Clutch Control Overcurrent Protection via Level-Based Inverter Duty
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Solution Overview
Problem
The existing clutch control systems in iMT systems lack effective overcurrent protection, leading to potential damage to both motor and controller, affecting safety and performance, as they do not differentiate between damage indices for motor and controller, resulting in system overload during high-speed travel and impaired gear shifting.
Innovation Solution
An apparatus and method that divide overcurrent into predetermined levels, using a microcomputer to detect and diagnose overcurrents, measure duration, and control the inverter by limiting pulse width modulation signal duty based on set thresholds and times, distinguishing between motor and controller damage indices to ensure safety and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If maximum current is used for high-performance clutch control, then clutch response speed and gear shifting performance are improved, but motor and controller damage risk increases
Solution Approach 1:
The overcurrent protection is segmented into multiple levels (first level, second level, third level) with different threshold values and duration limits. Each level corresponds to different damage risk zones for the motor and controller, allowing differentiated protection strategies for different current magnitudes and durations
Solution Approach 2:
The system changes protection parameters (current thresholds, duration limits, duty cycle limits) based on the detected overcurrent level. When overcurrent is detected at different levels, the system applies different duty cycle limitations (first limit duty, second limit duty, third limit duty) to balance performance and protection
2Reliability
If overcurrent protection is implemented with single threshold, then controller safety is improved, but system performance and productivity deteriorate
Solution Approach 1:
The protection system dynamically adjusts the duty cycle limits based on the detected overcurrent level and duration. Instead of a fixed single threshold, the system transitions between different protection states (first limit duty, second limit duty, third limit duty) depending on the severity and persistence of the overcurrent condition
Solution Approach 2:
The system pre-sets multiple overcurrent thresholds and corresponding duration limits for different protection levels. When an overcurrent condition is detected, the system immediately applies the appropriate pre-defined protection strategy based on which threshold level is exceeded, enabling rapid response without complex real-time calculations
3Device complexity
If overcurrent diagnosis is performed without level differentiation, then device complexity is reduced, but measurement precision and diagnostic accuracy worsen
Solution Approach 1:
The overcurrent diagnosis is segmented into multiple levels with distinct threshold values and duration criteria. The microcomputer compares the detected current against multiple pre-set thresholds and tracks duration for each level, enabling precise identification of which damage risk zone the current condition falls into
Solution Approach 2:
The system replaces complex hardware protection circuits with software-based overcurrent diagnosis and protection logic implemented in the microcomputer. The microcomputer performs current detection, level comparison, duration measurement, and duty cycle control through programmed algorithms, reducing hardware complexity while improving diagnostic precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach guarantees the safety and maximum performance of the clutch control system by accurately diagnosing and managing overcurrents, preventing damage and ensuring continuous operation during high-speed travel and gear shifting.
Implementation Method 1
an inverter including a plurality of switching elements and configured to convert DC power into AC power by ON/OFF of the plurality of switching elements and to provide the AC power to the motor
Implementation Method 2
a motor control unit configured to detect a current provided to the motor
Data Source
AI summary
Provided is an apparatus and method for protecting an overcurrent of a clutch control system including a motor, an inverter including a plurality of switching elements and configured to convert DC power into AC power by ON/OFF of the plurality of switching elements and to provide the AC power to the motor; a motor control unit configured to detect a current provided to the motor; and a microcomputer having an overcurrent threshold for overcurrent detection set for each of a predetermined number of levels, and configured to compare the detected current with the overcurrent threshold for each level, to diagnose whether there is a level corresponding to an overcurrent, to measure an overcurrent duration when there is a level corresponding to the overcurrent, and to control the inverter based on the overcurrent duration.