Universal Torque Interface for Multi-Supplier Hybrid Powertrains
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Solution Overview
Problem
Existing drive control architectures in fuel cell vehicles face challenges in efficiently distributing torque requests across various powertrain components, particularly when these components are sourced from different manufacturers, leading to suboptimal fuel efficiency, drivability, and durability.
Innovation Solution
A universal interface is implemented to receive torque requests and balance the output among fuel cell and battery systems, as well as motor generators, using splitter logic to distribute the torque effectively, regardless of the origin of the components, thereby optimizing the use of multiple power sources and extending their lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional drive control architecture is used with components from different manufacturers, then component integration is simplified, but torque distribution efficiency and fuel efficiency deteriorate
Solution Approach 1:
A universal interface controller is introduced as an intermediary between the OEM torque request and the powertrain components from different manufacturers. This controller receives the torque request and distributes it to appropriate components (fuel cell, battery, motor generator) based on their operating states and efficiency characteristics, thereby maintaining fuel efficiency while allowing integration of components from various suppliers.
Solution Approach 2:
The system dynamically changes operating parameters (torque distribution ratios, power split between fuel cell and battery) based on real-time component operating states. By adjusting these parameters according to efficiency maps and current conditions, the system optimizes fuel efficiency while managing components from different manufacturers through a standardized interface.
2Device complexity
If torque requests are not balanced across powertrain components, then system complexity is reduced, but component durability and fuel cell lifespan deteriorate
Solution Approach 1:
The universal interface controller implements feedback mechanisms by continuously monitoring component operating states (temperature, voltage, current, torque) and adjusting torque distribution accordingly. This feedback loop ensures that no single component is overloaded, extending durability and fuel cell lifespan while maintaining manageable control complexity through standardized protocols.
Solution Approach 2:
The system dynamically adjusts torque distribution ratios based on real-time component states rather than using fixed allocation. This dynamic adaptation allows the controller to respond to changing conditions and component wear patterns, improving durability without requiring overly complex predetermined control strategies.
3Device complexity
If fuel cells are frequently turned on and off to meet torque demands, then component count is reduced, but fuel cell durability and system reliability deteriorate
Solution Approach 1:
The system merges the fuel cell and battery into a coordinated hybrid power source managed by the universal interface controller. Instead of using the fuel cell alone, the controller combines it with the battery to meet torque demands, allowing the fuel cell to operate continuously at optimal points and avoiding frequent on/off cycling, thereby extending durability while maintaining a compact component configuration.
Solution Approach 2:
The controller performs preliminary action by pre-charging the battery or adjusting fuel cell operating points before high torque demands occur. This anticipatory management allows the fuel cell to remain in a stable operating state and avoid sudden shutdowns or restarts, improving durability while maintaining system simplicity.
4Ease of manufacture
If OEM-specific control architectures are used, then component integration is simplified, but adaptability to different component suppliers deteriorates
Solution Approach 1:
The universal interface controller implements a standardized, manufacturer-agnostic communication and control protocol that can interface with powertrain components from any supplier. This universal interface maintains ease of integration through consistent protocols while simultaneously providing adaptability to work with different component types and manufacturers, breaking the tie between OEM-specific architectures and supplier flexibility.
Data Source
AI summary
Systems and methods provide a drive system control architecture that comprises a seamless interface between original equipment manufacturer (OEM) vehicle systems or components (e.g., accelerator pedal, brake pedal, accessory components, etc.) and third-party (or non-OEM) vehicle systems or components (e.g., motor/generator (MG) and inverter systems, fuel cell and battery systems, transmission, etc.). A universal interface implemented in a vehicle may receive a request for a specified amount of torque from one or more components of a first set of vehicle components, and may determine a balance between one or more components of a second set of vehicle components for delivering the specified amount of torque. The universal interface may then instruct the one or more components of the second set of vehicle components to deliver a commensurate portion of the specified amount of torque.