Electrified Vehicle Limp-Home Control With ECU-ASIC Validation

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing control systems for electrified vehicles may unnecessarily shift to a limp home mode due to malfunctions in the high-order ECU, leading to improper vehicle operation.

Innovation Solution

A control system where a high-order ECU and an ASIC communicate to determine if a limp home mode is necessary, with the ASIC monitoring the microcomputer for failures and adjusting electricity supply to the motor, ensuring proper limp home mode engagement only when required.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the high-order ECU directly triggers limp home mode upon detecting processor failure, then the response speed is improved, but false activation occurs due to ECU malfunctions

Engineering Contradiction:
Improveresponse speedVSAvoidaccuracy of limp home mode activation
Core Design Contradiction:
SpeedVSReliability

Solution Approach 1:

The patent introduces a mode shift request mechanism where the high-order ECU sends a request to the second control device rather than directly activating limp home mode. The second control device's logic circuit then validates whether the processor failure is genuine before activating the mode. This intermediary request-validation process prevents false activation while maintaining rapid response.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If the system adds a validation mechanism to prevent false limp home mode activation, then the reliability is improved, but the system complexity increases

Engineering Contradiction:
Improveaccuracy of limp home mode activationVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The second control device's logic circuit performs self-validation by monitoring its own processor status and comparing it with the mode shift request from the high-order ECU. The logic circuit independently determines whether activation is appropriate based on internal state, eliminating the need for additional external validation components and keeping the system relatively simple.

Inventive Principle:
Principle #25Self-service

3Reliability

If the logic circuit independently monitors processor status, then the reliability of limp home mode activation is improved, but the communication complexity between control devices increases

Engineering Contradiction:
Improveprocessor failure detection accuracyVSAvoidcommunication structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The monitoring function is segmented into two parts: the logic circuit continuously monitors processor status independently, while the high-order ECU sends mode shift requests based on its own detection. This segmentation allows both components to operate semi-independently, reducing the need for complex continuous communication while maintaining high reliability through dual monitoring.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS20250222774A1Control system for electrified vehicle
Publication Date: 2025.07.10 TOYOTA JIDOSHA KK
  • US20250222774A1 patent drawing
  • US20250222774A1 patent drawing
  • US20250222774A1 patent drawing

AI summary

A control system includes a first control device, a processor, and a logic circuit. When a failure in the processor is detected, the first control device determines whether it is possible to perform a limp home mode, and when it is determined that it is possible to perform the limp home mode, outputs, to the logic circuit, a mode shift request for causing the logic circuit to shift to the limp home mode. The logic circuit is configured to be able to determine, based on the monitoring, whether a situation requires that the limp home mode be performed when the mode shift request is acquired from the first control device, and shifts to the limp home mode when the mode shift request is acquired from the first control device and also it is determined that a situation requires that the limp home mode be performed.