Electric Vehicle Powertrain Operating State Management
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Solution Overview
Problem
Existing electrified vehicle powertrains lack an efficient method to manage operating states, leading to potential component failure due to operating beyond hardware limits, without adequate real-time monitoring and adaptive control to ensure safe and optimal performance.
Innovation Solution
A method that identifies and manages distinct operating states by determining allowable, real, and ideal speed ranges, using a controller to command the powertrain to operate within safe limits, preventing component failure and optimizing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the powertrain operates at maximum hardware limits to optimize performance, then power output and speed are improved, but component reliability deteriorates due to operating beyond safe limits
Solution Approach 1:
The patent applies dynamics by implementing adaptive, real-time adjustment of operating limits through multiple hierarchical levels (hardware limits, real limits, ideal limits). The controller dynamically modifies speed and power thresholds based on actual operating conditions such as temperature, load, and component state, allowing the powertrain to operate near maximum capacity when conditions permit while automatically retreating to safer operating ranges when conditions deteriorate, thus resolving the contradiction between maximizing power output and maintaining component reliability
Solution Approach 2:
The patent implements feedback mechanisms by continuously monitoring operating parameters (temperature, speed, load, component status) and using this information to adjust operating limits in real-time. The controller receives feedback from sensors and diagnostic systems, compares actual operating conditions against predefined thresholds, and dynamically modifies the allowable operating range to prevent exceeding hardware limits while maximizing performance within safe boundaries, thereby maintaining both high power output and component reliability
2Productivity
If the powertrain operates beyond hardware limits to maximize performance, then productivity is improved, but the risk of component failure increases
Solution Approach 1:
The patent applies preliminary action by pre-establishing multiple hierarchical operating limit levels (hardware limits, real limits, ideal limits) before operation begins. These pre-defined thresholds create a structured framework that guides the controller in anticipating and preventing harmful operating conditions. By having these limits predetermined and systematically organized, the system can proactively adjust operation to avoid component failure while maximizing performance within safe boundaries
Solution Approach 2:
The patent implements beforehand cushioning by creating buffer zones between actual operating conditions and critical hardware limits through the intermediate real limits and ideal limits. These cushioning layers provide gradual transition zones that prevent sudden exceedance of hardware limits, allowing the system to approach maximum performance while maintaining a safety margin that cushions against unexpected conditions or measurement errors, thereby reducing component failure risk while preserving productivity
3Reliability
If real-time monitoring and adaptive control are implemented to ensure safe operation, then component reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the control system into distinct hierarchical layers (hardware limits layer, real limits layer, ideal limits layer) and separate functional modules (monitoring subsystem, analysis subsystem, control subsystem). Each layer handles specific aspects of limit management, and each module performs a dedicated function. This segmentation allows the complex control task to be distributed across manageable components, reducing overall system complexity while maintaining comprehensive monitoring and adaptive control capabilities for reliable operation
Data Source
AI summary
A method of managing available operating states in an electrified powertrain includes: identifying a plurality of operating states; determining an allowable hardware operating speed range for each of the plurality of operating states; determining a real operating speed range for each of the plurality of operating states; determining an ideal operating speed range for each of the plurality of operating states, the ideal operating speed range being a subset of the allowable real operating speed range; indicating an operating state of the plurality of operating states as ideal-allowed if an actual output speed of the electrified powertrain is within the ideal operating speed range for that operating state; and commanding the electrified powertrain to operate within one of the operating states that is indicated as ideal-allowed.