Control system for an all-wheel drive electric vehicle

• US 7,739,005 B1
• Filed: 02/26/2009
• Issued: 06/15/2010
• Est. Priority Date: 02/26/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Tang, Yifan
• Primary Examiner(s): Zanelli; Michael J.
• Application Number:
  US12/380,427
• Time in Patent Office: 474 Days
• Field of Search: None
• US Class Current: 701/22
• 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 2220/42 with use of more than one motor
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/24 Steering angle
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/425 Temperature
• CPC Class Codes: B60L 2240/461 Speed
• CPC Class Codes: B60L 2240/463 Torque
• CPC Class Codes: B60L 2240/465 Slip
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 2260/28 Four wheel or all wheel drive
• CPC Class Codes: B60L 3/10 Indicating wheel slip ; Correction of wheel slip
• CPC Class Codes: B60L 3/106 for maintaining or recovering the adhesion of the drive wheels
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60T 2270/202 for all-wheel drive vehicles
• CPC Class Codes: B60T 8/175 Brake regulation specially adapted to prevent excessive wheel spin during vehicle acceleration, e.g. for traction control safety devices for propulsion unit control responsive to, or preventing, skidding of wheels B60K28/16
• CPC Class Codes: B60T 8/3205 acceleration B60T8/34, B60T8/52, B60T8/54, B60T8/56, B60T8/58, B60T8/72, B60T8/86, B60T8/88 take precedence
• CPC Class Codes: B60W 30/02 Control of vehicle driving stability
• CPC Class Codes: B60W 30/18172 : Preventing, or responsive to skidding of wheels
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility

Abstract

A method and apparatus for optimizing the torque applied to the primary and assist drive systems of an all-electric vehicle is provided, the torque adjustments taking into account wheel slip as well as other vehicular operating conditions.

Claims

1. An electric vehicle drive system, comprising:

a primary drive system, comprising;

a primary electric motor, said primary electric motor mechanically coupled to at least one wheel of a first vehicle axle, wherein said primary electric motor provides propulsion power to said at least one wheel of said first vehicle axle; and

a primary power control module electrically connected to said primary electric motor, said primary power control module configured to receive primary motor torque commands, and said primary power control module configured to control said primary electric motor based on said primary motor torque commands;

an assist drive system, comprising;

an assist electric motor, said assist electric motor mechanically coupled to at least one wheel of a second vehicle axle, wherein said assist electric motor provides propulsion power to said at least one wheel of said second vehicle axle; and

a secondary power control module electrically connected to said assist electric motor, said secondary power control module configured to receive assist motor torque commands, and said secondary power control module configured to control said assist electric motor based on said assist motor torque commands;

a plurality of wheel speed sensors; and

a torque control system electrically connected to said primary and secondary power control modules and to said plurality of wheel speed sensors, wherein said torque control system outputs said primary motor torque commands to said primary power control module and outputs said assist motor torque commands to said secondary power control module, wherein said torque control system further comprises;

a traction control command generation unit for computing vehicle speed, wheel slip ratios corresponding to said plurality of wheel speed sensors, a first slip error corresponding to said first vehicle axle and a second slip error corresponding to said second vehicle axle;

a torque split unit for computing an optimal torque split between said primary drive system and said assist drive system based on said vehicle speed and a total required drive torque request, wherein said optimal torque split comprises an optimal primary motor torque request and an optimal assist motor torque request;

a traction and stability control unit comprising;

a first stage feedback control system for minimizing said first slip error and said second slip error;

a first torque limiter for transforming said optimal primary motor torque request into said primary motor torque command in response to an output from said first stage feedback control system; and

a second torque limiter for transforming said optimal assist motor torque request into said assist motor torque command in response to said output from said first stage feedback control system.

2. The electric vehicle drive system of claim 1, wherein said torque split unit cycles at a first frequency, wherein said traction and stability control unit cycles at a second frequency, and wherein said second frequency is between 10 and 30 times said first frequency.

3. The electric vehicle drive system of claim 2, wherein said first frequency is in the range of 100 Hz to 2 kHz.

4. The electric vehicle drive system of claim 1, further comprising at least one primary motor speed sensor and at least one assist motor speed sensor, said traction and stability control unit further comprising a second stage feedback control system for minimizing primary motor speed fast disturbances and assist motor speed fast disturbances, wherein said first torque limiter operates in response to said output from said first stage feedback control system and an output from said second stage feedback control system, and wherein said second torque limiter operates in response to said output from said first stage feedback control system and said output from said second stage feedback control system.

5. The electric vehicle drive system of claim 1, said traction and stability control unit further comprising a transient torque boost feedforward control circuit, wherein said transient torque boost feedforward control circuit acts on said output from said first stage feedback control system.

6. The electric vehicle drive system of claim 1, said torque control system further comprising a vehicle torque command generation unit for computing said total required drive torque request from said vehicle speed and from a plurality of user input sensors, said user input sensors comprised of a brake sensor and an accelerator sensor.

7. The electric vehicle drive system of claim 1, further comprising:

a primary motor speed sensor;

a primary motor temperature sensor;

an assist motor speed sensor;

an assist motor temperature sensor; and

wherein said torque control system further comprises;

a primary torque limiting unit for computing a primary motor maximum available torque, wherein said primary torque limiting unit is coupled to said primary motor speed and temperature sensors;

an assist torque limiting unit for computing an assist motor maximum available torque, wherein said assist torque limiting unit is coupled to said assist motor speed and temperature sensors; and

wherein said

first torque limiter limits said primary motor torque command by said primary motor maximum available torque; and

wherein said second torque limiter limits said assist motor torque command by said assist motor maximum available torque.

8. The electric vehicle drive system of claim 7, further comprising:

a primary power control module temperature sensor, wherein said primary torque limiting unit is coupled to said primary power control module temperature sensor; and

a secondary power control module temperature sensor, wherein said assist torque limiting unit is coupled to said secondary power control module temperature sensor.

9. The electric vehicle drive system of claim 7, further comprising:

a primary energy storage system (ESS) coupled to said primary power control module;

a primary ESS temperature sensor;

a primary ESS voltage sensor;

a primary ESS current sensor;

a secondary ESS coupled to said secondary power control module;

a secondary ESS temperature sensor;

a secondary ESS voltage sensor;

a secondary ESS current sensor; and

wherein said primary torque limiting unit is coupled to said primary ESS temperature, voltage and current sensors, and wherein said assist torque limiting unit is coupled to said secondary ESS temperature, voltage and current sensors.

10. The electric vehicle drive system of claim 7, further comprising:

an energy storage system (ESS) coupled to said primary and secondary power control modules;

an ESS temperature sensor;

an ESS voltage sensor;

an ESS current sensor; and

wherein said primary torque limiting unit is coupled to said ESS temperature, voltage and current sensors, and wherein said assist torque limiting unit is coupled to said ESS temperature, voltage and current sensors.

11. The electric vehicle drive system of claim 1, said torque control system further comprising:

a primary torque limiting unit for computing a primary motor maximum available torque, wherein said optimal primary motor torque request is limited by said primary motor maximum available torque; and

an assist torque limiting unit for computing an assist motor maximum available torque, wherein said optimal assist motor torque request is limited by said assist motor maximum available torque.

12. The electric vehicle drive system of claim 1, wherein said optimal primary motor torque request and said optimal assist motor torque request are interpolated from a look-up table.

13. The electric vehicle drive system of claim 1, wherein said torque split unit computes an optimal primary motor flux command and an optimal assist motor flux command, wherein said primary power control module is configured to receive said optimal primary motor flux commands and control said primary motor based on said primary motor torque commands and on said optimal primary motor flux commands, and wherein said secondary power control module is configured to receive said optimal assist motor flux commands and control said assist motor based on said assist motor torque commands and on said optimal assist motor flux commands.

14. The electric vehicle drive system of claim 1, further comprising:

a first motor speed sensor coupled to said primary electric motor and electrically connected to said torque control system;

a second motor speed sensor coupled to said assist electric motor and electrically connected to said torque control system; and

a steering sensor electrically connected to said torque control system; and

wherein said traction control command generation unit computes said vehicle speed based on output from said first motor speed sensor, said second motor speed sensor and said steering sensor.

15. A method of enhancing traction of an electric vehicle, the electric vehicle having a primary electric motor coupled to a first axle and an assist electric motor coupled to a second axle, the method comprising the steps of:

a) monitoring at least one first wheel speed sensor corresponding to said first axle and at least one second wheel speed sensor corresponding to said second axle, a primary motor speed sensor and an assist motor speed sensor, and computing a vehicle speed corresponding to said electric vehicle based on output from said at least one first wheel speed sensor, said at least one second wheel speed sensor, said primary motor speed sensor and said assist motor speed sensor, wherein said vehicle speed computing step is performed by a traction control command generation unit;

b) monitoring a brake sensor and an accelerator sensor, and computing a total torque requirement request based on output from said brake sensor and said accelerator sensor and said vehicle speed, wherein said total torque requirement request computing step is performed by a vehicle torque command generation unit;

c) splitting said total torque requirement request into an optimal primary motor torque request and an optimal assist motor torque request, wherein said total torque requirement request splitting step is performed by an optimal torque splitting unit;

d) inputting a first wheel target slip ratio and computing a first slip error corresponding to said first axle based on output from said at least one first wheel speed sensor and said vehicle speed and said first wheel target slip ratio, wherein said first slip error computing step is performed by said traction control command generation unit;

e) inputting a second wheel target slip ratio and computing a second slip error corresponding to said second axle based on output from said at least one second wheel speed sensor and said vehicle speed, wherein said second slip error computing step is performed by said traction control command generation unit;

f) minimizing said first slip error and said second slip error using a feedback control system implemented by a traction and stability control unit, said traction and stability control unit further performing the steps of transforming said optimal primary motor torque request into a primary motor torque command and transforming said optimal assist motor torque request into an assist motor torque command based on said step of minimizing said first slip error and said second slip error;

g) controlling said primary electric motor based on said primary motor torque command;

h) controlling said assist electric motor based on said assist motor torque command; and

i) repeating steps a)-h) throughout operation of said electric vehicle.

16. The method of claim 15, further comprising the step of:

monitoring a steering sensor, wherein said step of computing said vehicle speed is based on output from said at least one first wheel speed sensor, said at least one second wheel speed sensor, said primary motor speed sensor, said assist motor speed sensor, and said steering sensor.

17. The method of claim 15, wherein said total torque requirement request splitting step further comprises the step of interpolating data from a look-up table, said look-up table containing said optimal primary motor torque request and said optimal assist motor torque request as a function of said vehicle speed and said total torque requirement request.

18. The method of claim 15, step c) further comprising the steps of:

monitoring a primary motor temperature sensor;

computing a primary motor maximum available torque based on output from said primary motor speed sensor and said primary motor temperature sensor;

limiting said optimal primary motor torque request by said primary motor maximum available torque;

monitoring an assist motor temperature sensor;

computing an assist motor maximum available torque based on output from said assist motor speed sensor and said assist motor temperature sensor; and

limiting said optimal assist motor torque request by said assist motor maximum available torque.

19. The method of claim 18, further comprising the steps of:

monitoring a primary power control module temperature sensor, said primary power control module temperature sensor in thermal communication with a primary power control module, said primary power control module electrically connected to said primary motor, wherein said primary motor maximum available torque computing step is further based on output from said primary power control module temperature sensor; and

monitoring a secondary power control module temperature sensor, said secondary power control module temperature sensor in thermal communication with a secondary power control module, said secondary power control module electrically connected to said assist motor, wherein said assist motor maximum available torque computing step is further based on output from said secondary power control module temperature sensor.

20. The method of claim 18, further comprising the steps of:

monitoring a primary energy storage system (ESS) temperature sensor, said primary ESS temperature sensor in thermal communication with a primary ESS, said primary ESS electrically connected to a primary power control module, said primary power control module electrically connected to said primary motor;

monitoring a primary ESS voltage sensor;

monitoring a primary ESS current sensor, wherein said primary motor maximum available torque computing step is further based on output from said primary ESS temperature sensor, said primary ESS voltage sensor and said primary ESS current sensor;

monitoring a secondary ESS temperature sensor, said secondary ESS temperature sensor in thermal communication with a secondary ESS, said secondary ESS electrically connected to a secondary power control module, said secondary power control module electrically connected to said assist motor;

monitoring a secondary ESS voltage sensor; and

monitoring a secondary ESS current sensor, wherein said assist motor maximum available torque computing step is further based on output from said secondary ESS temperature sensor, said secondary ESS voltage sensor and said secondary ESS current sensor.

21. The method of claim 18, further comprising the steps of:

monitoring an energy storage system (ESS) temperature sensor, said ESS temperature sensor in thermal communication with an ESS, said ESS electrically connected to a primary power control module and to a secondary power control module, said primary power control module electrically connected to said primary motor, said secondary power control module electrically connected to said assist motor;

monitoring an ESS voltage sensor; and

monitoring an ESS current sensor, wherein said primary motor maximum available torque computing step and said assist motor maximum available torque computing step are further based on output from said ESS temperature sensor, said ESS voltage sensor and said ESS current sensor.

22. The method of claim 15, further comprising the steps of minimizing primary motor speed fast disturbances and assist motor speed fast disturbances using a second feedback control system implemented by said traction and stability control unit, wherein said steps of transforming said optimal primary motor torque request into said primary motor torque command and transforming said optimal assist motor torque request into said assist motor torque command are based on said step of minimizing said first slip error and said second slip error and based on said step of minimizing said primary motor speed fast disturbances and said assist motor speed fast disturbances.

23. The method of claim 15, step g) further comprising the steps of

monitoring a primary motor temperature sensor;

computing a primary motor maximum available torque based on output from said primary motor speed sensor and said primary motor temperature sensor;

limiting said primary motor torque command by said primary motor maximum available torque;

monitoring an assist motor temperature sensor;

computing an assist motor maximum available torque based on output from said assist motor speed sensor and said assist motor temperature sensor; and

limiting said assist motor torque command by said assist motor maximum available torque.

24. The method of claim 23, further comprising the steps of:

monitoring a primary power control module temperature sensor, said primary power control module temperature sensor in thermal communication with a primary power control module, said primary power control module electrically connected to said primary motor, wherein said primary motor maximum available torque computing step is further based on output from said primary power control module temperature sensor; and

monitoring a secondary power control module temperature sensor, said secondary power control module temperature sensor in thermal communication with a secondary power control module, said secondary power control module electrically connected to said assist motor, wherein said assist motor maximum available torque computing step is further based on output from said secondary power control module temperature sensor.

25. The method of claim 23, further comprising the steps of:

monitoring a primary energy storage system (ESS) temperature sensor, said primary ESS temperature sensor in thermal communication with a primary ESS, said primary ESS electrically connected to a primary power control module, said primary power control module electrically connected to said primary motor;

monitoring a primary ESS voltage sensor;

monitoring a primary ESS current sensor, wherein said primary motor maximum available torque computing step is further based on output from said primary ESS temperature sensor, said primary ESS voltage sensor and said primary ESS current sensor;

monitoring a secondary ESS temperature sensor, said secondary ESS temperature sensor in thermal communication with a secondary ESS, said secondary ESS electrically connected to a secondary power control module, said secondary power control module electrically connected to said assist motor;

monitoring a secondary ESS voltage sensor; and

monitoring a secondary ESS current sensor, wherein said assist motor maximum available torque computing step is further based on output from said secondary ESS temperature sensor, said secondary ESS voltage sensor and said secondary ESS current sensor.

26. The method of claim 23, further comprising the steps of:

monitoring an energy storage system (ESS) temperature sensor, said ESS temperature sensor in thermal communication with an ESS, said ESS electrically connected to a primary power control module and to a secondary power control module, said primary power control module electrically connected to said primary motor, said secondary power control module electrically connected to said assist motor;

monitoring an ESS voltage sensor; and

monitoring an ESS current sensor, wherein said primary motor maximum available torque computing step and said assist motor maximum available torque computing step are further based on output from said ESS temperature sensor, said ESS voltage sensor and said ESS current sensor.

27. The method of claim 15, wherein steps a) through e) are repeated at a first frequency and steps f) through h) are repeated at a second frequency, wherein said second frequency is between 10 and 30 times said first frequency.

28. The method of claim 15, wherein steps b) and c) are repeated at a first frequency, steps f) through h) are repeated at a second frequency between 10 and 30 times said first frequency, and wherein steps a), d) and e) are repeated at a third frequency, said third frequency between said first and second frequencies.

29. The method of claim 15, further comprising the step of computing an optimal primary motor flux command and an optimal assist motor flux command, wherein said step of computing said optimal primary motor flux command and said optimal assist motor flux command further comprises the step of interpolating data from a look-up table, said look-up table containing said optimal primary motor flux command and said optimal assist motor flux command as a function of said vehicle speed and said total torque requirement request.