Vehicle control using multiple sensors

• US RE42,464 E1
• Filed: 11/01/2004
• Issued: 06/14/2011
• Est. Priority Date: 03/15/2000
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Nada, Mitsuhiro
• Primary Examiner(s): ARTHUR JEANGLAUDE, GERTRUDE
• Application Number:
  US10/977,627
• Time in Patent Office: 2,416 Days
• Field of Search: 701/29, 701/34, 701/63, 701/70, 701/79, 123/399
• US Class Current: 701/34
• CPC Class Codes: B60K 26/04 of means connecting initiating means or elements to propulsion unit
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: B60L 2240/16 longitudinal
• CPC Class Codes: B60L 2240/486 Operating parameters
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 2250/28 Accelerator pedal thresholds
• CPC Class Codes: B60L 3/0023 Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/50 Control strategies for responding to system failures, e.g. for fault diagnosis, failsafe operation or limp mode
• CPC Class Codes: B60W 2050/0215 Sensor drifts or sensor failures
• CPC Class Codes: B60W 2520/10 Longitudinal speed
• CPC Class Codes: B60W 2520/105 Longitudinal acceleration
• CPC Class Codes: B60W 2530/14 Historical data
• CPC Class Codes: B60W 2540/10 Accelerator pedal position
• CPC Class Codes: B60W 2540/103 Accelerator thresholds, e.g. kickdown
• CPC Class Codes: B60W 2540/106 : Rate of change
• CPC Class Codes: B60W 2540/12 : Brake pedal position
• CPC Class Codes: B60W 2540/16 : Ratio selector position
• CPC Class Codes: B60W 2710/105 : Output torque
• CPC Class Codes: B60W 2720/106 : Longitudinal acceleration
• CPC Class Codes: F02D 11/107 : Safety-related aspects
• CPC Class Codes: F02D 2200/0404 : Throttle position
• CPC Class Codes: F02D 2200/602 : Pedal position
• CPC Class Codes: F02D 2400/08 : Redundant elements, e.g. two sensors for measuring the same parameter
• CPC Class Codes: F02D 41/222 : relating to the failure of sensors or parameter detection devices
• CPC Class Codes: F16H 2061/1208 : with diagnostic check cycles; Monitoring of failures
• CPC Class Codes: F16H 2061/1284 : the failing part is a sensor
• CPC Class Codes: Y02T 10/6217 : of the series type or range extenders
• CPC Class Codes: Y02T 10/6239 : Differential gearing distribution type
• CPC Class Codes: Y02T 10/6286 : Control systems for power distribution between ICE and other motor or motors
• CPC Class Codes: Y02T 10/7077 : on board the vehicle

Abstract

One of the two accelerator sensors 165a and 165b is detected faulty by analyzing variation patterns outputted by the two sensors even when the outputs of two sensors remain within their respective normal output ranges. An accelerator control input is determined using the output of the fault-free sensor if a faulty sensor is detected. The fault detector detects the faulty sensor by analyzing variation patterns of outputs of the first and second accelerator sensors when the outputs of the first and second accelerator sensors remain within respective normal output ranges thereof.

Claims

1. A control device for controlling a vehicle using first and second accelerator sensors configured to provide an accelerator control input, the control device comprising:

a fault detector configured to detect that one of the first and second accelerator sensors has developed a fault; and

an accelerator control input setting section configured to determine the accelerator control input using an output of a normal sensor other than a faulty sensor when the faulty sensor has been detected by the fault detector,

the accelerator control input setting section dividing a full range of output signal levels of the normal sensor into a plurality of regions including an opening region in which the accelerator control input increases at a first rate of change, and a closing region in which the accelerator control input decreases at a second rate of change,

the accelerator control input setting section determining a change in the accelerator control input depending on which of the plurality of regions contains the output signal level of the normal sensor.

2. A control device as defined in claim 1, wherein the plurality of regions have a holding region disposed between the opening region and the closing region and designed to keep the accelerator control input constant.

3. A control device as defined in claim 1, wherein at least one of the opening region and the closing region is divided into a plurality of smaller regions whose rates of change are set to mutually different levels.

4. A control device as defined in claim 1, wherein the accelerator control input setting section varies the rate of change according to a vehicle speed in at least one of the opening region and the closing region.

5. A control device as defined in claim 4, wherein the accelerator control input setting section increases the rate of change with an increase in vehicle speed in at least one of the opening region and the closing region.

6. A control device as defined in claim 1, wherein the accelerator control input setting section sets the accelerator control input to zero when a brake pedal of the vehicle is stepped on.

7. A control device as defined in claim 1, wherein the accelerator control input setting section determines the change in the accelerator control input in accordance with an actual acceleration of the vehicle and with which of the plurality of regions the output signal level of the normal sensor falls within.

8. A control device as defined in claim 7, wherein the accelerator control input setting section increases the accelerator control input stepwise at least once when the output signal level of the normal sensor falls within the opening region and an anticipated vehicle acceleration for a travel mode of the vehicle is opposite in sign to an actual acceleration of the vehicle.

9. A control device as defined in claim 7, wherein the accelerator control input setting section increases the accelerator control input stepwise at least once when the output signal level of the normal sensor falls within the opening region and an actual acceleration of the vehicle is below a preset minimum acceleration established in accordance with the vehicle speed.

10. A control device as defined in claim 7, wherein the vehicle is provided with at least one electric motor with a rotational angle sensor as a prime mover for driving an axle;

and

the accelerator control input setting section determines the actual acceleration of the vehicle from an output of the rotation angle sensor of the electric motor.

11. A control device as defined in claim 1, wherein the fault detector detects the faulty sensor by analyzing variation patterns of outputs of the first and second accelerator sensors when the outputs of the first and second accelerator sensors remain within respective normal output ranges thereof.

12. A control device as defined it claim 11, wherein the fault detector detects the faulty sensor by determining whether the variation pattern outputted by each sensor corresponds to one of a plurality of preset fault patterns.

13. A control device as defined in claim 12, wherein the plurality of fault patterns include at least one pattern selected from:

i) stepped variations of sensor output,

ii) oscillations of sensor output,

iii) abnormal variation of difference in the outputs of the first and second sensors, and

iv) abnormally fixed state of sensor output.

14. A control device as defined in claim 12, further comprising a fault history recorder configured to record a fault history that describes the detected fault pattern.

15. A control device as defined in claim 11, wherein when the accelerator control input is set using the normal sensor other than the faulty sensor, the accelerator control input setting section sets the accelerator control input on the basis of the output of the normal sensor such that the accelerator control input is below the level that will be obtained from the same sensor when both the first and second accelerator sensors are in a normal state.

16. A control device as defined in claim 11, wherein when the output of either the first or second accelerator sensor varies abruptly at a rate of change greater than a predetermined threshold value, the accelerator control input setting section sets the accelerator control input on the basis of the output of a sensor other than the sensor with the abruptly varying output in a provisional period between a moment the output undergoes the abrupt change and a later moment the fault detector determines that a fault has occurred.

17. A control device as defined in claim 11, wherein when the output of either the first or second sensor varies abruptly at a rate of change greater than a predetermined threshold value, the accelerator control input setting section adopts the lesser of the two accelerator control inputs obtained from the outputs of the first and second accelerator sensors in a provisional period between a moment the output undergoes the abrupt change and a later moment the fault detector determines that a fault has occurred.

66. The control device of claim 1, wherein the normal sensor is one of the first and second sensors, the output of the normal sensor being an output subsequent to the determination of the faulty sensor.

18. A vehicle comprising:

a prime mover configured to drive an axle of the vehicle; and

a control device configured to control the prime mover using first and second accelerator sensors for provide an accelerator control input as a control input,

the control device including;

a fault detector configured detect that one of the first and second accelerator sensors has developed a fault; and

an accelerator control input setting section configured to determine the accelerator control input using an output of a normal sensor other than a faulty sensor when the faulty sensor has been detected by the fault detector,

the accelerator control input setting section dividing a full range of output signal levels of the normal sensor into a plurality of regions including an opening region in which the accelerator control input increases at a first rate of change, and a closing region in which the accelerator control input decreases at a second rate of change,

the accelerator control input setting section determining a change in the accelerator control input depending on which of the plurality of regions contains the output signal level of the normal sensor.

19. A vehicle as defined in claim 18, wherein the plurality of regions have a holding region disposed between the opening region and the closing region and designed to keep the accelerator control input constant.

20. A vehicle as defined in claim 18, wherein at least one of the opening region and the closing region is divided into a plurality of smaller regions whose rates of change are set to mutually different levels.

21. A vehicle as defined in claim 18, wherein the accelerator control input setting section varies the rate of change according to a vehicle speed in at least one of the opening region and the closing region.

22. A vehicle as defined in claim 21, wherein the accelerator control input setting section increases the rate of change with an increase in vehicle speed in at least one of the opening region and the closing region.

23. A vehicle as defined in claim 18, wherein the accelerator control input setting section sets the accelerator control input to zero when a brake pedal of the vehicle is stepped on.

24. A vehicle as defined in claim 18, wherein the accelerator control input setting section determines the change in the accelerator control input in accordance with an actual acceleration of the vehicle and with which of the plurality of regions the output signal level of the normal sensor falls within.

25. A vehicle as defined in claim 24, wherein the accelerator control input setting section increases the accelerator control input stepwise at least once when the output signal level of the normal sensor falls within the opening region and an anticipated vehicle acceleration for a travel mode of the vehicle is opposite in sign to an actual acceleration of the vehicle.

26. A vehicle as defined in claim 24, wherein the accelerator control input setting section increases the accelerator control input stepwise at least once when the output signal level of the normal sensor falls within the opening region and an actual acceleration of the vehicle is below a preset minimum acceleration established in accordance with the vehicle speed.

27. A vehicle as defined in claim 24, wherein the prime mover includes at least one electric motor with a rotational angle sensor;

and

the accelerator control input setting section determines the actual acceleration of the vehicle from an output of the rotation angle sensor of the electric motor.

28. A vehicle as defined in claim 18, wherein the fault detector detects the faulty sensor by analyzing variation patterns of outputs of the first and second accelerator sensors when the outputs of the first and second accelerator sensors remain within respective normal output ranges thereof.

29. A vehicle as defined in claim 28, wherein the fault detector detects the faulty sensor by determining whether the variation pattern outputted by each sensor corresponds to one of a plurality of preset fault patterns.

30. A vehicle as defined in claim 29, wherein the plurality of fault patterns include at least one pattern selected from:

i) stepped variations of sensor output,

ii) oscillations of sensor output,

iii) abnormal variation of difference in the outputs of the first and second sensors, and

iv) abnormally fixed state of sensor output.

31. A vehicle as defined in claim 29, wherein the control device further comprises a fault history recorder configured to record a fault history that describes the detected fault pattern.

32. A vehicle as defined in claim 28, wherein when the accelerator control input is set using the normal sensor other than the faulty sensor, the accelerator control input setting section sets the accelerator control input on the basis of the output of the normal sensor such that the accelerator control input is below the level that will be obtained from the same sensor when both the first and second accelerator sensors are in a normal state.

33. A vehicle as defined in claim 28, wherein when the output of either the first or second accelerator sensor varies abruptly at a rate of change greater than a predetermined threshold value, the accelerator control input setting section sets the accelerator control input on the basis of the output of a sensor other than the sensor with the abruptly varying output in a provisional period between a moment the output undergoes the abrupt change and a later moment the fault detector determines that a fault has occurred.

34. A vehicle as defined in claim 28, wherein when the output of either the first or second sensor varies abruptly at a rate of change greater than a predetermined threshold value, the accelerator control input setting section adopts the lesser of the two accelerator control inputs obtained from the outputs of the first and second accelerator sensors in a provisional period between a moment the output undergoes the abrupt change and a later moment the fault detector determines that a fault has occurred.

67. The vehicle of claim 18, wherein the normal sensor is one of the first and second sensors, the output of the normal sensor being an output subsequent to the determination of the faulty sensor.

35. A control method for controlling a vehicle using first and second accelerator sensors configured to provide an accelerator control input as a control input, the control method comprising the steps of:

(a) detecting that one of the first and second accelerator sensors has developed a fault; and

(b) determine the accelerator control input using an output of a normal sensor other than a faulty sensor when the faulty sensor has been detected,

the step (b) including the steps of;

dividing a full range of output signal levels of the normal sensor into a plurality of regions including an opening region in which the accelerator control input increases at a first rate of change, and a closing region in which the accelerator control input decreases at a second rate of change, and

determining a change in the accelerator control input depending on which of the plurality of regions contains the output signal level of the normal sensor.

36. A control method as defined in claim 35, wherein the plurality of regions have a holding region disposed between the opening region and the closing region and designed to keep the accelerator control input constant.

37. A control method as defined in claim 35, wherein at least one of the opening region and the closing region is divided into a plurality of smaller regions whose rates of change are set to mutually different levels.

38. A control method as defined in claim 35, wherein the rate of change varies according to a vehicle speed in at least one of the opening region and the closing region.

39. A control method as defined in claim 38, wherein the rate of change increases with an increase in vehicle speed in at least one of the opening region and the closing region.

40. A control method as defined in claim 35, wherein the accelerator control input is set to zero when a brake pedal of the vehicle is stepped on.

41. A control method as defined in claim 35, wherein the change in the accelerator control input is determined in accordance with an actual acceleration of the vehicle and with which of the plurality of regions the output signal level of the normal sensor falls within.

42. A control method as defined in claim 41, wherein the accelerator control input increases stepwise at least once when the output signal level of the normal sensor falls within the opening region and an anticipated vehicle acceleration for a travel mode of the vehicle is opposite in sign to an actual acceleration of the vehicle.

43. A control method as defined in claim 41, wherein the accelerator control input increases stepwise at least once when the output signal level of the normal sensor falls within the opening region and an actual acceleration of the vehicle is below a preset minimum acceleration established in accordance with the vehicle speed.

44. A control method as defined in claim 41, wherein the vehicle is provided with at least one electric motor with a rotational angle sensor as a prime mover for driving an axle:

and

the actual acceleration of the vehicle is determined from an output of the rotation angle sensor of the electric motor.

45. A control method as defined in claim 35, wherein the faulty sensor is detected by analyzing variation patterns of outputs of the first and second accelerator sensors when the outputs of the first and second accelerator sensors remain within respective normal output ranges thereof.

46. A control method as defined in claim 45, wherein when the accelerator control input is set using the normal sensor other than the faulty sensor, the accelerator control input is set on the basis of the output of the normal sensor such that the accelerator control input is below the level that will be obtained from the same sensor when both the first and second accelerator sensors are in a normal state.

47. A control method as defined in claim 45, wherein when the output of either the first or second accelerator sensor varies abruptly at a rate of change greater than a predetermined threshold value, the accelerator control input is set on the basis of the output of a sensor other than the sensor with the abruptly varying output in a provisional period between a moment the output undergoes the abrupt change and a later moment the fault detector determines that a fault has occurred.

48. A control method as defined in claim 45, wherein when the output of either the first or second sensor varies abruptly at a rate of change greater than a predetermined threshold value, the lesser of the two accelerator control inputs obtained from the outputs of the first and second accelerator sensors is adopted in a provisional period between a moment the output undergoes the abrupt change and a later moment the fault detector determines that a fault has occurred.

49. A control method as defined in claim 45, wherein the faulty sensor is detected by determining whether the variation pattern outputted by each sensor corresponds to one of a plurality of preset fault patterns.

50. A control method as defined in claim 49, wherein the plurality of fault patterns include at least one pattern selected from:

i) stepped variations of sensor output,

ii) oscillations of sensor output,

iii) abnormal variation of difference in the outputs of the first and second sensors, and

iv) abnormal fixed state of sensor output.

51. A control method as defined in claim 49, further comprising the step of recording a fault history that describes the detected fault pattern in a non-volatile memory.

68. The control method of claim 35, wherein the normal sensor is one of the first and second sensors, the output of the normal sensor being an output subsequent to the determination of the faulty sensor.

52. A control device for controlling a prescribed control object using first and second sensors configured to provide a control input, the control device comprising:

a fault detector configured to detect that one of the first and second sensors has developed a fault by analyzing temporal variation patterns of outputs of the first and second sensors when the outputs of the first and second sensors remain within respective normal output ranges thereof, the fault detector detecting a faulty sensor by determining whether the temporal variation pattern output by each sensor corresponds to one of a plurality of preset fault patterns that represent mutually different fault events; and

a control input setting section configured to determine the control input using an output of a normal sensor other than the faulty sensor when the faulty sensor has been detected by the fault detector,

the control input setting section dividing a full range of output signal levels of the normal sensor into a plurality of regions in which the control input changes at different rates of change,

the control input setting section determining a change in the control input depending on which of the plurality of regions contains the output signal level of the normal sensor.

53. A control device as defined in claim 52, wherein the plurality of fault patterns include at least one pattern selected from:

i) stepped variations of sensor output,

ii) oscillations of sensor output,

iii) abnormal variation of difference in the outputs of the first and second sensors, and

iv) abnormally fixed state of sensor output.

54. A control device as defined in claim 53, further comprising a fault history recorder configured to record a fault history that describes the detected fault pattern.

56. A control device as defined in claim 52, wherein when the output of either the first or second sensor varies abruptly at a rate of change greater than a predetermined threshold value, the control input setting section determines the control input based on the output of a sensor other than the sensor with the abruptly varying output in a provisional period between a moment the output undergoes the abrupt change and a later moment when the fault detector determines that a fault has occurred.

57. A moving body comprising:

a prime mover; and

a control device according to claim 52 for controlling the prime mover.

69. The control device of claim 52, wherein the normal sensor is one of the first and second sensors, the output of the normal sensor being an output subsequent to the determination of the faulty sensor.

71. The control device of claim 52, wherein the temporal variation pattern output includes a plurality of outputs at a plurality of respective times.

55. A control device for controlling a prescribed control object using first and second sensors configured to provide a control input, the control device comprising:

a fault detector configured to detect that one of the first and second sensors has developed a fault by analyzing temporal variation patterns of outputs of the first and second sensors when the outputs of the first and second sensors remain within respective normal output ranges thereof, the fault detector detecting a faulty sensor by determining whether the temporal variation pattern output by each sensor corresponds to one of a plurality of preset fault patterns that represent mutually different fault events; and

a control input setting section configured to determine the control input using an output of a normal sensor other than the faulty sensor when the faulty sensor has been detected by the fault detector,

the control input setting section dividing a full range of output signal levels of the normal sensor into a plurality of regions in which the control input changes at different rates of change,

the control input setting section determining a change in the control input depending on which of the plurality of regions contains the output signal level of the normal sensor,

wherein the control input is determined by multiplying a control input value obtained from the output of the normal sensor by a prescribed coefficient less than 1.

58. A control method for controlling a prescribed control object using first and second sensors configured to provide a control input, comprising the steps of:

(a) detecting that one of the first and second sensors has developed a fault by analyzing temporal variation patterns of outputs of the first and second sensors when the outputs of the first and second sensors remain within respective normal output ranges thereof, and

(b) determining the control input using an output of a normal sensor other than a faulty sensor when the faulty sensor has been detected,

wherein the step (a) includes the step of detecting the faulty sensor by determining whether the temporal variation pattern output by each sensor corresponds to one of a plurality of preset fault patterns that represent mutually different fault events, and

the step (b) includes the steps of;

dividing a full range of output signal levels of the normal sensor into a plurality of regions in which the control input changes at different rates of change, and

determining a change in the control input depending on which of the plurality of regions contains the output signal level of the normal sensor.

59. A control method as defined in claim 58, wherein the plurality of fault patterns include at least one pattern selected from:

i) stepped variations of sensor output,

ii) oscillations of sensor output,

iii) abnormal variation of difference in the outputs of the first and second sensors, and

iv) abnormally fixed state of sensor output.

60. A control method as defined in claim 59, further comprising the step of recording a fault history that describes the detected fault pattern.

62. A control method as defined in claim 58, wherein when the output of either the first or second sensor varies abruptly at a rate of change greater than a predetermined threshold value, the control input is determined based on the output of a sensor other than the sensor with the abruptly varying output in a provisional period between a moment the output undergoes the abrupt change and a later moment when it is determined that a fault has occurred.

70. The control method of claim 58, wherein the normal sensor is one of the first and second sensors, the output of the normal sensor being an output subsequent to the determination of the faulty sensor.

72. The control method of claim 58, wherein the temporal variation pattern output includes a plurality of outputs at a plurality of respective times.

61. A control method for controlling a prescribed control object using first and second sensors configured to provide a control input, comprising the steps of:

(a) detecting that one of the first and second sensors has developed a fault by analyzing temporal variation patterns of outputs of the first and second sensors when the outputs of the first and second sensors remain within respective normal output ranges thereof, and

(b) determining the control input using an output of a normal sensor other than a faulty sensor when the faulty sensor has been detected,

wherein the step (a) includes the step of detecting the faulty sensor by determining whether the temporal variation pattern output by each sensor corresponds to one of a plurality of preset fault patterns that represent mutually different fault events,

wherein the step (b) includes the steps of;

dividing a full range of output signal levels of the normal sensor into a plurality of regions in which the control input changes at different rates of change, and

determining a change in the control input depending on which of the plurality of regions contains the output signal level of the normal sensor,

wherein the control input is determined by multiplying a control input value obtained from the output of the normal sensor by a prescribed coefficient less than 1.

63. A control device for controlling a prescribed control object using first and second sensors configured to provide identical control inputs when the first and second sensors are operating normally, the control device comprising:

a fault detector configured to detect that one of the first and second sensors has developed a fault, by analyzing temporal variation patterns of outputs of the first and second sensors when the outputs of the first and second sensors remain within respective normal output ranges thereof, the fault detector detecting a faulty sensor by determining whether the temporal variation pattern output by each sensor corresponds to one of a plurality of preset fault patterns that represent mutually different fault events; and

a control input setting section configured to determine the control input using outputs of the first and second sensors,

the control input setting section dividing a full range of output signal levels of the first or second sensor into a plurality of regions in which the control input changes at different rates of change,

the control input setting section determining a change in the control input depending on which of the plurality of regions contains the output signal level of the first or second sensor,

wherein, upon detection of a fault with respect to at least one of the first and second sensors, the control input setting section ignores the control inputs obtained from the outputs of the first and second sensors when the first and second sensors do not provide substantially identical control inputs, and the control input setting section determines the control input from the outputs of the first and second sensors when the first and second sensors provide substantially identical control inputs.

64. A moving body comprising:

a prime mover; and

a control device according to claim 63 for controlling the prime mover.

73. The control device of claim 63, wherein the temporal variation pattern output includes a plurality of outputs at a plurality of respective times.

65. A control method for controlling a prescribed control object using first and second sensors configured to provide identical control inputs when the first and second sensors are operating normally, the method comprising the steps of:

detecting that one of the first and second sensors has developed a fault, by analyzing temporal variation patterns of outputs of the first and second sensors when the outputs of the first and second sensors remain within respective normal output ranges thereof, a faulty sensor being detected by determining whether the temporal variation pattern output by each sensor corresponds to one of a plurality of preset fault patterns that represent mutually different fault events;

dividing a full range of output signal levels of the first or second sensor into a plurality of regions in which the control input changes at different rates of change, and

determining a change in the control input depending on which of the plurality of regions contains the output signal level of the first or second sensor, and upon detection of a fault with respect to at least one of the first and second sensors, ignoring the control inputs obtained from the outputs of the first and second sensors when the first and second sensors do not provide substantially identical control inputs, and determining the control input from the outputs of the first and second sensors when the first and second sensors provide substantially identical control inputs.

74. The control method of claim 65, wherein the temporal variation pattern output includes a plurality of outputs at a plurality of respective times.