Electric Drive Sensor Switching for Fault-Tolerant Torque Control

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Solution Overview

Problem

Existing electric drive systems face challenges in effectively managing sensor data sourcing patterns, particularly when sensor health data indicates faulty or unreliable data sources, which can lead to errors in control commands and torque transfer efficiency.

Innovation Solution

An electric drive system with an electronic controller that dynamically switches between different sensor data sourcing patterns based on health data from multiple sensing subsystems, ensuring reliable data sourcing by adjusting which sensors provide speed and direction of rotation data, thereby optimizing control commands and minimizing errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sensor redundancy is implemented to ensure backup data sources, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvesensor data reliabilityVSAvoidsensing subsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system dynamically switches between different sensor data sourcing patterns based on real-time health data. The electronic controller monitors sensor health and adaptively changes which sensors are used for control commands, transforming a static redundant sensor system into a dynamic one that optimizes reliability while managing complexity through intelligent control.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system implements feedback by continuously monitoring sensor health data and using this information to adjust the sensor data sourcing pattern. The electronic controller receives health data from sensors and uses this feedback to determine whether to switch between different sourcing patterns, ensuring reliable operation while managing system complexity through closed-loop control.

Inventive Principle:

Principle #23Feedback

2Reliability

If the system switches between different sensor data sourcing patterns based on health data, then reliability is improved, but control system complexity increases

Engineering Contradiction:

Improvecontrol command reliabilityVSAvoidelectronic controller complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electronic controller performs self-service by autonomously monitoring sensor health data and automatically switching between different sensor data sourcing patterns without external intervention. This self-service capability improves control command reliability while managing controller complexity through integrated health monitoring and adaptive control logic.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system prepares multiple sensor data sourcing patterns in advance and pre-configures the electronic controller with the logic to switch between them. By having alternative sourcing patterns ready beforehand and pre-programming the switching logic, the system improves reliability while minimizing the complexity burden during actual operation.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If multiple sensing subsystems are used to provide backup data sources, then measurement precision is maintained, but loss of information increases due to managing multiple data sources

Engineering Contradiction:

Improvespeed measurement precisionVSAvoidsensor data management overhead

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The system extracts and uses only the necessary sensor data from the available multiple sensing subsystems. The electronic controller selectively sources data from specific sensors based on their health status, extracting only the reliable information needed for control commands while discarding or ignoring data from degraded sensors, thus maintaining precision while reducing information management overhead.

Inventive Principle:

Principle #2Taking out (Extraction)

4Adaptability or versatility

If the system monitors and switches sensor data sourcing patterns, then adaptability is improved, but ease of operation decreases

Engineering Contradiction:

Improvesensor failure adaptationVSAvoidsystem operation simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The electronic controller performs self-service by automatically monitoring sensor health and switching between different data sourcing patterns without requiring operator intervention. This automated self-service approach improves adaptability to sensor failures while maintaining ease of operation, as the system handles the complexity of switching internally without burdening the operator.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11835130B1Electric drive system for machine configured for switching sensor data sourcing pattern based on health status

Publication Date: 2023.12.05 CATERPILLAR INC

AI summary

An electric drive system for a machine includes a transmission, and an electric drive motor coupled to a transmission input. The electric drive system also includes a plurality of sensing subsystems, each monitoring a speed of rotation and a direction of rotation of one of the electric drive motor or the transmission input. An electric drive control system in the electric drive system includes an electronic controller structured to receive health data of the sensing subsystems, and determine a drive system control command, according to a sensor data sourcing pattern that is dependent upon the health data. Related methodology and control logic is also disclosed.