Engine Controller Drive Torque Data Rainflow Analysis
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Solution Overview
Problem
Traditional powertrain and driveline system testing relies on subjective customer data and historical data that lacks context, leading to inaccurate design targets and inefficient development processes due to the variability and unreliability of proving ground data.
Innovation Solution
Implementing an engine controller in vehicles to collect and store drive torque data in real-time using a processor and memory, converting it into non-time domain formats like histograms and rainflow cycle counts, which can be downloaded and analyzed at a central data collection center for improved data accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If real-time drive torque data is collected and processed in the engine controller, then data accuracy and objectivity are improved, but device complexity and memory requirements increase
Solution Approach 1:
The patent extracts only the essential fatigue analysis features from raw torque data by implementing rainflow cycle counting algorithms directly in the engine controller. This converts continuous torque-time signals into discrete cycle count matrices that capture the critical fatigue information while eliminating redundant data, thereby improving measurement precision without proportionally increasing device complexity
Solution Approach 2:
The engine controller performs preliminary data processing and transformation of raw torque data into rainflow cycle counts and histograms before data leaves the vehicle. This preliminary action reduces the complexity of downstream analysis systems and ensures data accuracy is established at the source, preventing error propagation through the entire data chain
2Productivity
If drive torque data is stored in non-time domain formats like rainflow cycle counts, then data processing efficiency is improved, but loss of information occurs due to data transformation
Solution Approach 1:
The patent changes the parameter representation of torque data from time-domain continuous signals to frequency-domain cycle count distributions. By transforming the data into rainflow cycle counts organized in matrices and histograms, the system achieves more efficient processing for fatigue analysis while preserving the essential cyclic characteristics that drive component degradation
Solution Approach 2:
The patent transitions torque data from a one-dimensional time series to a two-dimensional rainflow cycle count matrix that organizes data by torque magnitude and cycle frequency. This dimensional transformation enables more efficient statistical analysis and pattern recognition while maintaining the critical fatigue-relevant information through the structured matrix representation
3Reliability
If historical data and proving ground data are used for durability testing, then testing cost is reduced, but reliability and accuracy of design targets deteriorate due to subjective and contextual-limited data
Solution Approach 1:
The patent implements a feedback mechanism where real-time drive torque data from actual customer vehicles continuously informs and updates durability testing parameters and simulation models. This closed-loop feedback ensures that design targets are based on objective, real-world usage patterns rather than subjective proving ground schedules, significantly improving data reliability for predicting component fatigue life
Solution Approach 2:
The patent creates a virtual copy of actual customer usage patterns by collecting and analyzing drive torque data from multiple field vehicles. This digital replica of real-world operating conditions provides a more accurate and reliable basis for durability testing than physical proving ground tests, enabling virtual validation that reduces both cost and time while improving reliability
Data Source
AI summary
An engine controller, system and method for collecting vehicle data. Drive torque data is determined using the engine controller in the vehicle and is stored in a memory in the vehicle. The drive torque data is stored in a non-time domain format, and may include a histogram of numbers of revolutions at predetermined intervals of drive torque values and/or a matrix of rainflow cycle counts. The drive torque data is temporarily stored in a buffer prior to being stored in the matrix of rainflow cycle counts using back-checking and binning. The drive torque data is downloaded from the vehicle and transmitted to a central data collection center.