EV Torque Control on Dangerous Roads to Protect Drivetrains
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Solution Overview
Problem
Electric vehicles (EVs) are prone to damage their driving systems when driven on dangerous roads due to rapid torque changes and increased inertia, which existing traction control systems and electronic stability controllers fail to adequately address, leading to potential hardware failure.
Innovation Solution
A vehicle control system using sensors to detect road conditions and vehicle states, determining the risk of system failure, and controlling torque to prevent damage by reducing or increasing torque at controlled rates to manage load on the driving system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If EV uses fixed gear ratio speed-reducer and direct motor-wheel connection without transmission, clutch or torque converter, then the structure is simplified and efficiency is improved, but the driving system becomes more vulnerable to damage on dangerous roads due to rapid torque changes and increased inertia
Solution Approach 1:
The control system performs preliminary detection of dangerous road conditions using sensors (accelerometers, gyroscopes, wheel speed sensors) and proactively restricts motor torque before damage can occur. When wheel lift-off is detected through sensor data analysis, the system preemptively reduces torque output to prevent bearing fatigue and component failure, rather than reacting after damage has begun
Solution Approach 2:
The control system acts as an intermediary between the motor and the driving system components. By inserting software-based torque restriction logic in the control unit, the system mediates the torque transmission, preventing direct transmission of harmful torque fluctuations to the speed-reducer, motor shaft, and bearings, thus protecting these components without adding mechanical intermediaries
2Power
If EV has larger driving battery to provide more power, then the power output is improved, but the inertia increases making the vehicle more susceptible to damage on bumpy roads
Solution Approach 1:
The control system dynamically changes the torque parameter based on detected road conditions. When dangerous conditions are detected (wheel lift-off, rapid vertical acceleration), the system adjusts the torque parameter from full power output to a restricted level, effectively decoupling the high power capability from actual power delivery to protect the driving system while maintaining the capability when needed
3Reliability
If TCS and ESC logic are used to reduce motor torque, then some torque control is achieved, but the operation time is late and torque restriction is insufficient to adequately protect the driving system on dangerous roads
Solution Approach 1:
The system continuously monitors sensor data (accelerometers, gyroscopes, wheel speed sensors) in real-time to detect dangerous road conditions before they cause damage. When wheel lift-off or rapid vertical acceleration is detected, the system immediately activates torque restriction, achieving faster response than conventional TCS/ESC systems that only react after loss of traction or instability occurs
Solution Approach 2:
The control system implements a feedback mechanism where sensor data from accelerometers, gyroscopes, and wheel speed sensors continuously feeds back to the control unit. This feedback loop enables real-time detection of dangerous conditions and immediate adjustment of motor torque, creating a closed-loop control system that responds dynamically to road conditions rather than relying on open-loop timing
Data Source
AI summary
A system of controlling a vehicle may include a sensor and a controller, in which the sensor may be configured to sense vehicle operation state information, and the controller may be configured to determine whether a vehicle is running on a dangerous road based on the sensed vehicle operation state information, determine whether there is a possibility that a vehicle driving state will cause a failure of a driving system based on the sensed vehicle operation state information in response to determining that the vehicle is running on the dangerous road, and decide that torque control of the vehicle.