Dual-Motor Differential Torque Control With Split ECUs
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Solution Overview
Problem
The existing differential mechanism in electric vehicles interferes with rotational torques, causing vibrations and making it difficult to apply precise torque differences to the wheels, especially when all sensor signals are input into a single ECU, which limits precise control.
Innovation Solution
A control system with two control units connected via high-speed communication, each controlling one electric motor, and a superordinate control unit calculating demanded torques based on vehicle information, using rotation speed sensors to achieve precise torque compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a differential mechanism mechanically connects two electric motors to left and right wheels, then a torque difference can be applied to the wheels, but rotational interference occurs causing vibrations and making it difficult to apply precise torque differences
Solution Approach 1:
The patent divides the control system into two independent control units, with each control unit controlling one electric motor. Each control unit receives sensor signals and calculates assigned torques independently, avoiding the rotational interference that occurs when a single control unit manages both motors through a mechanical differential mechanism. This segmentation of control functions eliminates the vibration and torque application problems while maintaining the ability to apply torque differences to the wheels.
2Device complexity
If all sensor signals are input into a single ECU, then the control configuration is simplified, but precise control is difficult to achieve due to rotational interference
Solution Approach 1:
The patent segments the control configuration into two independent control units, each receiving sensor signals and calculating assigned torques independently. This segmentation maintains relatively simple control configurations at each unit while achieving precise torque control by avoiding the rotational interference that plagues single-ECU differential mechanisms. Each control unit operates independently to ensure precise torque application to its respective motor.
3Force
If a differential mechanism with amplifying function is used, then a large torque difference can be generated, but rotational interference makes it impossible to apply the demanded torque difference
Solution Approach 1:
The patent eliminates the need for a differential mechanism with amplifying function by segmenting the control into two independent control units. Each control unit independently controls one motor and applies the required torque directly, achieving large torque differences without the rotational interference and precision problems associated with mechanical differential mechanisms. This approach maintains the ability to generate large torque differences while ensuring precise torque application.
Data Source
AI summary
A control system for a vehicle (1) provided with a differential mechanism (3) that applies a torque difference to left and right wheels (5) and two electric motors (2) coupled to the differential mechanism (3), the control system including: two control units (11, 12) being connected to each other via high-speed communication means and each controlling one of the two electric motors (2); a first rotation speed sensor (26R) that detects a first rotation speed of a first electric motor (2R) of the two electric motors (2) and outputs the first rotation speed to the two control units (11, 12); a second rotation speed sensor (26L) that detects a second rotation speed of a second electric motor (2L) of the two electric motors (2) and outputs the second rotation speed to the two control units (11, 12); and a superordinate control unit (10) that calculates demanded torques of the two electric motors (2) based on vehicle information of the vehicle (1). At least a first control unit of the two control unites (11, 12) calculates two assigned torques to achieve the demanded torques calculated in the superordinate control unit (10) based on detection signals of the two rotation speed sensors (26R, 26L).


