Electric Vehicle Powertrain Backlash Monitoring for Wear Detection
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Solution Overview
Problem
Monitoring the wear of complex powertrains in heavy electric vehicles is inefficient and costly due to the complexity of detecting mechanical wear in internal parts, such as gears in the transmission, using physical inspection methods.
Innovation Solution
A method involving an analysis cycle where the electric motor is rotated in both directions until a predetermined torque threshold is reached, allowing for the calculation of backlash values to assess powertrain wear, which can be compared to reference values to detect wear or defects, and optionally including measurements of angular positions to enhance precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical inspection methods are used to monitor powertrain wear, then detection capability is provided, but the method is costly and inefficient
Solution Approach 1:
The patent replaces physical inspection methods with a computational approach using motor current analysis. By analyzing the current drawn by the electric motor during operation, the system can detect wear in powertrain components without requiring physical disassembly or manual inspection, thereby improving both detection capability and monitoring efficiency
Solution Approach 2:
The patent introduces motor current as an intermediary parameter to indirectly measure powertrain wear. Instead of directly inspecting mechanical components, the system uses electrical current characteristics as a mediator to detect changes in mechanical condition, enabling non-intrusive and efficient monitoring
2Reliability
If physical inspection of internal parts is performed, then wear detection is possible, but the process is costly and time-consuming
Solution Approach 1:
The patent substitutes manual physical inspection with automated electrical measurement. The control unit continuously monitors motor current parameters and compares them against reference values to detect wear, eliminating the need for time-consuming physical inspections while maintaining reliable detection accuracy
Solution Approach 2:
The patent enables continuous monitoring of powertrain wear through ongoing analysis of motor current during normal operation. Unlike periodic physical inspections that require vehicle downtime, this method provides uninterrupted wear detection, significantly reducing time loss while maintaining reliable detection
3Power
If complex powertrain systems are used in heavy electric vehicles, then propulsion capability is improved, but monitoring complexity increases
Solution Approach 1:
The patent makes the control unit serve multiple functions: it not only controls the electric motor operation but also simultaneously monitors powertrain wear by analyzing motor current. This multi-functionality approach allows complex powertrain systems to be monitored using existing control infrastructure, preventing monitoring complexity from increasing proportionally with powertrain complexity
4Measurement precision
If motor current parameters are analyzed to detect wear, then monitoring precision is improved, but calculation complexity increases
Solution Approach 1:
The patent extracts specific relevant parameters from the motor current signal (such as RMS current, frequency components, or harmonic content) that are most indicative of wear. By focusing on these extracted key parameters rather than analyzing the entire complex current waveform, the system achieves high monitoring precision while keeping calculation complexity manageable
Data Source
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AI summary
The method (100) for monitoring the wear of a powertrain comprises an analysis cycle (120) that includes, in this order, preventing (121) mechanical components (12) from moving; rotating (123) an electric motor (16) in a first direction until a torque value delivered by the electric motor reaches a predetermined threshold, a first angular position of the electric motor being reached; rotating (125) the electric motor in a second direction opposite to the first direction until a torque value delivered by the electric motor reaches the predetermined threshold, a second angular position of the electric motor being reached; and calculating (127) a backlash value of the powertrain on the basis of the first and second angular positions. The method (100) further comprises comparing (130) the backlash value calculated (127) during the analysis cycle (120) to a reference value to monitor wear of the powertrain (14).