Multi-core Torque Validation for Electric Machines
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Solution Overview
Problem
Existing electrified vehicles face challenges in accurately determining and validating the torque produced by electric machines, leading to potential discrepancies between commanded and actual torque, which can result in suboptimal vehicle performance.
Innovation Solution
A multi-core processor with dedicated cores and analog-to-digital converters is used to independently estimate and compare torque values from rotor-angle data and phase current signals, and to command de-activation of the electric machine if a threshold difference is exceeded, ensuring accurate torque production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single-core processor is used to estimate torque, then the device complexity is low, but the measurement precision and reliability of torque determination deteriorate due to inability to independently validate torque values
Solution Approach 1:
The processor is divided into multiple independent cores (first core, second core, third core), where the first and second cores independently estimate torque using different algorithms or data sources. This segmentation enables parallel validation of torque values, improving measurement precision through cross-verification while distributing computational complexity across multiple units.
Solution Approach 2:
The system creates redundant copies of torque estimation functionality across multiple cores. Each core independently performs torque estimation, generating duplicate torque values that can be compared for validation. This copying approach ensures measurement precision through redundancy without requiring a single complex validation system.
2Reliability
If torque validation is not performed, then the device complexity remains low, but the reliability of torque production deteriorates due to potential discrepancies between commanded and actual torque
Solution Approach 1:
The system implements a feedback mechanism where the third core receives torque estimates from the first and second cores, compares them against commanded torque values, and validates whether actual torque production matches commanded torque. This feedback loop ensures reliability by continuously monitoring and verifying torque production, triggering fault detection when discrepancies exceed thresholds.
Solution Approach 2:
The multi-core processor performs self-validation of torque production using its own internal resources. The first, second, and third cores collectively execute the validation process without requiring external monitoring systems, enabling the system to self-verify torque production reliability through internal cross-checking and comparison mechanisms.
3Reliability
If multiple cores with independent ADCs are used to validate torque, then the measurement precision and reliability improve, but the device complexity and cost increase
Solution Approach 1:
Each core in the multi-core processor is designed with universal functionality to perform torque estimation, data processing, and validation tasks. The first, second, and third cores can independently execute similar functions, allowing the system to achieve high reliability through redundancy while maintaining modular complexity. This multi-functionality enables any core to compensate for others, reducing the need for specialized dedicated components.
Data Source
AI summary
A vehicle includes a multi-core processor having first, second, and cores and having first and second analog-to-digital converters (ADC) associated with the first and second cores, respectively. The first and second ADC are configured to convert analog phase currents to first and second digital phase current values, respectively. The multi-core processor is configured to generate first and second rotor-angle data from digital signals representing a position of the electric machine. The processor is programmed to, via the first core, estimate a first output torque of the electric machine based on the first rotor-angle data and the first digital phase current values, via the second core, estimate a second output torque based on the second rotor-angle data and the second digital phase current values, and, via the third core, command de-activation of the electric machine in response to a difference between the first and second output torques exceeding a threshold.