Torque-equalizing fault response for electric vehicle

Patent metadata

Field	Value
Publication number	US-11712967-B2
Application number	US-202117389058-A
Country	US
Kind code	B2
Filing date	Jul 29, 2021
Priority date	Jul 29, 2021
Publication date	Aug 1, 2023
Grant date	Aug 1, 2023

Abstract

Various disclosed embodiments include illustrative controllers, dual power inverter modules, and electric vehicles. In an illustrative embodiment, a controller includes one or more processors associated with a first and second power inverter for the drive unit. Computer-readable media for the one or more processors are each configured to store computer-executable instructions configured to cause the one or more processors to apply a same fault action to the first power inverter and the second power inverter responsive to a fault associated with an inverter chosen from the first power inverter and the second power inverter, wherein the same fault action includes applying equalized torque to each axle operatively coupled to the drive unit.

First claim

What is claimed is:

1. A controller comprising:
one or more processors associated with a first and second power inverter for a drive unit for an electric vehicle; and
one or more computer-readable media for the one or more processors, each being configured to store computer-executable instructions configured to cause its associated processor to apply a same fault action to the first power inverter and the second power inverter responsive to a fault associated with an inverter chosen from the first power inverter and the second power inverter, wherein the same fault action includes applying equalized torque to each axle operatively coupled to the drive unit;
wherein the computer-executable instructions are further configured to cause its associated processor to monitor for the fault;
wherein the fault action further includes an action chosen from causing all of a plurality of banks of three-terminal power semiconductor devices in the first power inverter and the second power inverter to open when motor speed is less than a threshold speed and causing one bank of three-terminal power semiconductor devices in each of the first power inverter and the second power inverter to short when motor speed is greater than the threshold speed.

2. The controller of claim 1 , further comprising a communications link, wherein the one or more processors includes a first processor associated with the first power inverter for the drive unit and a second processor associated with the second power inverter, and the communications link is between the first processor and the second processor.

3. The controller of claim 2 , further comprising three-phase short circuitry external to the first processor and the second processor and configured to apply a same fault action to the first power inverter and the second power inverter responsive to a fault not monitored by the first processor and the second processor, wherein the same fault action includes applying equalized torque to each axle operatively coupled to the drive unit.

4. The controller of claim 3 , further comprising health monitoring circuitry configured to monitor health of the first processor and the second processor.

5. The controller of claim 4 , wherein: the fault includes a fault chosen from a fault in a processor chosen from the first processor and the second processor and a fault in the health monitoring circuitry; and the three-phase short circuitry is further configured to cause one bank of three-terminal power semiconductor devices in the first power inverter and the second power inverter to short responsive to the fault chosen from a fault in a processor chosen from the first processor and the second processor and the fault in the health monitoring circuitry.

6. A dual power inverter module comprising:
a DC link capacitor electrically connectable to a source of high voltage direct current (DC) electrical power;
a first power inverter electrically connectable to the DC link capacitor and configured to convert high voltage DC electrical power to three phase high voltage alternating current (AC) electrical power, the first power inverter being further configured to supply the three phase high voltage AC electrical power to a first electric motor;
a second power inverter electrically connectable to the DC link capacitor and configured to convert high voltage DC electrical power to three phase high voltage AC electrical power, the second power inverter being further configured to supply the three-phase high voltage AC electrical power to a second electric motor; and
a controller including:
one or more processors associated with a first and second power inverter for a drive unit for an electric vehicle; and
one or more computer-readable media for the one or more processors, each being configured to store computer-executable instructions configured to cause its associated processor to apply a same fault action to the first power inverter and the second power inverter responsive to a fault associated with an inverter chosen from the first power inverter and the second power inverter, wherein the same fault action includes applying equalized torque to each axle operatively coupled to the drive unit;
wherein the computer-executable instructions are further configured to cause its associated processor to monitor for the fault;
wherein the fault action further includes an action chosen from causing all of a plurality of banks of three-terminal power semiconductor devices in the first power inverter and the second power inverter to open when motor speed is less than a threshold speed and causing one bank of three-terminal power semiconductor devices in each of the first power inverter and the second power inverter to short when motor speed is greater than the threshold speed.

7. The module of claim 6 , further comprising a communications link, wherein the one or more processors includes a first processor associated with the first power inverter for the drive unit and a second processor associated with the second power inverter, and the communications link is between the first processor and the second processor.

8. The module of claim 7 , further comprising three-phase short circuitry external to the first processor and the second processor and configured to apply a same fault action to the first power inverter and the second power inverter responsive to a fault not monitored by the first processor and the second processor, wherein the same fault action includes applying equalized torque to each axle operatively coupled to the drive unit.

9. The module of claim 8 , further comprising health monitoring circuitry configured to monitor health of the first processor and the second processor.

10. The module of claim 9 , wherein: the fault includes a fault chosen from a fault in a processor chosen from the first processor and the second processor and a fault in the health monitoring circuitry; and the three-phase short circuitry is further configured to cause one bank of three-terminal power semiconductor devices in the first power inverter and the second power inverter to short responsive to the fault chosen from a fault in a processor chosen from the first processor and the second processor and the fault in the health monitoring circuitry.

11. An electric vehicle comprising:
a vehicle body;
a high voltage direct current (DC) electrical battery disposed within the vehicle body;
first and second electric motors mechanically couplable to rotate at least one set of axles; and
at least one dual power inverter module including:
a DC link capacitor electrically connectable to the high voltage DC electrical battery;
a first power inverter electrically connectable to the DC link capacitor and configured to convert high voltage DC electrical power to three phase high voltage alternating current (AC) electrical power, the first power inverter being further configured to supply the three phase high voltage AC electrical power to an electric motor chosen from the first and second electric motors;
a second power inverter electrically connectable to the DC link capacitor and configured to convert high voltage DC electrical power to three phase high voltage AC electrical power, the second power inverter being further configured to supply the three-phase high voltage AC electrical power to the other electric motor chosen from the first and second electric motors; and
a common controller electrically connectable to the first power inverter and the second power inverter, the common controller being configured to control the first power inverter and the second power inverter, the common controller including:
one or more processors associated with the first and second power inverter

Assignees

• Rivian Ip Holdings Llc

Inventors

• Breese Richard M
• Harries Brian N
• Hiti Silva
• Kowalewski Daniel L
• Schulz Steven E
• Tang David

Classifications

• B60L3/003 Primary

  relating to inverters · CPC title

• B60L3/0092

  with use of redundant elements for safety purposes · CPC title

• B60L50/51 Primary

  characterised by AC-motors · CPC title

• B60L2210/40

  DC to AC converters · CPC title

• B60L2240/421

  Speed · CPC title