Modular Vehicle eModule Control via Dual Master Controllers
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Solution Overview
Problem
Conventional vehicle designs with fixed configurations and mechanically coupled systems are less than optimal for drivers who need to commute in congested areas, transport multiple passengers or cargo, and operate in different drive modes.
Innovation Solution
A modular robotic vehicle with electrically driven, self-contained eModules for steering, propulsion, and braking, controlled by a distributed network of primary and secondary master controllers via Ethernet for Control Automation Technology, enabling independent control of each corner and multiple drive modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed configuration vehicle chassis and powertrain are used, then the vehicle structure is simple and reliable, but the vehicle cannot adapt to different driving scenarios (congested area commuting, multiple passengers/cargo transport, different drive modes)
Solution Approach 1:
The vehicle is divided into four independent eModules, with each corner of the vehicle having a self-contained module housing electric steering, propulsion, braking, and suspension subsystems. This segmentation allows each module to be independently controlled and configured, enabling the vehicle to adapt to different driving scenarios by adjusting individual module operations rather than requiring complete system redesign.
Solution Approach 2:
The vehicle employs dynamic control capabilities where each eModule can be independently controlled in real-time. The distributed control network with primary and secondary master controllers enables dynamic reconfiguration of drive modes (e.g., single-axle drive, dual-axle drive, crab mode) by sending by-wire commands to specific modules, allowing the system to adapt its configuration on-the-fly based on driving conditions.
2Adaptability or versatility
If mechanically coupled steering, braking, and propulsion systems are used, then the system is simple and robust, but the system lacks flexibility for independent control of different vehicle functions
Solution Approach 1:
The patent replaces traditional mechanical linkages with electrical control systems. By-wire commands are transmitted through a distributed control network to control steering, propulsion, and braking functions. This substitution eliminates the need for complex mechanical couplings while enabling independent and flexible control of each eModule through electronic signals sent from the master controllers.
Solution Approach 2:
A distributed control network with primary and secondary master controllers acts as an intermediary between the driver inputs and the eModules. The master controllers receive driver inputs, process control logic, and transmit appropriate commands to the relevant eModules. This intermediary layer enables sophisticated control functions while maintaining system modularity and independence of each control unit.
3Reliability
If a single master controller is used, then the control system is simple, but the system reliability decreases when faults occur
Solution Approach 1:
The system incorporates a secondary master controller as a pre-prepared backup to cushion against primary controller failures. The secondary controller remains in standby mode, ready to take over control functions if the primary master controller experiences a fault. This beforehand cushioning ensures continuous operation and maintains system reliability without requiring complex real-time fault detection and switching mechanisms.
Solution Approach 2:
The control system dynamically changes its operational parameters based on the status of the master controllers. When the primary controller is functioning normally, it handles all control operations. When a fault is detected, the system transitions to using the secondary controller, changing the active control parameter from primary to secondary. This parameter change approach maintains reliability while keeping the controller architecture relatively simple.
Data Source
AI summary
A vehicle includes a chassis, a modular component, and a central operating system. The modular component is supported by the chassis. The central operating system includes a component control system, a primary master controller, and a secondary master controller. The component control system is configured for controlling the modular component. The primary and secondary master controllers are in operative communication with the component control system. The primary and secondary master controllers are configured to simultaneously transmit commands to the component control system. The component control system is configured to accept commands from the secondary master controller only when a fault occurs in the primary master controller.