Hybrid Engine Control for Sensor Sync Fault Reset

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Solution Overview

Problem

In hybrid vehicle architectures where the wheels are driven by an electric motor and the internal combustion engine charges the battery, synchronization errors in angular position sensors can lead to the engine being locked in a reduced operating mode, causing the battery to discharge and potentially immobilizing the vehicle due to insufficient charging.

Innovation Solution

Implement a method involving a timer-based synthetic fault status reset command to revert angular position sensor statuses to a fault-free state, independent of engine restart, to prevent the internal combustion engine from being locked in a reduced operating mode and ensure battery charging resumes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the engine is switched to reduced operating mode due to synchronization error detection, then the reliability of the angular position sensor system is improved, but the productivity of battery charging deteriorates

Engineering Contradiction:

Improveangular position sensor fault detectionVSAvoidbattery charging capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs preliminary fault detection by monitoring synchronization errors before they cause complete system failure. The error detection signal is generated in advance when synchronization deviations are detected, allowing the system to switch to reduced operating mode proactively and prevent catastrophic failure while maintaining partial charging capability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the operating mode of the internal combustion engine based on real-time sensor status. The engine can transition between normal operating mode (full charging capability) and reduced operating mode (limited charging capability) depending on whether synchronization errors are detected, allowing flexible adaptation to system conditions.

Inventive Principle:

Principle #15Dynamics

2Reliability

If the engine remains in reduced operating mode due to persistent fault status, then the reliability of the sensor fault protection is improved, but the loss of time for battery charging increases

Engineering Contradiction:

Improvesensor fault protectionVSAvoidbattery charging time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system continuously monitors the fault status of angular position sensors and provides feedback to the engine control. When a synchronization error is detected, the fault status is updated and the operating mode is adjusted. This closed-loop feedback ensures that the system responds appropriately to sensor conditions while minimizing unnecessary operational restrictions.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes the operating parameters of the internal combustion engine based on sensor fault status. When a fault is detected, the engine transitions to reduced operating mode with altered performance parameters. This parameter change allows the system to maintain reliability protection while adapting to the degraded sensor condition.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the fault status is not reset after false error detection, then the reliability of fault detection system is improved, but the device complexity increases due to manual intervention requirements

Engineering Contradiction:

Improvefault detection accuracyVSAvoidfault status reset procedure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system performs self-diagnosis and automatic fault status management. The engine control computer automatically detects synchronization errors, updates fault statuses, and manages operating mode transitions without requiring manual intervention. This self-service capability reduces system complexity while maintaining reliable fault detection.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical intervention (physically restarting the engine to reset fault status) with an electronic control system that automatically manages fault statuses. The computer-controlled system substitutes the mechanical restart procedure with automated electronic fault management, reducing complexity and improving reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250304083A1Engine control method suitable for a hybrid architecture with drive by the electric motor only

Publication Date: 2025.10.02 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A control method implemented in a motor vehicle computer (70), said vehicle comprising both an electric motor (40) and an internal combustion engine (10), the electric motor (40) being powered by at least one battery (30) and configured to drive the wheels (50) of the motor vehicle, and the internal combustion engine (10) being uncoupled from the wheels (50) of the motor vehicle and configured to drive an electric generator (20) that powers said battery (30), the method comprising the following steps:receiving a synchronization error detection signal (Err), and detecting an operating mode of the internal combustion engine (10);if it is confirmed that the internal combustion engine (10) is in a reduced operating mode, starting a timer;when the timer has reached a predetermined time threshold (Thd1), generating a synthetic fault status reset command (C), intended to reset, to a state indicating the absence of a fault, a fault status of each of the at least one associated angular position sensors.