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Advanced Redundancy Technology for a Drive System Using In-Wheel

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Advanced Redundancy Technology for a Drive System Using In-Wheel ISSN 2032-6653 The World Electric Vehicle Association Journal, Vol. 1, 2007 Advanced Redundancy Technology for a Drive System Using In-Wheel Motors Kiyomoto Kawakami*, Hidetoshi Tanabe**, Hiroshi Shimizu*, Hiroichi Yoshida* In electric vehicles that use in-wheel motors, the right and left traction forces become unbalanced if a motor malfunctions by motor lock or loss of traction, generating yaw moment. Control methods were designed to reduce this effect by stopping the motor output on the opposite side of the same axle. By using a prototype “Eliica” car, the maximum yaw rate and lateral acceleration were compared for a breakdown of one motor with the results from the “Sensitivity to lateral wind” indicated in Z108-76 of the Japanese Automobile Standards Organization. Under redundancy control, the test results were confirmed to be below the tolerance limits Keywords: Wheel Motor, Inverter, Control System, Vehicle Stability, Safety center-of-gravity point (CG) of the vehicle. Therefore, a 1. INTRODUCTION control method for the situation in which a motor Several prototype electric vehicles (EVs) with motors breaks down is important for achieving redundancy for installed in each wheel that exploit the torque a drive system that uses in-wheel motors. characteristics of the in-wheel motor [1] have been Our intention is to enhance the merits of function and developed by KEIO University. Unlike an internal safety of EVs by achieving a redundancy technology for combustion engine, an electric motor can generate drive systems that use in-wheel motors. maximum torque from standing still to a high speed. First in this report, the influence on vehicle stability The purpose of our research is to develop redundancy by a motor malfunction is described. Next, the results technology for the drive system of EVs that use of a fault tree analysis (FTA) of the case in which the in-wheel motors by constructing a control method for right and left traction forces become unbalanced are use in the case of motor malfunction, that optimizes the presented. Then, based on these results, an optimum composition of the drive system parts to maintain the formation of a drive system that uses in-wheel motors vehicle’s advantages and safety. and a control method of redundancy technology are An EV that uses in-wheel motors has the following proposed. Finally, by using a prototype vehicle “Eliica” three advantages: which these technologies were added, the utility of this 1) The freedom of the car’s design increases because study was evaluated. the motor is excluded from the usual engine compartment. As a result, a vehicle body shape with 2. INFLUENCES ON VEHICLE STABILITY low air drag and excellent collision safety can be achieved comparatively easily. BY UNBALANCED TRACTION FORCES 2) The independent direct control of the traction Figure 1 shows the vehicle model of the force of each wheel can be used for such applications as eight-wheel-drive (8WD) Eliica. The 8WD has nearly traction control and dynamic stability control with the same dynamics as 4WD, the difference being that excellent results [2]. 8WD has four axles, which are numbered 1 through 4 3) When one motor breaks down, driving can from the front, and the first two axles are steered. continue with the other motors. The cornering forces and the traction forces that The third advantage in particular is achieved in EVs occur on each tire are defined as shown in the figure as of the in-wheel motor type, in which two or more Cfl1, Cfr1, Cfl2, Cfr2, Crl1, Crr1, Crl2, Crr2, and Tl1, Tr1, Tl2, motors are installed. On the other hand, in such an EV, Tr2, Tl3, Tr3, Tl4, Tr4, respectively. The yaw moment the right and left traction forces become unbalanced if generated around the z-axis at the CG can be expressed one motor breaks down and yaw moment is generated by equation 1. It can be seen that the right and left in the z-axis, which passes through the traction forces become unbalanced if one motor malfunctions by motor lock or loss of traction and yaw * Keio University, 144-8 Ogura, Saiwai-ku, Kawasaki, 212-0054, moment is generated. As a result, vehicle stability may Japan, e-mail:[email protected]; [email protected]; [email protected] deteriorate. ** Keio Research Institute at SFC, 144-8 Ogura, Saiwai-ku, In the case of the Eliica, upon reaching 100 km/h Kawasaki, 212-0054, Japan, e-mail:[email protected] © 2007 WEVA Journal, pp. 46-53 46 ISSN 2032-6653 The World Electric Vehicle Association Journal, Vol. 1, 2007 3. ANALYSIS OF BREAKDOWN FACTORS THAT CAUSE UNBALANCED 1 1 TRACTION FORCES 1 1 = 2 X 2 2 The factors that would cause the right and left 2 traction forces to become unbalanced were analyzed by 1 1 fault tree analysis (FTA), which is a recognized 1 technique to anatomize quantitatively over the entire 3 2 2 system the breakdown factors leading to a specified 1 2 defect phenomenon. Figure 2 shows the resulting fault 4 1 tree. 2 The following three defect incidents were identified: 3 2 1) The traction force of a wheel on one side is lost by 1 1 a malfunction of the motor or the inverter. 4 y 2) The motor output of a wheel on one side is limited 2 by a temperature increase of the motor or the inverter. 2 1 = 2 3) A wheel on one side is locked by a stuck reduction gear, bearing, or brake. Furthermore, the basic phenomena that lead to these Fig. 1 Vehicle model of eight-wheel-drive Eliica defects were analyzed. A basic phenomenon is a top-level breakdown factor. These are shown within circle symbols in the figure. mV Tl1Tr 1 Tl 2 Tr 2 Tl 3 Tr 3 Tl 4 Tr 4 RES() V The purpose of FTA is to optimize the design of the basic phenomena so that the top-level breakdown mV()EJ C C C C C C C C fl1fr 1fl 2fr 2rl 1rr 1rl 2rr 2 probability is zero. However, as good as that design IJ l f1(Cfl1Cfr 1)cosG 1l f 2(Cfl2 Cfr 2)cosG 2 may be, there is a need to realize a redundancy control that can allow continued safe driving if a top-level lr1(Crl1 Crr 1) lr2(Crl2 Crr 2) breakdown occurs. To achieve this, the next chapter 1 1 examines methods to control the above three defect d f1(Tl1 Tr 1) d f 2(Tl2Tr 2) phenomena caused by top-level breakdowns. 2 2 1 1 dr1(Tl3 Tr 3) dr2(Tl4 Tr 4)Eq . (1) 2 2 V longitudinal velocity RES rolling resistance and air drag ȕ side slip angle at CG Ȗ yaw rate GG1, 2 steering angle I yaw inertia of vehicle d f 1, d f 2, dr1, dr 2 tread l f 1, l f 2, lr1, lr 2 wheel base while accelerating, if the traction force of a motor on one side is lost, yaw moment of about 1700 Nm is generated. On the other hand, if a malfunction by motor lock occurs, the influence of the braking force from the . tire causes the vehicle stability to deteriorate compared Fig. 2 Fault tree analysis of the phenomena that lead to a malfunction by loss of traction. If it is assumed that to unbalanced traction forces the coefficient of friction between the tires and the test road is 1.0, yaw moment of about 4400 Nm occurs if a motor locks on one side. The maximum torque that the Eliica can handle at 100 km/h is 90 Nm. © 2007 WEVA Journal, pp. 46-53 47 ISSN 2032-6653 The World Electric Vehicle Association Journal, Vol. 1, 2007 4. REDUNDANCY TECHNOLOGY FOR THE motors, is that it can continue driving unless all motors DRIVE SYSTEM break down. However, it is necessary for the inverter, batteries, and vehicle controller to be made redundant In this chapter, first the drive-system components of so that the multiple motors can be advantages. an EV using in-wheel motors are compared with those As shown in Figure 4, a pair of batteries supplies two of a conventional EV, and the system composition that inverters on the same axle, and a vehicle controller is most suitable for EVs is suggested. Next, methods to controls each pair of front and rear axles. In addition, to control the defect phenomena that lead to unbalanced govern the two vehicle controllers, a management right and left traction forces that are inextricably linked device was created. If a battery fails, the drive can to the system hardware composition are proposed. continue in 6WD. Moreover, yaw moment is not generated, because the power supplies to the motors on the same axle are shut at the same time. The processing contents of the two vehicle controllers are installed in the management device. The management device verifies the control contents of the two vehicle controllers, and if the vehicle controllers are not in accord, the control is separated and the vehicle continues running by 4WD. With the minimum 2WD, Eliica can satisfy a MOTOR standard value of acceleration and slope ability defined VEHICLE BATTERY INVERTER SHAFT DRIVE- in a technical standard for a vehicle. BOX CONTROLLER GEAR Error detection and torque control of a motor are the roles of an inverter, and the monitoring and ordering of an inverter are the duties of a vehicle controller. Power Line Therefore, if the communication speed between vehicle controllers and inverters is slow, control after detection Control Line of trouble is late, and sufficient deterrent of yaw moment is not provided.
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