Control system for an all-wheel drive electric vehicle

• US 10,131,248 B2
• Filed: 12/20/2016
• Issued: 11/20/2018
• Est. Priority Date: 01/29/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Inc.
• Inventors: Tang, Yifan
• Primary Examiner(s): Zanelli, Michael J
• Application Number:
  US15/384,723
• Publication Number:
  US 20170253143A1
• Time in Patent Office: 700 Days
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 2001/001 one motor mounted on a propulsion axle for rotating right and left wheels of this axle
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 15/2036 Electric differentials, e.g. for supporting steering vehicles
• CPC Class Codes: B60L 2240/24 Steering angle
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/486 Operating parameters
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 2510/087 Temperature
• CPC Class Codes: B60W 2520/28 Wheel speed
• CPC Class Codes: B60W 2540/10 Accelerator pedal position
• CPC Class Codes: B60W 2540/12 Brake pedal position
• CPC Class Codes: B60W 2540/16 Ratio selector position
• CPC Class Codes: B60W 2540/18 Steering angle
• CPC Class Codes: B60W 2710/083 Torque
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

An electric vehicle drive system includes first and second electric motors, first and second torque limiters and a torque splitter. The first and second torque limiters correspond to the first and second electric motors, respectively, and generate respective first and second maximum torques. The torque splitter receives a first input that includes at least a total torque request for the first and second electric motors and the first and second maximum torques and generates at least respective first and second torque requests for the first and second electric motors, wherein the torque splitter is configured to direct a torque request to the second motor only if the first maximum torque is less than a threshold. The torque splitter may generate a zero second torque request if a motor speed of the first electric motor exceeds a threshold.

Claims

1. An electric vehicle drive system comprising:

first and second electric motors;

first and second torque limiters for the first and second electric motors, respectively, the first and second torque limiters configured to generate respective first and second maximum torques; and

a torque splitter configured to receive first input that includes at least a total torque request for the first and second electric motors and the first and second maximum torques, the torque splitter further configured to process the first input and to generate at least respective first and second torque requests for the first and second electric motors, wherein the torque splitter is configured to direct a torque request to the second motor only if the first maximum torque is less than a threshold.

2. The electric vehicle drive system of claim 1 wherein the torque splitter generates a reduced second torque request upon detection of corresponding wheel slip.

3. The electric vehicle drive system of claim 1 wherein the torque splitter generates a reduced second torque request upon determining that a temperature of the second electric motor exceeds a temperature threshold.

4. The electric vehicle drive system of claim 1 wherein the second electric motor is an AC induction motor.

5. The electric vehicle drive system of claim 1 wherein the first electric motor is not an AC induction motor.

6. The electric vehicle drive system of claim 1 wherein the threshold is 95% or less of the first maximum torque at a first motor speed of 1000 rpm.

7. The electric vehicle drive system of claim 6 wherein the second electric motor is an AC induction motor.

8. The electric vehicle drive system of claim 6 wherein the first electric motor is not an AC induction motor.

9. An electric vehicle drive system comprising:

a primary electric motor;

an assist electric motor;

a first torque limiting unit configured to generate a first maximum torque using a primary electric motor speed;

a second torque limiting unit configured to generate a second maximum torque using an assist electric motor speed;

a torque control unit configured to receive input from an accelerator sensor and a brake sensor and to determine a total required torque; and

a torque split unit configured to use the first maximum torque, the second maximum torque, and the total required torque to compute a primary electric motor torque and an assist electric motor torque, wherein the torque split unit only computes a non-zero assist electric motor torque if the first maximum torque is insufficient to achieve the total required torque.

10. The electric vehicle drive system of claim 9 wherein the torque split unit computes a reduced assist electric motor torque upon detection of corresponding wheel slip.

11. The electric vehicle drive system of claim 9 wherein the torque split unit generates a reduced assist electric motor torque upon determining that a temperature of the assist electric motor exceeds a temperature threshold.

12. The electric vehicle of claim 9 wherein the assist electric motor is an AC induction motor.

13. The electric vehicle drive system of claim 9 wherein the assist electric motor has a flat torque curve over a range of speeds covering at least 9,000 rpm.

14. The electric vehicle drive system of claim 13 wherein the torque split unit is configured to direct a torque request to the assist motor only if the first maximum torque is less than a threshold.

15. The electric vehicle drive system of claim 14 wherein the threshold is 95% or less of the first maximum torque at a primary motor speed of 1000 rpm.

16. The electric vehicle drive system of claim 15 wherein the assist electric motor is an AC induction motor.

17. The electric vehicle drive system of claim 16 wherein the primary electric motor is not an AC induction motor.