Method of operating a dual motor drive and control system for an electric vehicle

• US 8,761,985 B2
• Filed: 04/19/2013
• Issued: 06/24/2014
• 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): Zanelli, Michael J
• Application Number:
  US13/866,214
• Publication Number:
  US 20130241445A1
• Time in Patent Office: 431 Days
• Field of Search: None
• US Class Current: 701/22
• 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 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. A method of operating an electric vehicle, the electric vehicle having a first electric motor coupled to a vehicle drive axle and a second electric motor coupled to said vehicle drive axle, the method comprising the steps of:

a) monitoring a wheel speed sensor corresponding to said vehicle drive axle, a first motor speed sensor and a second motor speed sensor, and computing a vehicle speed corresponding to said electric vehicle based on output from said wheel speed sensor, said first motor speed sensor and said second 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 first motor torque request and an optimal second motor torque request, wherein said total torque requirement request splitting step is performed by an optimal torque splitting unit;

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

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

f) controlling said first electric motor based on said first motor torque command;

g) controlling said second electric motor based on said second motor torque command; and

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

2. The method of claim 1, further comprising the step of monitoring a steering sensor, wherein said step of computing said vehicle speed is based on output from said wheel speed sensor, said first motor speed sensor, said second motor speed sensor, and said steering sensor.

3. The method of claim 1, 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 first motor torque request and said optimal second motor torque request as a function of said vehicle speed and said total torque requirement request.

4. The method of claim 1, step c) further comprising the steps of:

monitoring a first motor temperature sensor;

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

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

monitoring a second motor temperature sensor;

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

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

5. The method of claim 4, further comprising the steps of:

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

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

6. The method of claim 4, further comprising the steps of:

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

monitoring a first ESS voltage sensor;

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

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

monitoring a second ESS voltage sensor; and

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

7. The method of claim 4, 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 first power control module and to a second power control module, said first power control module electrically connected to said first motor, said second power control module electrically connected to said second motor;

monitoring an ESS voltage sensor; and

monitoring an ESS current sensor, wherein said first motor maximum available torque computing step and said second 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.

8. The method of claim 1, further comprising the steps of minimizing first motor speed fast disturbances and second motor speed fast disturbances using a second feedback control system implemented by said traction control unit, wherein said steps of transforming said optimal first motor torque request into said first motor torque command and transforming said optimal second motor torque request into said second motor torque command are based on said step of minimizing said slip error and based on said step of minimizing said first motor speed fast disturbances and said second motor speed fast disturbances.

9. The method of claim 1, step e) further comprising the steps of:

monitoring a first motor temperature sensor;

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

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

monitoring a second motor temperature sensor;

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

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

10. The method of claim 9, further comprising the steps of:

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

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

11. The method of claim 9, further comprising the steps of:

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

monitoring a first ESS voltage sensor;

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

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

monitoring a second ESS voltage sensor; and

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

12. The method of claim 9, 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 first power control module and to a second power control module, said first power control module electrically connected to said first motor, said second power control module electrically connected to said second motor;

monitoring an ESS voltage sensor; and

monitoring an ESS current sensor, wherein said first motor maximum available torque computing step and said second 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.

13. The method of claim 1, wherein steps a) through d) are repeated at a first frequency and steps e) through g) are repeated at a second frequency, wherein said second frequency is between 10 and 30 times said first frequency.

14. The method of claim 1, wherein steps b) and c) are repeated at a first frequency, steps e) through g) are repeated at a second frequency between 10 and 30 times said first frequency, and wherein steps a) and d) are repeated at a third frequency, said third frequency between said first and second frequencies.

15. The method of claim 1, further comprising the step of computing an optimal first motor flux command and an optimal second motor flux command, wherein said step of computing said optimal first motor flux command and said optimal second motor flux command further comprises the step of interpolating data from a look-up table, said look-up table containing said optimal first motor flux command and said optimal second motor flux command as a function of said vehicle speed and said total torque requirement request.