Dual motor drive and control system for an electric vehicle

• US 8,453,770 B2
• Filed: 05/18/2010
• Issued: 06/04/2013
• Est. Priority Date: 01/29/2009
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Tang, Yifan
• Primary Examiner(s): Shriver, II, J. Allen
• Assistant Examiner(s): EVANS, BRYAN A
• Application Number:
  US12/782,413
• Publication Number:
  US 20100222953A1
• Time in Patent Office: 1,113 Days
• Field of Search: 180/65.1, 180/65.6, 180/65.7
• US Class Current: 180/65.1
• 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

A method and apparatus for optimizing the torque applied by each motor of a dual motor drive system 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 drive system, comprising;

a first electric motor, said first electric motor mechanically coupled to a vehicle drive axle, wherein said first electric motor provides propulsion power to a wheel of said vehicle drive axle;

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

a second electric motor, said second electric motor mechanically coupled to said vehicle drive axle, wherein said second electric motor provides propulsion power to said wheel of said vehicle drive axle; and

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

a wheel speed sensor; and

a torque control system electrically connected to said first and second power control modules and to said wheel speed sensor, wherein said torque control system outputs said first motor torque commands to said first power control module and outputs said second motor torque commands to said second 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 wheel speed sensor, and a slip error corresponding to said vehicle drive axle;

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

a traction control unit comprising;

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

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

a second torque limiter for transforming said optimal second motor torque request into said second 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 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 first motor speed sensor and at least one second motor speed sensor, said traction control unit further comprising a second stage feedback control system for minimizing first motor speed fast disturbances and second 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 control unit further comprising a torque boost feedforward control circuit, wherein said 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 6, wherein said total required drive torque request is further computed from a stability torque request generated by a vehicle stability control system.

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

a first motor speed sensor;

a first motor temperature sensor;

an second motor speed sensor;

an second motor temperature sensor; and

wherein said torque control system further comprises;

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

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

wherein said first torque limiter limits said first motor torque command by said first motor maximum available torque, and wherein said second torque limiter limits said second motor torque command by said second motor maximum available torque.

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

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

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

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

an energy storage system (ESS) coupled to said first and second power control modules;

an ESS temperature sensor;

an ESS voltage sensor;

an ESS current sensor; and

wherein said first torque limiting unit is coupled to said ESS temperature, voltage and current sensors, and wherein said second 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 first torque limiting unit for computing a first motor maximum available torque, wherein said optimal first motor torque request is limited by said first motor maximum available torque; and

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

12. The electric vehicle drive system of claim 1, wherein said optimal first motor torque request and said optimal second 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 first motor flux command and an optimal second motor flux command, wherein said first power control module is configured to receive said optimal first motor flux commands and control said first motor based on said first motor torque commands and on said optimal first motor flux commands, and wherein said second power control module is configured to receive said optimal second motor flux commands and control said second motor based on said second motor torque commands and on said optimal second motor flux commands.

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

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

a second motor speed sensor coupled to said second 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. The electric vehicle drive system of claim 1, wherein a first motor base speed corresponding to said first electric motor is at least 50% higher than a second motor base speed corresponding to said second electric motor.