The subject disclosure relates to electric vehicles and, more specifically, to a system and method for operating a multi-speed drive unit of a transmission of an electric vehicle to achieve a desired response.
Electric vehicles have been designed to include an electric motor on each axle. A transmission for an axle controls a gear ratio between the associated electric motor and the axle. It is desired to maintain a smooth ride during a gear shift, such as by maintaining a constant acceleration of the electric vehicle. This goal is complicated by having electric motors on multiple axles. Accordingly, it is desirable to coordinate the operation of electric motors on different axles in order to ensure a smooth gear shift operation.
In one exemplary embodiment, a method of operating an electric vehicle is disclosed. A request is received at a controller of the electric vehicle. The controller receives a torque signal from a drive unit at a first axle of the electric vehicle. At least one of a first motor torque at the first axle and a second motor torque at a second axle of the electric vehicle is determined based on the torque signal and the request. At least one of the first motor torque is applied at the first axle and the second motor torque is applied at the second axle to satisfy the request.
In addition to one or more of the features described herein, the method further includes applying the at least one of the first motor torque and the second motor torque to maintain an acceleration profile of the electric vehicle during a gear shift operation. The controller is one of a vehicle controller in communication with a first motor of the first axle and a second motor of the second axle and a processing circuit of the first motor that determines only the first motor torque and applies the first motor torque at the first axle. The torque signal is indicative one of a current output torque of the drive unit and a predicted output torque of the drive unit. The method further includes determining the at least one of the first motor torque and the second motor torque based on at least one of a difference between the torque signal and a torque sensed at the first axle and a difference between a torque at the first axle and a torque at the second axle. The request is at least one of a speed of the electric vehicle, an acceleration of the electric vehicle, and a torque at the electric vehicle. The method further includes generating a torque delivery fault when at least one of a difference between a requested input torque to the drive unit to an estimated input torque to the drive unit exceeds a calibratable limit and the difference between a requested output torque of the drive unit and an estimated output torque of the drive unit exceeds the calibratable limit.
In another exemplary embodiment, a system for operating an electric vehicle is disclosed. The system includes a first motor, a drive unit between the first motor and a first axle of the electric vehicle, a second motor, and a processor. The processor is configured to receive a request for the electric vehicle, receive a torque signal from the drive unit, determine at least one of a first motor torque for the first motor and a second motor torque for the second motor based on the torque signal and the request, and apply the at least one of the first motor torque at the first motor and the second motor torque at the second motor to satisfy the request.
In addition to one or more of the features described herein, the processor is further configured to apply the at least one of the first motor torque and the second motor torque to maintain an acceleration profile of the electric vehicle during a gear shift operation. The processor is one of a vehicle controller in communication with the first motor and the second motor and a processing circuit of the first motor that determines only the first motor torque and applies the first motor torque at the first axle. The torque signal is one of a current output torque of the drive unit and a predicted output torque of the drive unit. The processor is further configured to determine the at least one of the first motor torque and the second motor torque based on at least one of a difference between the torque signal and a torque sensed at the first axle and a difference between a torque at the first axle and a torque at the second axle. The request is at least one of a speed of the electric vehicle, an acceleration of the electric vehicle, and a torque at the electric vehicle. The processor is further configured to generate a torque delivery fault when at least one of a difference between a requested input torque to the drive unit to an estimated input torque to the drive unit exceeds a calibratable limit and the difference between a requested output torque of the drive unit and an estimated output torque of the drive unit exceeds the calibratable limit.
In yet another exemplary embodiment, an electric vehicle is disclosed. The electric vehicle includes a first motor, a drive unit between the first motor and a first axle of the electric vehicle, a second motor, and a processor. The processor is configured to receive a request for the electric vehicle, receive a torque signal from the drive unit, determine at least one of a first motor torque for the first motor and a second motor torque for the second motor based on the torque signal and the request, and apply the at least one of the first motor torque at the first motor and the second motor torque at the second motor to satisfy the request.
In addition to one or more of the features described herein. The processor is further configured to apply the at least one of the first motor torque and the second motor torque to maintain an acceleration profile of the electric vehicle during a gear shift operation. The processor is one of a vehicle controller in communication with the first motor and the second motor and a processing circuit of the first motor that determines only the first motor torque and applies the first motor torque at the first axle. The torque signal is one of a current output torque of the drive unit and a predicted output torque of the drive unit. The processor is further configured to determine the at least one of the first motor torque and the second motor torque based on at least one of a difference between the torque signal and a torque sensed at the first axle and a difference between a torque at the first axle and a torque at the second axle. The request is at least one of a speed of the electric vehicle, an acceleration of the electric vehicle, and a torque at the electric vehicle.
The above features and advantages, and other features and advantages of the disclosure are readily apparent from the following detailed description when taken in connection with the accompanying drawings.
Other features, advantages and details appear, by way of example only, in the following detailed description, the detailed description referring to the drawings in which:
The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. As used herein, the term module refers to processing circuitry that may include an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.
In accordance with an exemplary embodiment,
The first drive system 102 includes a first battery 108, a first motor 110, and a first transmission or first drive unit 112. The first motor 110 is an electric motor that converts power from the first battery 108 into kinetic energy in the form of a rotation. The first drive unit 112 can engage the first motor 110 to transfer the rotation from the first motor to the first axle 104 and first wheels 106. The first motor 110 can include a first regenerative braking system 114. During braking, the first regenerative braking system 114 converts rotational energy of the first axle 104 into electrical energy or current which is used to recharge the first battery 108.
Similarly, the second drive system 122 includes a second battery 128, a second motor 130, and a second transmission or second drive unit 132. The second motor 130 is an electric motor that converts power from the second battery 128 into kinetic energy in the form of a rotation. The second drive unit 132 can engage the second motor 130 to transfer the rotation to the second axle 124 and second wheels 126. The second motor 130 can include a second regenerative braking system 134. During braking, the second regenerative braking system 134 converts rotational energy of the second axle 124 into electrical energy or current which is used to recharge the second battery 128. In an embodiment, the second drive system 122 can be engaged when the vehicle is placed in an all-wheel drive mode and can be disengaged or shut down when not in the all-wheel drive mode.
While the electric vehicle 100 of
A vehicle controller 140 is in communication with the first drive system 102, including the first motor 110 and the first drive unit 112, and the second drive system 122, including the second motor 130 and the second drive unit 132. The vehicle controller 140 may include processing circuitry that may include an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality. The vehicle controller 140 may include a non-transitory computer-readable medium that stores instructions which, when processed by one or more processors of the vehicle controller 140, implement a method of controlling shifting of gears of at least one of the first drive unit 112 and the second drive unit 132, according to one or more embodiments detailed herein.
In various embodiments, the first motor 110 includes a processing circuit that controls operation of the first motor. For illustrative purposes, the second drive unit 132 is not shown. Second motor 130 is connected directly to the second axle 124 and transmits its torque to the second axle and second wheels 126. The second motor 130 includes a processing circuit that controls operation of the second motor. The processing circuit of the second motor 130 communicates signals, such as the second motor torque and/or the second motor speed to the vehicle controller 140. In addition, the first drive unit 112 includes a processing circuit that can control operation of the drive unit and communicate an electric signal to the vehicle controller 140 indicating, for example, a current drive output torque To, a current wheel torque Tw, a current drive output velocity ωo, etc.
To operate the control system 200, the vehicle controller 140 receives a request with respect to vehicular motion or vehicular dynamics. The request can be a speed request, an acceleration request, a torque request, or any combination thereof. The request can be either a human request from a human machine interface 204 or an autonomous request from the electric vehicle 100. The human machine interface 204 can be, for example, a gas pedal, brake pedal, etc. through which driver enters the request. The vehicle controller 140 satisfies the request by determining a torque at the vehicle that meets or satisfies the request, determining an allocation of torques among the first motor 110 and the second motor 130, and sending appropriate signals to one or both of the first motor 110 and the second motor 130. The vehicle controller 140 can determine torque allocation based on the request and feedback from the first drive unit 112 and the second motor 130. In various embodiments, the torque is allocated to maintain a desired acceleration profile at the electric vehicle 100, such as a constant acceleration, an increase in acceleration, a decrease in acceleration, etc.
The vehicle controller 140 can compare a requested input torque at the drive unit to an estimated input torque and generate a torque delivery fault if the difference between the requested input torque and the estimated input torque exceeds a calibratable limit. Similarly, the vehicle controller 140 can compare a requested output torque at the drive unit to an estimated output torque and generate a torque delivery fault if the difference between the requested output torque and the estimated output torque exceeds a calibratable limit. Additionally, the vehicle controller 140 can determine first motor torque and second motor torque based on a difference between a first torque at the first axle and a second torque at the second axle.
Torque losses and speed losses occur at the input shaft 308 during operation. An equation of motion for the input shaft is shown as indicated in Eq. (1):
where x is an angle of rotation of the input shaft, {dot over (x)} is an angular velocity of the input shaft and {umlaut over (x)} is an angular acceleration of the input shaft. Tm is a motor torque applied to the input shaft 308. Ti is a torque applied to the input shaft 308 by the first drive unit 112. The parameter η1 represents unmodelled dynamics, such as friction loss or other torque based on speed, temperature, etc.
The input shaft torque Ti and input shaft speed ωi are input to the first drive unit 112. The input shaft torque is received at the ring gear 306 and transmitted to the carrier gear 304 and from there to the sun gear 302. A clutch at the sun gear 302 controls an output torque To and output speed ωo by the first drive unit 112.
The first clutch torque T1 is dependent on a clutch pressure P1 and a clutch slip speed ω1, as shown in Eq. (2):
The first axle 104 connects the first drive unit 112 to the first wheels 106 and transfers the output torque to the wheel. The clutch torque can be represented by a continuous function (such as the tanh function) to help in performing calculations in real-time.
The first drive unit 112 provides its output torque To and output speed ωo to the first axle 104. Torque losses and speed losses occur at the first axle 104, as indicated in Eq. (3):
where y is an angle of rotation of the axle, {dot over (y)} is an angular velocity of the axle and ÿ is an angular acceleration of the input shaft. To is the output torque of the first drive unit 112 and Tw is a torque applied to the axle by the first wheels 106. The wheel torque Tw can result from a brake force Fb and/or a road force Fr. The parameter η2 represented unmodelled dynamics, such as friction loss or other torque based on speed, temperature, etc.
The vehicle controller 140 receives requests, determines a desired motion for the vehicle from the requests, determines various torques for meeting the desired motion, and determines an allocation of the torques among the motors. The vehicle controller 140 can make these calculations for a gear shift operation.
In one embodiment, the vehicle controller 140 receives commanded signals such as the motor torque Tm, wheel torque Tw, first clutch pressure P1 and second clutch pressure P2, as well as measured values of current motor angular velocity ωm, current output angular velocity ω0 and current wheel angular velocity ωm. The vehicle controller 140 calculates output torque To, motor angular velocity ωm, output angular velocity ω0 and wheel angular velocity ωw to be applied to the drive system from these inputs.
In another embodiment, motor torque Tm and wheel torque Tw are commanded signals provided to the vehicle controller 140. Measurements are made of the first clutch pressure P1 and the second clutch pressure P2, motor angular velocity ωm, output angular velocity ω0 and wheel angular velocity ωw. These measurements are provided as input to the vehicle controller 140. The vehicle controller 140 outputs an output torque To, motor angular velocity ωm, output angular velocity ω0 and wheel angular velocity ωw, first clutch pressure P1 and second clutch pressure P2 to be applied to the drive system.
Returning to
The terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The term “or” means “and/or” unless clearly indicated otherwise by context. Reference throughout the specification to “an aspect”, means that a particular element (e.g., feature, structure, step, or characteristic) described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects.
When an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.
Unless specified to the contrary herein, all test standards are the most recent standard in effect as of the filing date of this application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.
Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this disclosure belongs.
While the above disclosure has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from its scope. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within the scope thereof.