Multi-Core EV Supervisory Control for Sub-2-Second Start-Up

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Solution Overview

Problem

Conventional electrified vehicles take longer than internal combustion engine vehicles to achieve propulsion system readiness due to delays in enabling electrified powertrain electronic control units, cybersecurity, and functional safety testing, necessitating a solution to expedite start-up without increasing cost and complexity.

Innovation Solution

A control system utilizing a hybrid control processor (HCP) and an auxiliary hybrid control processor (AHCP) connected via a hardwire wakeup line, performing parallel processing to expedite the start-up procedure, including shutoff path testing and communication with ePT ECUs via CAN buses, achieving a complete start-up in under two seconds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If conventional electrified vehicle start-up procedures are used with sequential ECU enablement, then functional safety and cybersecurity requirements are met, but start-up time exceeds customer acceptance threshold

Engineering Contradiction:

Improvestart-up speedVSAvoidstart-up time

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

The system performs preliminary actions by pre-enabling the auxiliary HCP and establishing hardwired wakeup lines before the actual start-up request occurs. When the driver door opens or start button is pressed, the auxiliary HCP is already ready to immediately wake up all ePT ECUs via CAN bus, eliminating sequential enablement delays. This preliminary preparation allows the system to meet the sub-2-second start-up target while maintaining all safety and security protocols.

Inventive Principle:

Principle #10Preliminary action

2Speed

If hardwired wakeup lines are added to all ePT ECUs to reduce start-up time, then start-up speed improves, but system complexity and cost increase

Engineering Contradiction:

Improvestart-up speedVSAvoidsystem complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The auxiliary HCP serves as an intermediary device that coordinates the wake-up process. Instead of requiring hardwired wakeup lines to every single ePT ECU, the auxiliary HCP receives a single wakeup signal from the main HCP and then systematically wakes up all ePT ECUs through controlled CAN bus communication. This intermediary approach reduces wiring complexity while achieving rapid start-up.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The control system is segmented into a main HCP and an auxiliary HCP with distinct roles. The main HCP handles high-level control and decision-making, while the auxiliary HCP manages the specific task of waking up ePT ECUs. This segmentation allows the wakeup functionality to be isolated and optimized without complicating the entire system architecture.

Inventive Principle:

Principle #1Segmentation

3Reliability

If sequential enablement of ePT ECUs is performed to ensure functional safety, then safety requirements are met, but start-up duration increases beyond acceptable limits

Engineering Contradiction:

Improvefunctional safetyVSAvoidstart-up duration

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The system maintains continuous useful action by keeping the auxiliary HCP in a low-power ready state with continuous monitoring capability. This allows the auxiliary HCP to immediately respond to wakeup requests without full sequential initialization, enabling parallel activation of ePT ECUs while maintaining functional safety through continuous safety monitoring and verification protocols.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS12454185B2Techniques for expediting electrified vehicle propulsion functionalities using a multi-core supervisory controller

Publication Date: 2025.10.28 FCA US LLC

AI summary

An expedited start-up procedure of an electrified vehicle involves a hybrid control processor (HCP) connected to a controller area network (CAN) having electrified powertrain (ePT) modules and an auxiliary HCP (AHCP) connected to the CAN and connected to the HCP via a hardwire wakeup line. In response to a start-up request, the HCP initializes the start-up procedure in which it sends a wakeup signal to the AHCP via the hardwire wakeup line, performs shutoff path testing via a first CAN bus, and confirms enabled ePT modules communication via a second CAN bus to complete the start-up procedure. In response to the wakeup signal from the HCP, the AHCP initializes and then participates in the start-up procedure in which it wakes up and enables communication by the plurality of ePT modules via the second CAN bus. A duration of the start-up procedure is less than a customer annoyance threshold.