EV Traction Power Derating for Battery Fault Get-Home Control

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Solution Overview

Problem

Plug-in electric vehicles face significant battery charge depletion issues due to limited charging infrastructure, leading to potential stranding far from home bases.

Innovation Solution

The implementation of a system that derates vehicle traction control in response to detected system faults, reducing battery depletion rates and enhancing the vehicle's get-home capability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the vehicle operates in normal mode with full traction power, then the vehicle performance and speed are improved, but the battery charge depletes faster

Engineering Contradiction:

Improvevehicle speedVSAvoidbattery charge depletion rate

Core Design Contradiction:

SpeedVSUse of energy by moving object

Solution Approach 1:

The controller dynamically switches between normal mode and derate mode based on detected system faults. When a fault is detected, the system transitions from full power operation to reduced power operation, adjusting the power control signals to maintain a safe operating state while preserving minimum get-home capability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the power output parameter by producing derated traction power control signals when faults are detected. This reduces the power delivered to the traction motor from its normal maximum level to a derated level that conserves battery charge while maintaining essential vehicle functionality.

Inventive Principle:

Principle #35Parameter changes

2Use of energy by moving object

If the vehicle operates in derate mode to conserve battery power, then the battery charge depletion rate is reduced, but the vehicle performance and speed are limited

Engineering Contradiction:

Improvebattery charge depletion rateVSAvoidvehicle speed

Core Design Contradiction:

Use of energy by moving objectVSSpeed

Solution Approach 1:

The derate mode provides partial action by delivering reduced power control signals to the traction motor rather than full power. This partial power delivery is sufficient to maintain basic vehicle operation and enable get-home capability while conserving battery charge, accepting reduced performance as a necessary trade-off during fault conditions.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If the vehicle continues operation after system faults, then the get-home capability is maintained, but the risk of complete battery depletion increases

Engineering Contradiction:

Improveget-home capabilityVSAvoidbattery charge limitation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The derate mode acts as a cushioning mechanism that reduces power consumption beforehand to prevent complete battery depletion. By operating at reduced power levels when faults are detected, the system creates an energy buffer that extends the vehicle's operational range, ensuring sufficient charge remains to reach home or a safe location.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12233851B2Plug-in electric vehicles with derated traction control upon system faults

Publication Date: 2025.02.25 CUMMINS INC

AI summary

A method for controlling the distribution of power to a traction motor in a plug-in electric vehicle having a plurality of on-board sources of electric power. Power is distributed at a normal power control relationship in response to an operator control input during operation in a normal mode. Power is depleted at a first rate during operation of the vehicle in the normal mode. Power is distributed at a derate power control relationship in response to the operator control input during operation in a derate mode. Power is depleted at a second rate that is less than the first rate during operation in the derate mode to conserve the power of the one or more on-board sources. Operation in the derate mode can be initiated in response to information from sensors identifying a vehicle condition indicating a battery charge limitation.