Motor Controller Autonomous Charging Torque During Communication Loss

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Solution Overview

Problem

In hybrid electric vehicles, a loss of communication between the electric motor system and the vehicle network can lead to automatic shutdown, which is undesirable, as existing technologies lack strategies to maintain continuous operation and battery charging during such events.

Innovation Solution

Implementing a vehicle operating strategy that restricts the electric motor to a limited operating mode, controlling it to generate charging torque for the battery when communication is lost, and deactivating it when necessary, while also discharging high voltage energy from powertrain components to prevent total shutdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the vehicle automatically shuts down upon loss of communication between the electric motor system and vehicle network, then system safety is improved, but vehicle operational continuity deteriorates

Engineering Contradiction:

Improvesystem safetyVSAvoidvehicle operational continuity

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The patent segments the vehicle operation into normal mode and limited operation mode (LOS mode). During communication loss, the system transitions to LOS mode where the motor controller operates independently without vehicle network commands, allowing continued vehicle operation while maintaining safety through restricted motor functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary actions by pre-charging the battery during communication loss events. The motor controller charges the battery when motor speed exceeds a threshold, ensuring sufficient energy is stored before potential shutdown, thereby extending operational continuity and reducing the impact of communication failures.

Inventive Principle:

Principle #10Preliminary action

2Use of energy by moving object

If the motor is restricted to limited operating mode during communication loss, then battery charging capability is improved, but motor performance deteriorates

Engineering Contradiction:

Improvebattery charging capabilityVSAvoidmotor performance

Core Design Contradiction:

Use of energy by moving objectVSPower

Solution Approach 1:

The patent implements dynamic operation modes for the motor. The motor can operate in normal mode when communication is available, switching to limited operation mode when communication is lost. In LOS mode, the motor dynamically adjusts between providing vehicle propulsion and charging the battery based on real-time conditions, optimizing energy utilization while maintaining adequate motor performance.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters by implementing speed thresholds for motor operation. The motor is deactivated when speed falls below a threshold during communication loss, and charging operations are initiated when speed exceeds a threshold. These parameter changes enable the motor to balance between maintaining vehicle drivability and charging the battery during limited operation.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If the motor is deactivated during communication loss, then energy consumption is reduced, but vehicle drivability deteriorates

Engineering Contradiction:

Improveenergy consumptionVSAvoidvehicle drivability

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The patent applies partial action by selectively deactivating the motor only when motor speed falls below a threshold during communication loss events. When motor speed is sufficient, the motor remains active to maintain vehicle drivability. This partial deactivation strategy reduces energy consumption only when necessary while preserving drivability when the motor can still contribute effectively.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This strategy prevents total vehicle shutdown and allows battery charging during communication loss with minimal impact on drivability and functionality, ensuring continued vehicle operation by maintaining a stable battery state of charge.

Implementation Method 1

control the motor to generate a charging torque for a battery

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

discharging high voltage (HV) energy stored in at least one HV powertrain component

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS10549748B2Autonomous motor control during loss of motor communications

Publication Date: 2020.02.04 FORD GLOBAL TECH LLC

AI summary

A vehicle includes an electric motor and an engine selectively coupled to the electric motor. The vehicle has an electric motor controller configured to, in response to (i) an absence of receiving a motor command signal within a predetermined time, (ii) a battery voltage being below a first threshold and (iii) a motor speed exceeding a second threshold, restrict operation of the electric motor to a limited operating mode and control the electric motor to generate a charging torque for a battery.