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

VSEngineering 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

Engineering Contradiction:
Improvetorque differenceVSAvoidrotational interference
Core Design Contradiction:
ForceVSReliability

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.

Inventive Principle:
Principle #1Segmentation

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

Engineering Contradiction:
Improvecontrol configurationVSAvoidtorque control precision
Core Design Contradiction:
Device complexityVSMeasurement precision

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.

Inventive Principle:
Principle #1Segmentation

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

Engineering Contradiction:
Improvetorque difference magnitudeVSAvoidtorque difference application
Core Design Contradiction:
ForceVSManufacturing precision

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.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS20240286492A1Control system for vehicle
Publication Date: 2024.08.29 MITSUBISHI MOTORS CORP
  • US20240286492A1 patent drawing
  • US20240286492A1 patent drawing
  • US20240286492A1 patent drawing

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).