Vehicle Module Coast-Down Testing for Mechanical Loss Measurement
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Solution Overview
Problem
Existing end-of-line testing for vehicle modules, particularly those with built-in gearboxes, is inefficient and unreliable, failing to accurately determine mechanical losses in individual sub-modules due to the complexity and need for dedicated test equipment, leading to increased costs and reduced throughput.
Innovation Solution
An end-of-line method involving controlling an electric motor to a specific speed, switching to open circuit mode, monitoring operational parameters related to deceleration, and determining mechanical loss based on these parameters, allowing for high-throughput testing without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If standard EOL testing procedures are used to measure mechanical loss in vehicle modules, then measurement capability is provided, but device complexity increases and testing throughput decreases
Solution Approach 1:
The patent extracts the mechanical loss measurement capability from complex dedicated test equipment and implements it through a simplified controller that utilizes existing sensor data (current, voltage, speed) already present in the vehicle module. The controller calculates mechanical loss by processing operational parameters through defined equations, eliminating the need for separate measurement devices while maintaining measurement capability.
Solution Approach 2:
The controller is designed to perform multiple functions: it manages motor control operations and simultaneously measures mechanical loss using the same operational parameters. This multi-functional approach allows the existing controller to serve dual purposes without requiring additional dedicated test equipment, thereby reducing device complexity while maintaining measurement precision.
2Measurement precision
If standard EOL testing procedures are used to measure mechanical loss in vehicle modules, then measurement capability is provided, but testing time increases
Solution Approach 1:
The mechanical loss measurement is performed continuously during normal motor operation rather than requiring separate dedicated measurement phases. The controller utilizes operational parameters (current, voltage, speed) that are continuously available during motor operation to calculate mechanical loss in real-time, eliminating the need for additional measurement time while maintaining measurement precision.
Solution Approach 2:
The system performs self-diagnosis by using its own operational parameters to determine mechanical loss. The controller monitors its own current, voltage, and speed data to calculate mechanical loss without requiring external test equipment or additional measurement procedures, thereby reducing testing time while maintaining measurement accuracy.
3Measurement precision
If separate dedicated test equipment is used for each measurement, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the mechanical loss measurement function with the existing motor control system by utilizing the same controller and sensor infrastructure. Instead of combining multiple separate measurement devices, the solution integrates measurement capabilities into the existing control architecture, reducing overall system cost while maintaining measurement precision through sophisticated calculation algorithms.
Solution Approach 2:
The solution replaces expensive dedicated test equipment with a software-based calculation approach that uses inexpensive operational parameters already available from the motor's normal operation. The mechanical loss is determined through mathematical processing of current, voltage, and speed data rather than through expensive physical measurement devices, significantly reducing manufacturing costs while maintaining measurement capability.
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
Enables efficient and accurate measurement of mechanical losses in vehicle modules, including gear assemblies, by comparing monitored deceleration characteristics with references, ensuring compliance with end-of-line requirements and reducing testing time and costs.
Implementation Method 1
determining mechanical loss in the vehicle module based on the operational parameter
Data Source
AI summary
A method for measuring mechanical loss in a vehicle module. The vehicle module includes an electric motor, and the method includes controlling the electric motor to run at a specific speed, changing the control of the electric motor to open circuit mode, monitoring an operational parameter associated with the deceleration of the vehicle module, and determining mechanical loss in the vehicle module based on the operational parameter.