Dual Inverter Fault Control With Equalized Axle Torque
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Solution Overview
Problem
Conventional electric vehicles with two electric motors per drive unit, each controlled by a separate inverter controller, incur increased weight and energy consumption, reducing vehicle range.
Innovation Solution
Implement a dual power inverter module with a common controller to manage both inverters, applying a same fault action to ensure equalized torque across axles, and utilize a shared DC link capacitor to reduce weight and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate inverter controllers are used for each inverter, then control reliability is improved, but weight and energy consumption increase
Solution Approach 1:
The patent combines two separate inverter controllers into a single common controller that manages both inverters. This integration reduces the total weight of control systems while maintaining reliable control through a unified architecture that can coordinate both inverters and apply fault actions consistently.
Solution Approach 2:
The common controller is designed to perform multiple functions: controlling the first inverter, controlling the second inverter, monitoring faults in either inverter, and applying fault actions to both inverters. This multi-functional design eliminates the need for separate dedicated controllers for each inverter.
2Measurement precision
If separate inverter controllers are used for each inverter, then control precision is improved, but energy consumption increases
Solution Approach 1:
By merging control functions into a single common controller, the patent reduces the total energy consumption associated with multiple independent control systems. The unified controller can optimize energy usage through coordinated control of both inverters and shared fault response mechanisms.
Solution Approach 2:
The common controller implements feedback mechanisms to monitor the operational status of both inverters and apply appropriate fault actions. This feedback-based control maintains precision while optimizing energy consumption through intelligent decision-making rather than independent continuous operation of separate controllers.
3Weight of moving object
If a common controller manages both inverters, then weight and energy consumption are reduced, but fault response complexity increases
Solution Approach 1:
The patent segments the fault response mechanism into distinct fault actions that can be independently defined and applied to either or both inverters. This segmentation allows the common controller to manage complexity by treating fault responses as modular, reusable components rather than monolithic control logic.
Solution Approach 2:
The system allows dynamic parameter changes in fault actions, enabling the common controller to adapt fault responses based on the specific inverter affected and the nature of the fault. This parameter-based approach simplifies the control architecture by using configurable parameters rather than hard-coded complex logic.
4Stability of the object's composition
If equalized torque is applied to both axles during fault, then vehicle stability is improved, but torque delivery capability is reduced
Solution Approach 1:
The patent implements dynamic torque management where the common controller can adjust torque distribution between axles based on operational conditions and fault status. During faults, equalized torque provides stability, but the system can dynamically revert to differential torque distribution when conditions permit, optimizing both stability and power delivery as needed.
Solution Approach 2:
The system prepares for potential torque delivery reduction by implementing fault detection and response mechanisms in advance. When faults are detected, the common controller proactively applies equalized torque to prevent instability, cushioning against the negative effects of reduced torque delivery capability through anticipatory control actions.
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
The solution reduces weight and energy consumption by integrating inverters with a common controller, enhancing vehicle range and efficiency by minimizing stress on the DC link capacitor and reducing ripple currents.
Implementation Method 1
A DC link capacitor is electrically connectable to a source of high voltage direct current (DC) electrical power
Implementation Method 2
configured to convert high voltage DC electrical power to three phase high voltage alternating current (AC) electrical power
Data Source
AI summary
Various disclosed embodiments include illustrative controllers, dual power inverter modules, and electric vehicles. In an illustrative embodiment, a controller includes one or more processors associated with a first and second power inverter for the drive unit. Computer-readable media for the one or more processors are each configured to store computer-executable instructions configured to cause the one or more processors to apply a same fault action to the first power inverter and the second power inverter responsive to a fault associated with an inverter chosen from the first power inverter and the second power inverter, wherein the same fault action includes applying equalized torque to each axle operatively coupled to the drive unit.