Resolver Angle Decoding With Dual-Channel ASIL C Diagnosis
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Solution Overview
Problem
Existing motor controllers for electric vehicles require expensive safety decoding chips to achieve the necessary ASIL C level for torque safety, increasing material costs and complexity.
Innovation Solution
A motor angle detection and diagnosis apparatus that uses two-channel simultaneous sampling and real-time diagnosis to decode the electrical angle without a safety decoding chip, employing a signal generation module, resolver exciting processing circuit, and diagnosis signal sampling circuit to control the motor controller into a safe state when abnormalities are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety decoding chip of at least ASIL C is used to decode resolver feedback signal, then angle sampling can reach at least ASIL C level, but material costs of motor controller are increased
Solution Approach 1:
The patent creates a virtual copy of the safety decoding chip functionality by implementing identical decoding algorithms and diagnosis mechanisms in software form. The processor executes safety-critical software that replicates the chip's angle decoding and fault diagnosis capabilities, achieving ASIL C certification without requiring expensive hardware chips. This software-based approach maintains full safety functionality while eliminating the need for costly physical decoding chips.
Solution Approach 2:
The patent replaces the mechanical/electronic safety decoding chip with a software-based system running on a general-purpose processor. Instead of using dedicated hardware circuitry to decode resolver signals and diagnose faults, the invention uses programmable software that performs the same functions through algorithmic processing. This substitution of hardware with software achieves the same safety objectives while reducing material costs and increasing flexibility.
2Reliability
If a safety decoding chip of at least ASIL C is used to decode resolver feedback signal, then angle sampling can reach at least ASIL C level, but complexity of motor controller is increased
Solution Approach 1:
The patent merges the safety decoding chip functionality with the existing motor controller processor by integrating angle decoding and fault diagnosis software into the controller's central processing unit. Instead of adding a separate hardware decoding chip that would increase system complexity, the invention combines all decoding and safety functions into a unified software architecture that runs on the existing processor, thereby maintaining simplicity while achieving ASIL C safety level.
Solution Approach 2:
The patent makes the motor controller processor universal by enabling it to perform both standard motor control functions and safety-critical angle decoding functions through software. The same processor that handles routine motor control tasks also executes safety-critical decoding and diagnosis algorithms, eliminating the need for dedicated safety hardware. This multi-functional approach reduces overall system complexity while maintaining high safety standards.
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 solution enables angle decoding to reach at least ASIL C without the need for a safety decoding chip, reducing material costs and ensuring the motor controller can enter a safe state when faults occur, thus ensuring personal safety and reducing production expenses.
Implementation Method 1
The resolver is a sensor that accurately measures an angular position and speed of a rotation component such as a motor through a magnetic coupling effect between a primary winding and two secondary windings
Data Source
AI summary
A motor angle detection and diagnosis apparatus is connected to a drive motor using a resolver. The resolver is configured to output a resolver feedback signal of an electrical angle of the drive motor. An angle sampling and diagnosis system in the motor angle detection and diagnosis apparatus performs two-channel simultaneous sampling on a resolver feedback signal, obtained after adjustment by the resolver feedback processing circuit, separately calculates a first electrical angle and a second electrical angle; diagnoses data obtained after the two-channel sampling of the first electrical angle and the second electrical angle in real time, diagnoses hardware circuits, and controls the motor controller to enter a safe state when a diagnosis result is abnormal. In this solution, sampling is performed by using two sampling channels, so that angle decoding of at least an ASIL C can be implemented.