Electric Machine Control Strategy for Controller Reset Recovery
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Solution Overview
Problem
Electric vehicles experience intermittent microprocessor resets leading to communication failures between controllers, which can cause inoperability of the electric machine during vehicle operation, resulting in significant customer dissatisfaction.
Innovation Solution
A vehicle powertrain control system with a first controller configured to store and provide calibration values to a second controller upon reset, ensuring minimal inoperability of the electric machine by using pre-calculated current commands based on torque commands, thereby maintaining vehicle operation during resets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a controller reset occurs during vehicle operation, then the controller can recover from internal errors, but the electric machine becomes inoperable for an extended period due to communication loss and recalibration requirements
Solution Approach 1:
The patent applies preliminary action by having the first controller store calibration values before a reset occurs. When a reset happens, these pre-stored values are immediately provided to the second controller, eliminating the need for time-consuming recalibration and keeping the electric machine operational with minimal interruption.
Solution Approach 2:
The first controller acts as an intermediary that bridges the communication gap during a reset event. It stores and transmits calibration values to the second controller, maintaining the control chain and preventing complete system failure during the reset period.
2Reliability
If standard controller reset procedures are followed, then the controller can recover from errors, but vehicle operation is significantly disrupted due to loss of communication and recalibration requirements
Solution Approach 1:
The first controller performs preliminary action by pre-storing calibration values before a reset occurs. This allows the second controller to immediately resume operation with pre-calibrated values, maintaining vehicle operation continuity while still allowing the reset to occur for error recovery.
Solution Approach 2:
The system implements feedback by monitoring controller health status and detecting when a reset occurs. Based on this feedback, the first controller automatically provides stored calibration values to the second controller, enabling seamless recovery without disrupting vehicle operation.
3Measurement precision
If recalibration is performed after a controller reset, then the controller can return to optimal operation, but the process takes more than one second causing electric machine inoperability
Solution Approach 1:
The patent applies preliminary action by having calibration values pre-calculated and stored in the first controller before a reset occurs. When a reset happens, these pre-stored values are immediately provided to the second controller, eliminating the need for time-consuming recalibration while maintaining calibration accuracy.
Solution Approach 2:
The system uses copying by having the first controller store copies of calibration values that can be immediately transferred to the second controller during a reset. This copying mechanism allows the second controller to resume operation with accurate calibration data without performing time-consuming recalibration procedures.
Data Source
AI summary
A vehicle is provided including an electric machine and at least one controller. The controller, or controllers, are configured to, in response to a reset of the at least one controller while a speed of the vehicle is greater than a threshold value, provide a current command to the electric machine in accordance with calibration values calculated prior to the reset such that inoperability of the electric machine due to the reset is less than one second.