EV Inverter Fault Group Encoding for Faster Single-Channel Response

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Solution Overview

Problem

Inverters used in electric vehicles face delays and bandwidth consumption issues in fault reporting due to the need to transmit multiple unique fault types over a single channel, which can lead to delayed responses and potential damage from undetected faults.

Innovation Solution

Encoding faults using a fault response group that corresponds to a specific type of fault, allowing for reduced data transmission and faster communication, where each fault type within a group requires the same response, thereby minimizing delay and bandwidth usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple unique fault types are transmitted over a single channel, then fault detection accuracy is improved, but communication bandwidth consumption increases and response time is delayed

Engineering Contradiction:
Improvefault detection accuracyVSAvoidresponse time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

Multiple fault types that require the same response action are merged into a single fault response group. Instead of transmitting individual fault type identifiers, the system transmits a consolidated fault response group identifier that represents multiple fault types requiring identical corrective actions, thereby reducing communication time and bandwidth usage while maintaining adequate fault detection capability

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The fault response group is segmented into multiple sub-groups or levels, allowing hierarchical fault reporting. Critical faults can be reported with higher priority and more detail, while less critical faults use compressed representations, optimizing the balance between detection accuracy and communication efficiency

Inventive Principle:
Principle #1Segmentation

2Loss of information

If multiple unique fault types are transmitted over a single channel, then comprehensive fault information is provided, but communication bandwidth is substantially consumed

Engineering Contradiction:
Improvefault information completenessVSAvoidbandwidth consumption
Core Design Contradiction:
Loss of informationVSQuantity of substance

Solution Approach 1:

A universal fault response group encoding scheme is implemented where a single transmitted code can represent multiple fault types that share the same response requirements. This multi-functional encoding allows the communication channel to convey comprehensive fault information in a compressed format, reducing bandwidth consumption while preserving the essential information needed for appropriate fault response

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

Instead of transmitting detailed individual fault type information for each fault, the system transmits a compressed copy or representation in the form of fault response group identifiers. This copying approach maintains the essential functional information needed for fault response while significantly reducing the amount of data that must be transmitted over the communication channel

Inventive Principle:
Principle #26Copying

Data Source

PatentUS12179610B2Systems and methods for single channel fault encoding for inverter for electric vehicle
Publication Date: 2024.12.31 BORGWARNER US TECHNOLOGIES LLC
  • US12179610B2 patent drawing
  • US12179610B2 patent drawing
  • US12179610B2 patent drawing

AI summary

A system comprises: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a point-of-use controller configured to: detect a fault; determine a fault type of the detected fault from among n fault types; determine a fault response group to which the determined fault type belongs from among m fault response groups; encode the determined fault response group; and transmit the encoded fault response group via a communication interface; and a phase controller configured to: receive the encoded fault response group from the point-of-use controller via the communication interface; determine the fault response group; decode the determined fault response group; and output the decoded fault response group.