Powertrain Fault Management via Dynamic Power Capping

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Solution Overview

Problem

Vehicle powertrains face malfunctions and overheating issues, leading to potential damage and reduced operability, which existing systems struggle to address effectively without burdening occupants with noise, vibration, and harshness.

Innovation Solution

A computer-controlled system that caps power provided by the powertrain to a predetermined limit in response to critical conditions, such as temperature thresholds, while allowing power above the limit for acceleration demands, thereby prolonging vehicle operation and reducing NVH.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the powertrain operates at full power to meet acceleration demands, then the vehicle performance is maintained, but the powertrain may overheat and suffer damage

Engineering Contradiction:

Improvepowertrain reliabilityVSAvoidpower output

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The system dynamically adjusts the powertrain's power output based on real-time temperature conditions. When overheating is detected, the system transitions from full power operation to a reduced power mode, creating a dynamic response that balances reliability protection with performance maintenance. This is achieved through continuous monitoring of temperature sensors and adaptive control of powertrain components.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters (power limits, torque constraints) based on temperature thresholds. When the powertrain temperature exceeds safe thresholds, the system modifies the power delivery parameters to prevent damage while still allowing controlled operation. This parameter adaptation enables the powertrain to operate safely under thermal stress conditions.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If the powertrain power is capped to prevent overheating, then the powertrain reliability is improved, but the vehicle acceleration performance deteriorates

Engineering Contradiction:

Improvepowertrain reliabilityVSAvoidacceleration capability

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The system applies partial power capping rather than complete power restriction. Instead of eliminating acceleration capability entirely, the system caps power at a level that prevents overheating while still providing sufficient acceleration for safe operation. This partial action approach maintains essential vehicle functionality while protecting against thermal damage.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system continuously monitors powertrain temperature and adjusts power capping levels based on real-time feedback. When temperatures are within safe ranges, the system reduces or removes power caps to restore acceleration performance. When temperatures approach critical thresholds, the system increases power capping to prevent overheating. This closed-loop feedback control dynamically balances reliability and performance.

Inventive Principle:

Principle #23Feedback

3Duration of action of moving object

If the powertrain operates continuously without intervention, then the vehicle can reach its destination, but the powertrain may suffer complete failure

Engineering Contradiction:

Improveoperational durationVSAvoidpowertrain reliability

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The system takes preliminary protective action by detecting early signs of overheating and applying power caps before critical failure occurs. Rather than waiting for complete failure, the system proactively monitors temperature trends and intervenes in advance, extending the operational duration of the powertrain by preventing thermal damage accumulation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides beforehand cushioning by implementing progressive power restrictions that cushion against thermal stress. Instead of allowing the powertrain to operate at full power until failure, the system gradually reduces power output as temperatures rise, creating a cushioning effect that protects the powertrain from sudden thermal shock and extends its operational life.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Temperature

If the powertrain power is restricted to reduce thermal stress, then the powertrain temperature is controlled, but the energy consumption increases

Engineering Contradiction:

Improvepowertrain temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The system applies periodic or intermittent power restrictions rather than continuous restriction. When temperature thresholds are exceeded, the system applies power caps to reduce thermal stress. When temperatures return to safe ranges, the system lifts or reduces the caps, allowing more efficient operation. This periodic action pattern balances temperature control with energy efficiency, avoiding continuous energy waste from unnecessary power restrictions.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS10486704B2Powertrain fault management

Publication Date: 2019.11.26 FORD GLOBAL TECH LLC

AI summary

A computer is programmed to cap power provided by a powertrain to a power limit in response to data indicating a critical condition of the powertrain; and provide power from the powertrain above the power limit in response to a demand for acceleration above an acceleration threshold. The computer may be programmed to cap power provided by the powertrain above the power limit to an energy limit.