration illustrates how all VCM-to-platform communication is performed through the remote / external computer, and VCM-to-VCM communication may be augmented.

[0161] 12C illustrates a scenario in which the vehicle platform is disconnected from direct communication with the VCM, but has a communication link with a remote / external computer and a service station. A communication link is also in effect between the remote / external computer and the service station. Thus, communication between the platform and the VCM occurs in two ways: via the service station and via the remote / external computer.

[0162] Reference is now made to Figure 13, which illustrates a process for operating a VCM and communicating VCM data with other systems in an embodiment of the present invention.

[0163] The operation of the VCM may be related to systems and processes that contribute to the selection of operating parameters and operating profiles. The operation of the VCM may also be related to systems and databases used for financial purposes and business transactions. Usage costs may be useful for business transactions such as vehicle rental, VCM rental, service plans, and subscription services. Examples of operating parameters that can be communicated to other systems include mileage, driving time, and acceleration (maximum, frequency), all of which may be associated with the wear rate of the VCM. The operating data may be compared to planned values. Planned values may be part of a business plan established for the VCM and / or vehicle, such as when the VCM is purchased, when the VCM is rented, when a service plan for the VCM (e.g., VCM as a Service) is purchased / subscribed to, and when a usage plan is purchased. Financial data may relate to information used in an insurance plan. The insurance plan may be related to the VCM and / or the vehicle. The cost of the insurance plan may be based on historical data for the VCM. According to some embodiments, the operation of the VCM may be controlled according to financial data and considerations. In some embodiments, the VCM's performance (operational profile) is selected as a dependency of the selected plan. In some embodiments, the VCM's performance (operational profile) is selected as a dependency of actual VCM data on a preceding plan. As shown in FIG. 13 , operation of the VCM may include receiving a vehicle corner module (step 1302) according to a plan established for the vehicle platform, operator profile, etc. As described elsewhere above, the VCM is coupled (plugged in) to the vehicle platform (step 1304). Prior to launching the VCM (1308), there may be a step of receiving (1306) information regarding the operation plan established for the VCM. Setting of the VCM profile (1310) may be according to the operation plan.

[0164] The VCM's operational data may be recorded (step 1312) for use by other systems and then output (step 1314). The other system, which may be a financial system, may receive the operational data (step 1316). The received data can be used to analyze the VCM's data usage (step 1318) and calculate a financial charge according to the analyzed data (step 1320). The financial charge is output to the VCM holder (step 1322). In some embodiments, the analyzed data is output to update the VCM's operational plan (step 1324).

[0165] As shown in steps 1330 to 1336, an operation plan for the VCM can be created based on the business plan set in the VCM. The operation plan for the VCM can be set (step 1332), stored in a database (step 1334), and output (step 1336) to other devices (e.g., an external computer, a cloud, a vehicle platform computing device, and a corner module computing device) as needed.

[0166] Reference is now made to FIGS. 14A-14D, which illustrate an example of a wheeled vehicle 100 according to an embodiment. While only a four-wheeled vehicle is illustrated, embodiments of the present invention can be implemented in vehicles with fewer or more wheels. FIGS. 14A and 14B illustrate a vehicle 100 fitted with four VCMs 150, one at each corner, each including a respective on-board (i.e., mounted on the VCM) VCM controller 50. The vehicle 100 of FIG. 14A includes a communication bus 153 that enables electronic communication between the on-board vehicle controller 115 and each of the four VCM controllers 50. Thus, the communication arrangement is similar to that shown in FIG. 2D, in that communication between the vehicle controller and each VCM controller is enabled, but direct communication between the VCM controllers is not enabled by the communication bus shown in FIG. 14A. In some embodiments, the communication bus 153 can be expanded to include VCM-to-VCM communication.

[0167] The vehicle 100 shown in FIG. 14B includes a communication bus 154 connecting the VCM controllers 50 to one another. In some embodiments, as shown in FIG. 14B, the communication bus 154 can further enable communication between the vehicle controller 115 and any one or more (or all) of the VCM controllers 50. One example of a communication bus 153 or 154 is a multi-master serial bus configured as a controller area network (CAN) bus. In some embodiments (not shown), physically separate and / or assigned, e.g., permanently or temporarily assigned, communication channels can be implemented between specific endpoints alongside or as extensions of the communication bus. For example, the VCM controllers can have such direct channel communication with sensors located within their respective VCMs.

[0168] 14A and 14B, the vehicle 100 may include multiple pairs of opposing VCMs 150, i.e., opposing wheels. In other examples, such as those shown in Figures 14C and 14D, the vehicle 100 may include only a single pair of opposing VCMs 150, while the other wheels, if any, of the vehicle 100 are implemented in other manners, such as with conventional arrangements for steering, drive, braking, and / or suspension systems.

[0169] 15. The VCM 150 according to the embodiment includes multiple subsystems, each consisting of mechanical and / or electrical components. Each of the subsystems is in contact with or connected to the subframe 161 and in contact with the wheel interface 175. The multiple subsystems of each VCM 150 are selected from the following four subsystems:

[0170] a. The steering subsystem 200 can include any or all of the mechanical and / or electrical components necessary for steering, i.e., pivoting the vehicle's wheels about a steering axis, including, but not limited to, a steering motor, a steering actuator, a steering rod, a steering system controller or control unit, a steering inverter, and wheel angle sensors. Some components of the steering subsystem are shown in FIGS. 3B and 4A. In an embodiment, the VCM controller 50 of the VCM 150 receives steering instructions as electrical (including electronic) inputs from the vehicle, e.g., a driver-operated steering mechanism or an autonomous steering unit, and responds to the instructions by, e.g., adjusting the current and voltage transmitted to the steering actuator and / or by transmitting high-level instructions to a steering system controller, and executes the instructions, e.g., by causing movement of the steering rod via the steering actuator to cause rotation of the wheels. The steering motor, actuator, and / or inverter can receive power from an external power source ("external" meaning external to the VCM), such as a battery pack installed on the vehicle's chassis, or from a power source associated with a test setup, e.g., the test fixture of FIG. 21. The steering system controller may receive power from either the power supply 59 (shown in FIG. 17A) of the VCM controller 50 or from an external power source as described above, if applicable.

[0171] b. Drive system 180 can include any or all of the mechanical and / or electrical components necessary to operate a drive shaft that rotates the vehicle's wheels to drive the vehicle, including, but not limited to, an electric drive motor, a drive shaft rotated by the motor, and a gear assembly, optionally including a single-gear or multi-gear transmission, that transmits the rotation to the wheels, and sensors, such as wheel speed sensors (in non-limiting examples, rotary encoders). Some components of the drive system are shown in FIGS. 3A, 3E, 3F, 4A, and 4B. In some embodiments, the drive motor is included in the VCM, and in some embodiments, the drive motor is on the vehicle, e.g., mounted to the chassis. In embodiments, VCM controller 50 of VCM 150 is configured to adjust the motor power and / or wheel rotational speed and / or transmission gear selection in response to instructions received via electrical input from the vehicle, e.g., a driver-operated drive mechanism (e.g., accelerator pedal) or an autonomous driving device. In embodiments, the instructions include, for example, current and voltage for operating the electric drive motor. In an embodiment, drive subsystem 180 can be used in a regenerative braking scheme, in which the drive motor functions as a generator of electricity when the vehicle decelerates. Storage of the regenerated electricity can occur in an on-board energy storage device. As an example, when the driver releases their foot from the accelerator pedal (or the autonomous drive system terminates power to the drive wheels), the regenerative braking scheme begins to recover electrical energy generated by the vehicle's deceleration, i.e., as the generator rotates, which is converted into mechanical resistance through the driveline. In another example, regenerative braking is augmented by friction braking, i.e., normal operation of brake system 176, in response to the driver pressing the brake pedal (or receiving a brake application command from the autonomous drive computer). In such an example, a portion of the energy used to brake the vehicle is lost to heat in a "normal" friction brake system, and at least a portion of that energy is recaptured as stored electrical energy.In an embodiment, the "cooperation" of drive system 180 and brake subsystem 176 when combining regenerative braking with friction braking is controlled by VCM controller 50. In yet another example where the VCM controller is configured (e.g., programmed) to control multiple subsystems in cooperation with one another, steering subsystem 200 can be used to assist braking, i.e., cooperate with the brake system, by rotating the wheels to increase friction with the road surface, whether steering symmetrically, with opposing wheels rotating in the same direction in tandem, or asymmetrically, with opposing wheels not rotating in tandem. In a similar example, the VCM controller controls steering subsystem 200 in cooperation with the brake system to mitigate the effects of steering-induced brake pull (a phenomenon also known as "brake steer" or "steering drift"). In yet another example, the VCM controller coordinates control of the drive system (with respect to regenerative braking), the brake system (with respect to friction braking), and the steering system (with respect to brake-by-steering) to achieve a desired braking effect.

[0172] c) The brake system 176 may optionally include some or all of the mechanical and electrical components that actuate the brake assemblies (e.g., brake discs, brake calipers, etc.) including one or more of a VCM-mounted hydraulic system, a VCM-mounted vacuum boost system, or a hybrid brake assist system incorporating a pressurized gas accumulator and brake actuator. Some components of the brake system are shown in Figures 3C, 3G, and 4C. In an embodiment, the VCM controller 50 of the VCM 150 is configured to adjust the output of the braking system, e.g., to cause braking, in response to electrical inputs from the vehicle, e.g., instructions received from a driver-operated braking mechanism (e.g., a brake pedal) or an autonomous braking device.

[0173] d. The suspension system 240 may optionally include an active suspension system that is controllable by the VCM controller 50 of the VCM 150 (e.g., via a suspension system control unit). Some components of an active suspension system, including springs and dampers, movement sensors, and a control unit, are shown in FIG. 4B.

[0174] In some embodiments, the plurality of VCM subsystems in any VCM 150 includes all four of the above a.-d. subsystems. In other embodiments, the plurality of VCM subsystems in a given VCM 150, or in each VCM 150 of a given pair of opposing VCMs 150, may include two or three selected subsystems. For example, in FIG. 16A, an exemplary VCM 150 for installation as the right front VCM 150 of a vehicle is shown. RF includes a steering subsystem 200, a braking subsystem 176, and an active suspension system 240. For example, in FIG. 16B, an exemplary VCM 150 for installation as the right rear VCM 150 of a vehicle is shown. RR includes drive subsystem 180 and brake subsystem 176. In both examples, the included subsystems can be arranged such that all of the mechanical and electrical components required for their respective functions are mounted on VCM 150, with electrical transmission and communication arrangements passed from the vehicle to the VCM controller and / or respective subsystems (e.g., their controllers, motors and / or actuators) that are contained entirely within / on the VCM. The electrical transmission and communication arrangements can be passed through subframe 161 that is mounted on the "host" vehicle.

[0175] 17A, a VCM controller 50 according to an embodiment is illustrated schematically to show selected components. The example VCM controller 50 of FIG. 17A includes one or more computer processors 55, a computer-readable storage medium 58 (storage), a communications module 57, and a power supply 59. The computer-readable storage medium 58 may include transient and / or temporary storage devices and may include one or more storage devices according to desired functionality and design choices. In an embodiment, the storage medium 58 may be used to store program instructions in firmware and / or software executed by the one or more processors 55 of the VCM controller 50, as well as one or more of historical operating data, maintenance data, and / or ownership data associated with the VCM and / or any one or more of its subsystems and components. Communications module 59 is configured to establish communications links with on-board vehicle controller 115 via communications arrangement 71, with another VCM controller 50, e.g., VCM controller 50 of VCM 150 of the same vehicle 100, via communications arrangement 72, with VCM subsystems 200, 180, 176, 240 (including their respective subsystem control units via communications arrangement 70) via communications arrangement 74, and with sensors 155 located, e.g., in / on VCM 150, via communications arrangement 73. In an embodiment, VCM controller 50 does not include all of the components shown in FIG.

[0176] External computer 75 may be, for example, testing computer 13 shown in FIG. 21 or an external computer that serves as an authorization system or a financial and administrative system. The "authorization system" in external computer 75 may be, for example, but not exclusively, configured to: approve the replacement of a VCM with another VCM; initiate or perform financial operations related to the maintenance or replacement of a VCM (such as recording costs or processing payments); record VCM operational and maintenance data (such as operational and maintenance history); and / or authorize the maintenance or replacement of a VCM pursuant to a financial and / or subscription-type service or leasing arrangement, either as part of the maintenance or arrangement or as an additional fee, for example, according to a tariff or discount established in connection with the maintenance or arrangement.

[0177] The storage medium 58 of the exemplary VCM controller 50 is shown in Figure 17B to include program instructions 60 related to installing the VCM 150 in the vehicle 100 so that the VCM can be replaced with another, for example, at a service station, such as the service station 110 of Figure 1D or the service station of Figure 12C. In the example illustrated in Figure 17B, the program instructions 60 include two groups of program instructions GPI01, GPI02 that are executed by the one or more processors 55 of the VCM controller 50.

[0178] Program instructions GPI01 are for establishing (by VCM controller 50) a communication link with vehicle controller 115. Establishing the communication link includes electronically transferring information about VCM 150 from VCM controller 50 to vehicle controller 115. In some embodiments, the communication link with vehicle controller 115 is a bidirectional link, and establishing the communication link additionally includes receiving information about vehicle 100 and / or another VCM 150 attached to vehicle 100. The information about vehicle 100 and / or another VCM 150 attached to vehicle 100 may include, for example, operational and maintenance data and / or history of vehicle 100 and / or another VCM 150. In some embodiments, the information about VCM 150 transferred from VCM controller 50 to vehicle controller 115 includes information about at least one of a plurality of subsystems and / or includes results of self-diagnostic tests performed prior to installation. The plurality of subsystems may include two, three, or four subsystems selected from VCM subsystems 200, 180, 176, and 240. In some embodiments, the communication link with the vehicle controller 115 is established prior to installation of the replacement VCM in the vehicle 100; in other words, the communication link is established while the replacement VCM (or, in some embodiments, the potential replacement VCM) is not connected to or installed in the vehicle. Such a communication link with the vehicle controller may be established, for example, while the replacement VCM is still in storage at a service station or has already been selected for use with the vehicle and removed from storage. In some embodiments, failure to establish a communication link may be grounds for disqualifying a given VCM from being installed in the vehicle, or at least delaying installation until the reason for the failure to establish the communication link can be determined. Similarly, even if the communication link is successfully established, information transferred from the VCM controller to the vehicle controller (or vice versa) may cancel or delay installation of the given VCM in the vehicle.As one example, the VCM controller may transfer information regarding the part's specifications, operating history, or maintenance history, allowing the vehicle controller to determine that a given VCM should not be installed. In an embodiment, the pre-installation information exchange may include checking compatibility with another VCM already installed in the vehicle, such as whether the replacement VCM has the same type and version of a given subsystem or item of hardware or software. In another example, multiple different replacement VCMs may establish respective communication links with the vehicle controller, and the vehicle controller may "select" the most compatible VCM stocked at a service station location or "shop around" for the VCM with the most favorable economic terms for installation (e.g., determining whether a VCM is subscribed to a subscription service or lease agreement, or is designed for premium customers who pay the VCM owner or provider more).

[0179] Program instructions GPI02 are for executing a post-installation verification process that, in response to installation of VCM 150 on the vehicle, verifies a plurality of subsystems (selected from VCM subsystems 200, 180, 176, 240) and communicates the results of the verification to vehicle controller 115. In some embodiments, verifying the plurality of subsystems includes receiving information from one or more sensors 155 onboard VCM 150. In some embodiments, operation of vehicle 100 after installation is contingent on receiving a positive verification process result, and failure to complete the verification process can mean that the vehicle is not operational until the failure is resolved.

[0180] In various embodiments, as shown in FIG. 17C , the program instructions 60 stored in the storage medium 58 of the exemplary VCM controller 50 may additionally include any one or more, or all, of the additional groups of program instructions GPI11, GPI12, and GPI13 for execution by one or more processors 55 of the VCM controller 50.

[0181] Program instructions GPI11 are for regulating or controlling the operation of at least one of the plurality of subsystems in response to electrical signals received from outside the VCM.

[0182] The program instructions GPI 12 are for exchanging information with (by way of) a VCM controller 50 on board a VCM of another VCM 150 on board the vehicle 100 .

[0183] Program instructions GPI13 are for determining an operational profile for VCM 150 based on data received from vehicle controller 115. The operational profile may include profiles, i.e., physical, mechanical, electrical, and / or operational data, of any one or more of VCM subsystems 200, 180, 176, 240 of the second VCM. By way of non-limiting example, the operational profile may include a braking profile based on the design and / or operating history of braking subsystem 176 of second VCM 150, a motor and transmission dynamic response profile based on the design and / or operating history of drive subsystem 180 of second VCM 150, a steering profile based on the design and / or operating history of steering subsystem 200 of second VCM 150, and a suspension damping profile based on the design and / or operating history of suspension subsystem 240 of second VCM 150.

[0184] 18, a method is disclosed in accordance with any one or more of the embodiments disclosed herein, for example, any of the vehicles 100 shown and described herein, incorporating a communication bus (e.g., communication bus 153 of FIG. 14A or communication bus 154 of FIG. 14B) and at least one pair of opposing VCMs 150 having respective VCM controllers 50. As illustrated by the flowchart of FIG. 18, the method comprises:

[0185] In step S01, VCM controller 150 controls the operation of one or more of the VCM's multiple VCM subsystems (selected from VCM subsystems 200, 180, 176, 240) in response to electrical inputs external to VCM 150.

[0186] 19A , a method of replacing a first vehicle corner module (VCM) with a second VCM is disclosed. Those skilled in the art will appreciate that the method of replacing a VCM with a second VCM is applicable, mutatis mutandis, to reinstalling a VCM that has been removed from a vehicle for maintenance, for example. Therefore, the concept of "replacing with a second VCM" in both this specification and the appended claims should be understood to include instances in which the first VCM and the second VCM are the same, and such instances are fully within the scope of the present invention.

[0187] According to the method shown in Figure 19A, at least the second VCM (and optionally the first VCM / replacement VCM) is a VCM 150 according to any one or more of the embodiments disclosed herein, and includes a subframe 161 mountable to a reference frame of the vehicle 100, a wheel hub assembly 174 (shown in Figures 16A-16B), a VCM-mounted VCM controller, and a plurality of subsystems interposed between the subframe 161 and the wheel hub assembly 174, selected from VCM subsystems 200, 180, 176, and 240. As shown in the flowchart of Figure 19A, the method is configured as follows:

[0188] Step S11 includes establishing an electronic communication link between each VCM controller 50 of the second VCM 150 and the onboard vehicle controller 115, and communicating information about the second VCM 150 from the respective VCM controller 50 (of the second VCM 150) to the vehicle controller 115. In some embodiments, the electronic communication link with the vehicle controller 115 is a bidirectional link, and establishing the electronic communication link additionally includes receiving information about the vehicle 100 and / or information about another VCM 150 installed in the vehicle. In some embodiments, the vehicle controller 115 can send a query to the VCM controller 50 of the second VCM 150, and at least some of the information about the second VCM 150 transferred from the respective VCM controller 50 to the vehicle controller 115 includes a response to the query received from the vehicle controller 115. In some embodiments, the information about the second VCM 150 includes results of self-diagnostic tests performed prior to installation, for example, by the second VCM 150 itself or by a test apparatus, such as the test apparatus 10 of FIG. 21 . In some embodiments, the information about the second VCM 150 includes at least one of the operation history and maintenance history of the second VCM 150. In some embodiments, an electronic communication link between each VCM controller 50 of the second VCM 150 and the onboard vehicle controller 115 is established prior to installation of the second VCM 150. In other words, the communication link is established while a replacement VCM (or, in some embodiments, a potential replacement VCM) is not connected to or installed in a vehicle. In some embodiments, failure to establish a communication link can be grounds for disqualifying a given VCM for installation in a vehicle, or at least delaying installation until the reason for the failure to establish the communication link can be determined. Similarly, even if a communication link is successfully established, information transferred from the VCM controller to the vehicle controller (or vice versa) can cancel or delay installation of a given VCM in a vehicle.As one example, the VCM controller may transfer information regarding the part's specifications, operating history, or maintenance history, allowing the vehicle controller to determine that a given VCM should not be installed. In an embodiment, the pre-installation information exchange may include checking compatibility with another VCM already installed in the vehicle, such as whether the replacement VCM has the same type and version of a given subsystem or item of hardware or software. In another example, multiple different replacement VCMs may establish respective communication links with the vehicle controller, and the vehicle controller may "select" the most compatible VCM stocked at a service station location or "shop around" for the VCM with the most favorable economic terms for installation (e.g., determining whether a VCM is subscribed to a subscription service or lease agreement, or is designed for premium customers who pay more to the VCM owner or provider).

[0189] In step S12, in response to and conditional on the installation of the second VCM 150 to the vehicle 100, a post-installation verification (including verifying each of the multiple subsystems of the second VCM 150 and communicating the results of the verification to the vehicle controller 115) is completed.

[0190] In step S13, the validation results communicated to the vehicle controller in step S12 are used to enable or disable operation of the vehicle 100 after installation of the second VCM 150. In some embodiments, validation of the multiple subsystems includes receiving information from one or more sensors 155 mounted on the second VCM 150, such as, but not limited to, suspension travel sensors, wheel angle sensors, wheel speed sensors, or sensors of the hydraulic braking system, such as pressure sensors or level sensors.

[0191] In some embodiments, the method includes the additional step S14 as shown in the flowchart of FIG. 19B.

[0192] In step S14, information regarding the replacement of the first VCM with the second VCM is transmitted to an authorization system in the external computer. In embodiments, the information transmitted to the authorization system includes at least two of identification information for each of the first and second VCMs, usage information for one or more of the plurality of subsystems of the first VCM, and maintenance information for one or more of the plurality of subsystems of the first VCM. In some embodiments, a value is assigned to the replacement or equivalently, maintenance check based on at least one of the usage information for one or more of the plurality of subsystems of the first VCM, the usage information for one or more of the plurality of subsystems of the second VCM, the maintenance information for one or more of the plurality of subsystems of the first VCM, and the maintenance information for one or more of the plurality of subsystems of the second VCM.

[0193] As further shown in the flowchart of FIG. 19B, in some embodiments in which the method includes step S14, the method additionally includes either step S15a or S15b.

[0194] Step S15a receives authorization from an authorization system, which authorization is based on a service subscription, such as, by way of non-limiting example, a lease agreement or an annual service contract.

[0195] Step S15b receives authorization from an authorization system, in non-limiting examples based on a transaction such as a payment or credit check.

[0196] In some embodiments, both steps S15a and S15b are included in the method. In an illustrative example, the lease agreement provides for maintenance and / or replacement of the VCM based on a predetermined tariff price or discount price, e.g., a percentage discount.

[0197] In some embodiments, the method includes the additional step S16 as shown in the flowchart of FIG. 19C.

[0198] In step S16, an operational profile for the second VCM is determined based on information received from the vehicle controller. The operational profile may include profiles, i.e., physical, mechanical, electrical, and / or operational data, of any one or more of the VCM subsystems 200, 180, 176, 240 of the second VCM. By way of non-limiting example, the operational profile may include a braking profile based on the design and / or operational history of the braking subsystem 176 of the second VCM 150, a motor and transmission dynamic response profile based on the design and / or operational history of the drive subsystem 180 of the second VCM 150, a steering profile based on the design and / or operational history of the steering subsystem 200 of the second VCM 150, and a suspension damping profile based on the design and / or operational history of the suspension subsystem 240 of the second VCM 150.

[0199] 20, a second method is disclosed for replacing a first vehicle corner module (VCM) with a second VCM (or equivalently, reinstalling a VCM that has been removed from a vehicle, for example, for maintenance). According to the method shown in FIG. 20, at least the second VCM (and optionally the first VCM / replacement VCM) is a VCM 150 according to any one or more of the embodiments disclosed herein, and includes a subframe 161 mountable to a reference frame of the vehicle 100, a wheel hub assembly 174 (shown in FIGS. 16A-16B), a VCM-mounted VCM controller, and a plurality of subsystems interposed between the subframe 161 and the wheel hub assembly 174, selected from VCM subsystems 200, 180, 176, and 240. As shown in the flowchart of FIG. 20, the method is configured as follows:

[0200] In step S21, an electronic communication link is established between the VCM controller 50 of each second VCM 150 and the vehicle controller 115 onboard the host vehicle 100. In some embodiments, the communication link is established before the VCM 150 to be replaced / serviced is installed in the host vehicle 100.

[0201] In step S22, information about the second VCM 150 is transferred from each VCM controller 50 of the second VCM 150 to the vehicle controller 115. In some embodiments, the transferred information includes the results of verification of multiple subsystems by the VCM controller 50. In some embodiments, operation of the host vehicle 100 after the replaced / serviced VCM 150 is installed is conditioned on receiving a positive verification process result from the VCM controller 50.

[0202] Reference is now made to FIG. 21 , which is a schematic diagram of a test rig 10 including a support element 15 for a removed VCM 150. The support element 15 can be designed to support some or all of the weight of the VCM, some or all of the weight of the subframe 161, some or all of the VCM subsystems 200, 180, 176, 240, or components thereof. In some embodiments, multiple support elements 15 are present, for example, to support different components or subsystems. In some examples, the test rig 10 can include a fixed installation where the removed (or possibly installed) VCM 150 is tested, while in other examples, the test rig 10 can include a storage container for storing and / or transporting the VCM 150. The test rig can include test sensors 14, a diagnostic device 12, and a test computer 13. One example of a diagnostic device 12 in a fixed installation test rig is a chassis dynamometer. In embodiments, the VCM controller 50 transmits to the vehicle controller 115 the results of self-diagnostic tests performed using the test apparatus 10 before or during installation of the VCM 150 on the vehicle 100. In another example, such tests can be performed without the test apparatus 10, for example, if the VCM is stored in a facility or container that does not have some or all of the above-mentioned components of the test apparatus 10. In another example, the VCM controller 50 transmits the results of self-diagnostic tests performed using the test apparatus 10 after receiving them from the test apparatus 10. In some embodiments, the vehicle controller 115 can receive the results of the VCM 150 self-diagnostic tests directly from the test apparatus 10 on which the tests were performed.

[0203] Further discussion of the inventive concept

[0204] Inventive concept 1: A vehicle corner module (VCM) system comprising a subframe that is an interface between the VCM and the vehicle platform, a wheel interface for coupling the wheels to the VCM, one or more VCM modules including mechanical assemblies and electrical units for steering the wheels when assembled to a vehicle, and one or more electrical interfaces for exchanging signals and data between the VCM modules and the vehicle platform.

[0205] Inventive concept 2: A vehicle corner module (VCM) system as described in inventive concept 1, comprising one or more sensors for measuring operational data of one or more VCM modules, and a VCM controller electrically connected to one or more electrical interfaces and one or more electrical units of the VCM modules.

[0206] Inventive Concept 3: A vehicle corner module (VCM) system according to any one of Inventive Concepts 1 or 2, wherein the VCM module comprises one or more of a suspension module, a wheel drive module, a steering module and a control module, and the wheel drive module comprises one or more of an electric motor unit, a transmission unit and a brake unit.

[0207] Inventive concept 4: A VCM system according to any one of inventive concepts 1 to 3, wherein the one or more VCM modules are disposed between the wheel interface and the subframe.

[0208] Inventive Concept 5: A VCM system according to any one of Inventive Concepts 1 to 4, wherein one or more electrical units comprise a VCM module controller, the VCM module controller comprising an integrated circuit having hardware and software for controlling two or more VCM modules.

[0209] Inventive concept 6: A vehicle having one or more VCMs according to inventive concepts 1-5.

[0210] Inventive concept 7: A vehicle as described in inventive concept 6, comprising a VCM control unit (CSCU) and a platform VCM bus for communication between the vehicle and one or more electrical circuits located in the VCM.

[0211] Inventive concept 8: The vehicle of inventive concept 7, wherein the VCMs are in direct electrical communication to allow data to be exchanged between the VCMs, bypassing the CSCU.

[0212] Inventive concept 9: A method for operating a VCM, comprising the steps of mounting the VCM on a vehicle platform, setting a VCM operating profile, and activating the VCM to operate with the VCM operating profile.

[0213] Inventive concept 10: A method according to inventive concept 9, comprising a step of matching between the vehicle platform and a motion profile of the VCM, and setting the motion profile of the VCM is to match the VCM with the motion profile.

[0214] Inventive concept 11: A method according to any one of inventive concepts 9 or 10, comprising the steps of: matching between an operational profile of the VCM and an operational profile of another VCM coupled to the vehicle platform; and setting the operational profile of the one or more VCMs coupled to the vehicle platform according to the matching between the operational profiles of the one or more VCMs.

[0215] Inventive concept 12: A method according to any one of inventive concepts 9 to 11, comprising the steps of receiving an operating plan defined for the VCM and setting a VCM operating profile according to the operating plan.

[0216] Inventive concept 13: A method according to any one of inventive concepts 9 to 12, comprising recording operational data of the VCM and outputting the operational data to a computing system external to the VCM.

[0217] Inventive concept 14: A method for servicing a vehicle having one or more vehicle corner modules (VCMs), comprising the steps of receiving an indication that a system located in the VCM requires maintenance, stopping operation of the vehicle, disconnecting the VCM from the vehicle, installing a replacement VCM on the vehicle, and resuming operation of the vehicle.

[0218] The present invention has been described using detailed descriptions of embodiments thereof, which are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the invention utilize only some of the features or possible combinations of the features. Variations of the described embodiments of the invention and embodiments of the invention comprising different combinations of the features noted in the described embodiments will occur to those skilled in the art to which the invention pertains.

[0219] In the description and claims herein, the verbs "comprise," "include," and "have," as well as their conjugations, are used to indicate that the object or object of the verb is not necessarily an exhaustive list of members, components, elements, or parts of the subject or object of the verb. As used herein, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. For example, the terms "marking" or "at least one marking" can include a plurality of markings.

[0220] CROSS-REFERENCE TO RELATED APPLICATIONS

[0221] This application claims priority to U.S. Provisional Patent Application No. 62 / 956,358, filed January 2, 2020, the entirety of which is incorporated herein by reference.

Claims

1. 1. An apparatus for use in offline testing of a vehicle corner module (VCM) when the VCM is mechanically disconnected from a vehicle, comprising: The VCM is a subframe mountable to a reference frame of the vehicle; a wheel hub assembly; a VCM controller mounted on the VCM; a plurality of subsystems mounted on the VCM and interposed between the subframe and the wheel hub assembly, the subsystems being selected from the group consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem; The device comprises: (a) a support element that at least partially supports the weight of the subframe and limits movement of the subframe; (b) at least one diagnostic device that measures operational data of at least one of the plurality of subsystems; (c) a computing device in communication with the VCM controller and configured to receive diagnostic information related to the offline test from the VCM controller; the offline testing includes a functional test of at least one of the plurality of subsystems; Device.

2. The computing device (i) receiving diagnostic information related to said test from at least one diagnostic device; (ii) configured to combine diagnostic information received from the at least one diagnostic device with diagnostic information received from the VCM controller; 10. The apparatus of claim 1.

3. the device is configured to emulate a complete connection of a VCM to an operating vehicle; said emulating including injecting a test signal into the VCM under test; 10. The apparatus of claim 1.

4. the functional testing of at least one of the plurality of subsystems includes testing two or more subsystems in an operational scenario that includes combined operation of the subsystems.

10. The apparatus of claim 1.

5. A containment unit for a vehicle corner module (VCM), The VCM comprises: a mountable subframe; a wheel hub assembly; a VCM controller; a plurality of subsystems mounted on the VCM and interposed between the subframe and the wheel hub assembly, the subsystems being selected from the group consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem; The storage unit comprises: (a) one or more mechanical mounts adapted to support the weight of the VCM within the containment unit; (b) a storage unit controller programmed to perform health tests on the VCMs stored in the storage unit; (c) one or more sensors each selected from a vibration sensor, a mechanical load sensor, and a mechanical moment sensor; (d) a local interface device configured to provide test results and / or enable control of test parameters of the VCM; Including, Storage unit.

6. the operational status test is performed by activating one or more subsystems of the VCM; The storage unit of claim 5 .

7. the one or more mechanical mounts are configurable to accommodate different types of VCMs; The storage unit of claim 5 .

8. It is sized and shaped to accommodate multiple VCMs simultaneously; The storage unit of claim 5 .

9. a vehicle corner module (VCM) for coordinating the operation of a host vehicle, the vehicle includes an on-board vehicle controller; The VCM is (a) a subframe attachable to a reference frame of the host vehicle; (b) a wheel hub assembly having a wheel hub; (c) a plurality of subsystems interposed between the subframe and the wheel hub assembly, the subsystems being selected from the group of subsystems consisting of a drive subsystem, a steering subsystem, a suspension subsystem, and a braking subsystem; (d) a VCM controller for mounting on a VCM, the VCM controller having one or more processors and a computer-readable medium storing program instructions that, when executed by the one or more processors, cause the one or more processors to perform the steps of establishing a communications link with the vehicle controller, the establishing including electrically transferring information relating to the VCM from the VCM controller to the vehicle controller; Equipped with The information about the VCM includes the results of a self-diagnostic test performed before installation. Vehicle Corner Module (VCM).

10. 10. An apparatus for performing self-diagnostic testing of a VCM when the VCM is mechanically disconnected from any vehicle as recited in claim 9, comprising: (a) a support element for at least partially supporting the weight of the subframe and limiting movement of the subframe; (b) at least one diagnostic device that measures operational data of at least one of the plurality of subsystems; (c) a computing device configured to communicate with the VCM controller and receive diagnostic information related to the self-diagnostic test of the VCM when the VCM is mechanically disconnected from any vehicle; the self-diagnostic test includes a functional test of at least one of the plurality of subsystems; Device.

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