Electric vehicle traction control system and method

• US 9,840,165 B2
• Filed: 10/20/2015
• Issued: 12/12/2017
• Est. Priority Date: 12/09/2011
• Status: Active Grant

• Current Assignee: Borealis Technical Limited (Borealis Exploration Ltd.)
• Original Assignee: Borealis Technical Limited (Borealis Exploration Ltd.)
• Inventors: Cox, Isaiah W.
• Primary Examiner(s): Khatib, Rami
• Application Number:
  US14/887,874
• Publication Number:
  US 20160107539A1
• Time in Patent Office: 784 Days
• Field of Search: None
• 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 15/2009 for braking
• CPC Class Codes: B60L 2200/10 Air crafts
• CPC Class Codes: B60L 2220/12 Induction machines
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/16 DC brushless machines
• CPC Class Codes: B60L 2220/18 Reluctance machines
• CPC Class Codes: B60L 2240/12 Speed
• 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 3/106 for maintaining or recovering the adhesion of the drive wheels
• CPC Class Codes: B60L 3/108 whilst braking, i.e. ABS
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 7/006 Dynamic electric braking by reversing current, i.e. plugging
• CPC Class Codes: B60L 7/18 Controlling the braking effect B60L7/12, B60L7/14, B60L7/16 take precedence
• CPC Class Codes: B64C 25/405 Powered wheels, e.g. for taxing
• 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 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility

Abstract

A traction control system and method are provided for electric vehicles with at least one drive wheel powered by an electric drive motor to maintain optimum maximum traction while the vehicle is driven on the ground. The traction control system includes drive means capable of transmitting torque through a vehicle drive wheel and controllable to move the vehicle over a ground surface. A preferred drive means is an electric motor designed to move the vehicle at desired ground speeds in response to operator input. Operator input requests a desired speed, and the system determines drive wheel torque required to produce the desired speed and provides maximum current to produce maximum torque to drive the vehicle with optimum traction at the desired speed. The system uses constant feedback to find maximum current corresponding to torque required for an inputted speed request to automatically control traction in any electric powered vehicle.

Claims

1. A method for controlling and maintaining optimal traction between wheels of a vehicle equipped with one or more drive wheels electrically powered to drive the vehicle and a drive surface on which said vehicle is driven comprising:

a. equipping a vehicle with one or more electric drive motors controllable to translate torque through one or more vehicle drive wheels to drive said vehicle on a drive surface, and providing a source of electric power supplying electric current to the one or more electric drive motors through one or more inverters, a vehicle operator input in communication with the one or more inverters and with a processor and a controller;

b. programming the processor to automatically select a motor model torque/speed curve for the one or more electric drive motors that defines optimal vehicle speed and traction on the drive surface and produces a motor commanded torque at an expected rotor speed for the optimal vehicle speed and traction on the drive surface as defined by the motor model torque/speed curve;

c. communicating a vehicle operator input comprising at least desired vehicle speed, motor commanded torque from desired vehicle speed, rotor speed, motor stator temperature, and available inverter voltage to the processor and setting the motor commanded torque at the expected rotor speed corresponding to the selected motor torque/speed curve in response to the communicated vehicle operator input;

d. automatically determining a maximum electric current to be supplied to the one or more electric drive motors to produce the motor commanded torque at the expected rotor speed to drive the one or more drive wheels on the drive surface;

e. automatically controlling the supply of electric current from the source of electric power to direct the determined maximum electric current to the one or more inverters in accordance with the selected motor torque/speed curve, maintaining the maximum electric current, and driving the vehicle with optimal traction on the drive surface; and

f. when the ground surface is icy and traction between at least one of the one or more drive wheels and the drive surface is lost, applying an amount of electric current to the one or more electric drive motors sufficient to melt ice under the at least one of the one or more drive wheels with heat generated by operation of the one or more electric drive motors.

2. The method of claim 1, further comprising communicating the desired vehicle speed to the processor, converting the desired speed into a torque required to drive the vehicle at the desired speed, determining the maximum electric current required for the one or more electric drive motors to translate the torque required to drive the vehicle at the desired speed in accordance with the selected motor model torque/speed curve, directing the determined maximum electric current to the one or more inverters, and maintaining the determined maximum electric current supplied to the one or more electric drive motors while the vehicle is driven on the icy drive surface.

3. The method of claim 2, further comprising continuously monitoring the desired vehicle speed during vehicle ground travel, automatically finding a maximum electric current draw for the desired vehicle speed, and applying the maximum electric current to the one or more drive motors.

4. The method of claim 1, further comprising measuring electric current consumed by the one or more drive motors, wherein a decrease in current consumed indicates that at least one of the one or more drive wheels is slipping and traction is not optimal.

5. The method of claim 4, further comprising when a decrease in electric current consumed is measured, intermittently supplying pulses of electric current to the one or more drive motors and restoring traction of the at least one of the one or more drive wheels to optimal.

6. The method of claim 1, further comprising maintaining a supply of electric current in the range of about 95% to 98% of the determined maximum electric current to the one or more drive motors, and reducing wear on tires mounted on the one or more drive wheels.

7. A method for controlling and maintaining optimal traction between wheels of a vehicle equipped with one or more drive wheels electrically powered to drive the vehicle and a drive surface on which said vehicle is driven comprising:

a. equipping a vehicle with one or more electric drive motors comprising induction electric motors controllable to translate torque through one or more vehicle drive wheels to drive said vehicle on a drive surface, and providing a source of electric power supplying electric current to the one or more electric drive motors through one or more inverters, a vehicle operator input in communication with the one or more inverters and with a processor and a controller;

b. programming the processor to automatically select a motor model torque/speed curve for the one or more electric drive motors that defines optimal vehicle speed and traction on the drive surface and produces a motor commanded torque at an expected rotor speed for the optimal vehicle speed and traction on the drive surface as defined by the motor model torque/speed curve;

c. communicating a vehicle operator input comprising at least desired vehicle speed, motor commanded torque from desired vehicle speed, rotor speed, motor stator temperature, and available inverter voltage to the processor and setting the motor commanded torque at the expected rotor speed corresponding to the selected motor torque/speed curve in response to the communicated vehicle operator input;

d. automatically determining a maximum electric current to be supplied to the one or more electric drive motors to produce the motor commanded torque at the expected rotor speed to drive the one or more drive wheels on the drive surface;

e. automatically controlling the supply of electric current from the source of electric power to direct the determined maximum electric current to the one or more inverters in accordance with the selected motor torque/speed curve, maintaining the maximum electric current, and driving the vehicle with optimal traction on the drive surface; and

f. providing an open loop torque control that uses vehicle operator inputs adjusted by limit laws to set the motor commanded torque at a value based on a motor model.

8. The method of claim 7, further comprising maintaining a supply of electric current to the one or more electric drive motors in the range of about 95% to 98% of the determined maximum electric current.

9. The method of claim 7, further comprising controlling and maintaining optimum traction between wheels of a vehicle selected from the group comprising automobiles, trucks, construction vehicles, military vehicles, aircraft, and trains and the drive surface on which the selected vehicle is driven in accordance with the automatically selected motor model torque/speed curve.

10. The method of claim 9, further comprising controlling and maintaining optimum traction in a vehicle comprising an automobile driven on a ground surface.

11. The method of claim 9, further comprising controlling and maintaining optimum traction in a vehicle comprising an aircraft driven on an airport ground surface.

12. The method of claim 7, further comprising continuously automatically determining the maximum electric current for the one or more electric drive motors, wherein the one or more drive motors are selected from the group of electric motors comprising toroidally-wound motors, axial flux motors, permanent magnet brushes motors, synchronous motors, pancake motors, switched reluctance motors, and induction motors, and automatically continuously supplying the determined maximum electric current for the selected one or more electric motors to the one or more inverters.

13. The method of claim 7, further comprising detecting a change in desired vehicle speed, comparing the changed desired vehicle speed to the motor model, and calculating a new synchronous speed to produce a desired motor commanded torque.

14. The method of claim 13, further comprising automatically detecting sudden acceleration of one of the one or more vehicle drive wheels indicating wheel slip on the drive surface, measuring wheel slip, and using the motor model to adjust motor commanded torque to control acceleration of the slipping wheel and produce optimal traction between the vehicle drive wheel and the drive surface.

15. The method of claim 14, further comprising, when sudden acceleration of the vehicle drive wheel is detected, controlling the motor driving the vehicle wheel by directly controlling the synchronous speed and selecting the motor torque/speed curve that produces optimal torque at a target wheel speed.