Electric Machine Predictive Torque Control for Fast Working Point Shifts

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Solution Overview

Problem

Existing field-oriented control methods for electric machines are inefficient in setting desired working points quickly, particularly in emergency situations like emergency braking or maximum acceleration, leading to suboptimal performance and longer braking distances.

Innovation Solution

Implementing a predicted pilot control action based on the current actual working point, using a model predictive controller to determine a time-optimized trajectory for setting the desired working point, which can be stored offline for faster implementation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If field-oriented control is used to set the desired working point, then the control method is simple and reliable, but the response time is slow and the setting process is not time-optimized

Engineering Contradiction:
Improveresponse time for setting working pointVSAvoidcontrol system complexity
Core Design Contradiction:
Loss of timeVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-calculating and storing optimal control sequences (pilot control actions) for various desired working points in a lookup table during system initialization. When a working point change is required, the controller retrieves the pre-computed control sequence corresponding to the target working point and executes it directly, eliminating the need for real-time iterative optimization. This significantly reduces the response time for setting desired working points while maintaining controlled complexity through the use of pre-computed solutions.

Inventive Principle:
Principle #10Preliminary action

2Productivity

If predictive control sequences are pre-calculated and stored for rapid retrieval, then the response speed increases significantly, but the computational load during runtime increases

Engineering Contradiction:
Improvespeed of setting working pointVSAvoidcomputational energy consumption
Core Design Contradiction:
ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent performs the computationally intensive predictive control calculations during system initialization or offline phases, storing the results in lookup tables. During runtime, when a working point change is needed, the controller simply retrieves the pre-computed control sequence from memory based on the desired working point, which requires minimal computational resources. This shifts the computational burden from runtime to initialization, achieving high productivity during operation with low energy consumption.

Inventive Principle:
Principle #10Preliminary action

3Measurement precision

If the control sequence is predicted based on current actual working point, then the accuracy of reaching desired working point improves, but the computational complexity increases

Engineering Contradiction:
Improveaccuracy of working point settingVSAvoidcomputational complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses the current actual working point as input to retrieve the appropriate pre-computed control sequence from lookup tables that were generated based on predictive control algorithms. This approach maintains high accuracy because the control sequences were pre-calculated using accurate predictive models, while avoiding the computational complexity of real-time predictive calculations. The system achieves precision by matching the current state to pre-analyzed scenarios stored in memory.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS12592658B2Method for operating an electric machine, device for operating an electric machine, and electric drive system
Publication Date: 2026.03.31 ROBERT BOSCH GMBH
  • US12592658B2 patent drawing
  • US12592658B2 patent drawing
  • US12592658B2 patent drawing

AI summary

The invention relates to a method for operating an electric machine (2), in particular in a motor vehicle, the machine (2) comprising a rotatably mounted rotor and a motor winding that is electrically connected to an electrical energy store (4) by means of a power electronics (3). In said method, by triggering the power electronics (3), the electric machine (2) is controlled in a field-oriented manner in such a way that the machine (2) generates a specified desired torque (Ttarget). According to the invention, when it is ascertained that based on a current actual working point (AP1) of the electric machine (2) a specified desired working point (AP2) of the electric machine (2) should be set at least substantially in a time-optimized manner, a predicted pilot control action is specified, and that the desired working point (AP2) is set by triggering the power electronics (3) according to the predicted pilot control action.