Dual-Axle Recuperation Control With Predictive Motor Coupling

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Solution Overview

Problem

Existing vehicle systems with multiple electric machines for recuperation face inefficiencies and stability issues due to energy loss and synchronization challenges when coupling additional electric machines for deceleration and energy recovery.

Innovation Solution

An apparatus and method that uses sensor data to predict and selectively activate a secondary electric machine for recuperation based on energy efficiency and stability considerations, including synchronization and clutch management to optimize energy recovery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a second electric machine is coupled to a second axle for recuperation, then the amount of recuperated electric energy increases, but the energy expenditure for activation and coupling increases

Engineering Contradiction:
Improverecuperated electric energyVSAvoidenergy expenditure for activation
Core Design Contradiction:
Loss of energyVSUse of energy by moving object

Solution Approach 1:

The control apparatus predicts whether an upcoming recuperation event will occur and activates the second electric machine in advance, before the actual recuperation begins. This preliminary activation allows the electric machine to be ready for immediate energy recovery, capturing more recuperated energy while avoiding the energy loss of repeated activation cycles.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the coupling state of the second electric machine based on predicted driving conditions. The clutch is controlled to couple or decouple the second electric machine from the second axle according to real-time predictions of recuperation opportunities, optimizing the balance between energy recovery potential and activation energy expenditure.

Inventive Principle:
Principle #15Dynamics

2Stability of the object's composition

If a second electric machine is coupled to a second axle for recuperation, then the stability of driving operation increases, but the device complexity increases

Engineering Contradiction:
Improvestability of driving operationVSAvoidcomplexity of multiple electric machines
Core Design Contradiction:
Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The control apparatus performs preliminary prediction of recuperation events using sensor data and vehicle operating conditions. This advance prediction allows the system to proactively manage the coupling and activation of the second electric machine, ensuring stable driving operation during predicted recuperation events while avoiding unnecessary complexity from continuous monitoring and activation.

Inventive Principle:
Principle #10Preliminary action

3Loss of energy

If the second electric machine is activated for recuperation, then the amount of recuperated electric energy increases, but the time required for synchronization increases

Engineering Contradiction:
Improverecuperated electric energyVSAvoidsynchronization time
Core Design Contradiction:
Loss of energyVSLoss of time

Solution Approach 1:

The control apparatus predicts upcoming recuperation events in advance and activates the second electric machine before the actual recuperation begins. This preliminary activation eliminates the synchronization delay that would occur if the machine were activated at the last moment, allowing immediate energy recovery when the recuperation event occurs.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

By predicting recuperation events beforehand, the system skips the synchronization time that would normally be required upon activation. The second electric machine is pre-synchronized and ready to immediately contribute to energy recovery, effectively rushing through the activation and synchronization phase by performing it in advance.

Inventive Principle:
Principle #21Skipping (Rushing through)

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

Enhances energy efficiency and driving stability by optimizing the use of multiple electric machines during recuperation processes, increasing the amount of recoverable energy and maintaining vehicle control.

Implementation Method 1

the electric machines of the vehicle can be used to decelerate the vehicle and to recuperate electric energy at the same time, which can be stored in an electric energy storage device of the vehicle

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

In a friction-locked clutch, the successive closing of the clutch is typically sufficient to couple the second electric machine to the second axle, wherein the second electric machine is sped up here by the kinetic energy of the vehicle

Methodology Applied
Scientific EffectFriction: Friction

Data Source

PatentUS12370899B2Method and apparatus for controlling an electric machine during a recuperation process
Publication Date: 2025.07.29 BAYERISCHE MOTOREN WERKE AG
  • US12370899B2 patent drawing

AI summary

An apparatus for operating an electric machine of a vehicle during a recuperation process is provided. The vehicle includes a first electric machine which is coupled to a first axle of the vehicle, and a second electric machine which can be coupled to a second axle of the vehicle. The apparatus is configured to determine, on the basis of sensor data from one or more sensors in the vehicle, whether the second electric machine should be used to recuperate electric energy during a recuperation process in addition to the first electric machine. The apparatus is also configured, depending on this determination, to operate the second electric machine during the recuperation process in order to recuperate electric energy.