WO2022229979A1

WO2022229979A1 - System and method for operating automobiles with an electric drivetrain

Info

Publication number: WO2022229979A1
Application number: PCT/IN2022/050394
Authority: WO
Inventors: Vilas Tank; Geeth Prajwal Reddy P; Nikhil Warwadekar
Original assignee: Aventose Energy Private Limited
Priority date: 2021-04-29
Filing date: 2022-04-26
Publication date: 2022-11-03

Abstract

The present invention provides a system and method for operating automobiles with an electric drivetrain, which activates the safe mode operation of the electric drive train in case of vehicle fault detection. The present invention provides a system for operating automobiles with the electric drivetrain which includes an event monitoring module (108) which is configured to detect a predefined set of events and a safe mode activation module (110) which is configured to automatically activate the safe mode operation upon detection of the predefined set of events reducing the probability of the rider being stranded due to vehicle faults. During the safe mode operation the vehicle parameters including power, torque, discharge current and speed are restricted reducing the probability of the components reaching their safe operating limits limits. Further the safe mode operation is deactivated when the plurality of parameters restores to its normal operational conditions.

Description

System and method for operating automobiles with an electric drivetrain

CROSS - REFERENCE TO RELATED PATENT APPLICATION

The embodiments herein claim the priority of Indian patent application 202141019671 filed on April 29, 2021.

Field of Invention

The present invention relates generally to the field of automobile. More specifically, the present invention relates to automobile with an electric drivetrain which activates and operates in safe mode operation in case of detection of vehicle fault affecting the performance of the automobile.

Background of the Invention

In past decade, electric vehicles have emerged as a viable alternative to fossil fuel-based automobiles. There is a growing need for the electrification of the transportation industry. Electrically powered automobiles are vehicles that do not depend on internal combustion engines for propulsive power, but rather on electric traction batteries. The traction battery of an electric automobile is engaged with an electric traction motor for propelling the automobile, and the traction battery is rechargeable to permit repeated use of it. There is currently a trend in the automotive industry to replace combustion engines with electric motors or a combination of an electric motor and a combustion engine, thereby substantially reducing the environmental impact of automobiles by reducing or completely eliminating emissions. V arious strategies have emerged in the quest to develop commercially viable, energy advantageous vehicles that use electrical energy in full or in part to propel the vehicle. The term “electric vehicle” as used includes vehicles having an electric motor for vehicle propulsion, such as battery electric vehicles (BEV), hybrid electric vehicles (HEV), and plug-in hybrid electric vehicles (PHEV). These vehicles are capable of being at least partially driven by an electric machine.

This switch in drive train technology is not without its technological hurdles. The use of an electric motor translates to the need for inexpensive batteries with high energy densities, long operating lifetimes, and operable in a wide range of conditions. Additionally, it Is imperative that the battery pack of a vehicle pose no undue health threats, either during vehicle use or during periods of storage. The user faces several problems while riding or driving automobiles with electric drive train. The problems may include overheating of battery and motor, thermal runaway or rapid heating up of battery pack, the battery State of Charge (SoC) reaching below a threshold limit, which could make the rider stranded in an unlikely place.

Electric vehicles typically use a Vehicle Control Unit (VCU) to interpret driver inputs (e.g., Drive Mode selection, accelerator position etc.,) to coordinate each of the vehicle subsystems, and to determine the vehicle system operation state. The vehicle system controller generates commands to appropriate subsystems based on driver inputs and control strategies, and sends the generated commands to the respective subsystems effective to cause the subsystems to take appropriate actions to meet the driver's demands.

While the foregoing control strategy is effective to efficiently operate the vehicle under normal operating conditions, it suffers from some drawbacks. Particularly, if a fault occurs in any one or more of the vehicle's power train subsystems, the vehicle may no longer be driveable, thereby leaving a driver or operator stranded.

In these vehicles, to prevent immediate or long-term failure of components necessary for electric propulsion and to ensure safety of the vehicle occupants, corrective actions would be necessary. Since shutdown of the entire vehicle may be undesirable, limited operation strategy (LOS) modes can be implemented to enable the operator of the vehicle to continue to drive while the vehicle operates at a limited capacity or power output. There is therefore a need for an improved electric vehicle which includes a limited operation strategy which allows the vehicle to continue to function and drive in the presence of a fault in one or more of the power train subsystems.

In order to address the aforementioned problems marring the Electric vehicle (EV) segment, a Vehicle Control Unit (VCU) or certain other components are upgraded to identify the problem or issues with the automobiles. A number of approaches have been employed to reduce the risk of faulty power train drive systems. US patent 9130487 discloses a control strategy for an electric machine in a vehicle comprising a traction battery, at least one electric-machine, and a controller, lire controller is configured to alter a voltage between the battery and the electric-machine based on a measured voltage of the battery or the high voltage bus. In response to an indication that the measured voltage is faulty during a drive cycle, the controller instead alters the voltage between the battery and the electric machine based on a substituted battery voltage signal such that the electric-machine remains operable for the drive cycle.

Chinese patent application 105774557 provides an intelligent high-voltage management system of an electric car. According to the intelligent high-voltage management system of the electric car, a signal collecting system collects the car operation state, failure detection object state and car posture state in real time; an intelligent high-voltage control unit receives an instruction of a vehicle control unit (VCU) and/or a battery management system (BMS), enables a high- voltage electricity distribution system to normally distribute electricity to vehicle high-voltage equipment and feeds back the execution result to the VCU and/or the BMS; meanwhile, fault diagnosis and detection are carried out on the high-voltage electricity distribution system according to collected data and received vehicle real-time interaction data; the fault type is determined according to a preset fault database, the high-voltage electricity distribution system is made to execute the high-voltage electricity on-off control logic under the preset fault types, and the diagnosis result is stored and sent; the high-voltage electricity distribution system caries out high-voltage electricity distribution, high-voltage electricity on/off control, circuit overcurrent protection and high-voltage pre-charging on all high-voltage devices of the car according to the instruction of the intelligent high-voltage control unit. The intelligent high- voltage management system of the electric car realizes intelligent management of high-voltage electricity of the whole car, and better improves the high-voltage safety of the electric car.

Chinese utility model CN2772880Y discloses an entire vehicle safety control system of an electric vehicle, which solves the technical problems of the monitoring of multiple items of electrical safety hidden trouble, the real-time collection of safety information, the reception and the sending of data, the monitoring of the preservation of raw data, etc. existing in the current electric vehicles. The utility model can carry out real-time detection and processing to more than eight items of electrical safety hidden trouble, such as the voltage of power battery groups, the insulation resistance of a positive bus-bar, the insulation resistance of a negative bus-bar, a drain current of a main motor, the start and the closing of a main relay, a key stage, the connection and the disconnection of a fuse, the voltage of an auxiliary source, etc. and the preservation of the raw data of safety information. The utility model carries out data communication with an entire vehicle control system of the electric vehicle through a data bus. and sends monitoring and alarm data to the entire vehicle control system of the electric vehicle, and the utility model receives the parameter setting carried out by the entire vehicle control system of the electric vehicle to the system. The utility model has the characteristics of multiple detection points, high detection precision, raw data record, etc. After the entire vehicle control system receives the monitoring data and an alarm signal, an operator can take relative protective measures, and the utility model satisfies the electrical safety requirement of the electric vehicle in operation and parking maintenance.

Chinese patent application CN108357368 discloses a kind of security diagnostics monitoring methods of new - energy automobile power battery system, include the following steps: VCU calculates electric system, electric air-conditioning system, the power consumption total amount of the high voltage parts such as electric heating system. According to the error range of parts itself, the performance number range of system consumption under current working is calculated; ECU is calculated by the voltage and current signal of power battery under current working, the power of power battery; VCU verifies ECU under current working, if the power curve that ECU is calculated exceeds the power curve range that VCU is calculated. VCU judges that electrokinetic cell system breaks down, carries out torque and power limit, while alarming by instrument. The present invention can verify the output of power battery in conjunction with the signal of vehicle other systems, can promote the diagnostic accuracy of power battery, and improve the safety of power battery and the person.

Another Chinese patent CN 104512422 provides a hybrid electric vehicle fault handling method and its fault processing system. A kind of hybrid electric vehicle fault handling method, comprises the following steps: The failure mode that each parts of hybrid electric vehicle currently occur is detected, the failure rank of each parts is determined according to the failure mode; According to the failure rank of each parts, mapping obtains the failure response rank of each parts: Highest failure response rank in the failure response rank of the described each parts for obtaining is defined as final failure response rank; According to the final failure response rank, corresponding troubleshooting is carried out. Fault handling method provided in an embodiment of the present invention is more complete, can effectively prevent full-vehicle control from being started a leak when failure occurs, and eliminates safe hidden trouble, and can suitably adjust vehicle dynamic Control according to specific failure.

US patent US6405818 provides a hybrid electric vehicle with limited operation strategy. A hybrid electric vehicle having a propulsion system which includes an internal combustion engine, a generator/motor and an electric motor or a “traction inverter module” which cooperatively provide power to the drive train of vehicle. Vehicle includes a controller which is effective to detect whether any faults are present within any of the torque providing subsystems (e.g., in engine, generator/motor and/or motor), and if one or more faults is present, to provide a limited operation strategy which allows the vehicle to be drivable by use of the remaining operational subsystem(s).

The cited prior arts disclose fault detection and related control strategies, however, in some cases, it is still not equipped to accurately identify the problems in real-time, which makes it challenging to identify what is causing the vehicle breakdown and suggest remedy or take necessary action to help the user.

In one approach, the EV is equipped to detect one or more issues and communicate the same to the user either via dashboard or Human Machine Interface (HMI). However, this improvement falls short since it is very difficult for the user to read the information while driving or riding the automobile. In some scenarios, the user tends to ignore such alerts. Further, it becomes very challenging for the user to figure out necessary action to be taken to overcome the ongoing issue with the automobile. This often leads to user’s anxiety and panic and causes user’s lack of concentration and focus on the road. This is very dangerous as the lack of concentration and focus on the road might lead to accidents.

Therefore, there is a need for an improved system and method for operating automobiles with the electric drive train. The present invention provides a system and method for operating automobiles with an electric drivetrain, in particular system and method for activating and operating the electric drive train in safe mode operation in case of vehicle fault detection. The present invention provides a system for operating automobiles with the electric drivetrain which includes an event monitoring module which is configured to detect a predefined set of events and automatically activate the safe mode operation upon detection of the predefined set of events reducing the probability of the rider being stranded due to vehicle faults. Further the present invention provides a method for operating automobiles with an electric drivetrain which includes capturing a plurality of parameters of the vehicle in real time. Objects of the Invention:

The main object of the present invention is to provide a system and method for operating automobiles with an electric drivetrain, which activates the operation of the electric drive train in safe mode in case of vehicle fault detection.

The primary object of the present invention to provide a system and method for operating automobiles with an electric drivetrain in a safe mode operation in case of vehicle fault detection reducing the probability of the rider being stranded due to vehicle faults.

It is another object of the present invention to provide a method for operating automobiles with an electric drivetrain which includes capturing a plurality of parameters of the vehicle in real time. It is yet another object of the present invention to provide a system and method to detect a predefined set of events which affects the performance of the electric drivetrain vehicle and automatically activate a safe mode operation of the electric drivetrain vehicle upon detection of the said predefined set of events.

It is another object of the present invention to operate the vehicle with restricted parameters under the safe mode operation reducing the probability of the components reaching their threshold limits. It is still another object of the present invention to provide a system and method for deactivating the safe mode operation of the electric drivetrain vehicle when the plurality of parameters restores to its normal operational conditions.

SUMMARY OF THE INVENTION

The present invention focuses on a system and method for operating automobiles with an electric drivetrain in a safe mode operation in case of vehicle fault detection reducing the probability of the rider being stranded due to vehicle faults. The present invention provides a system for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : atleast a controller (100), configured to monitor and operate the automobile with an electric drivetrain; atleast a memory unit (106); an event monitoring module (108), configured to detect a predefined set of events which affects the performance of the electric drivetrain vehicle; a safe mode activation module (110), configured to automatically activate a safe mode operation of the electric drivetrain upon detection of the said predefined set of events; atleast a BUS; and atleast a processor; Wherein the said memory unit and processor are operatively coupled to the bus (106), wherein under the safe mode operation of the electric drivetrain vehicle is operated with restricted parameters.

In the preferred embodiment of the present invention, wherein the said event monitoring module includes a Vehicle Control Unit (VCU) configured to detect a predefined set of events based on the data received from the Battery Management System (BMS) and the Motor control unit (MCU).

In the preferred embodiment of the present invention, wherein the said predefined set of events includes at least one of loss of controller area network (CAN) communication between the MCU/BMS and the VCU, an event of battery overheating based on data representative of operating condition of the battery, overheating of the motor or exceeding safe operating limit of the motor, drop of State of charge (SoC) of the battery beyond a pre-set percentage of charge. In the preferred embodiment of the present invention, Wherein the vehicle when operated under safe mode operation the vehicle parameters including power, torque, discharge current and speed are restricted reducing the probability of the components reaching their threshold limits.

In another embodiment of the present invention provides, a method for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : capturing a plurality of parameters of the vehicle in real time; monitoring the said plurality of parameters captured in real-time by the VCU; identifying one or more predefined events in the vehicle based on the captured plurality of parameters; activating a safe mode operation upon detection of one or more predefined events in the vehicle; deactivating the safe mode operation when the captured plurality of parameters of the vehicle do not fall under predefined events and indicates normal operation of the vehicle; and repeating the cycle again in loop.

In the preferred embodiment of the present invention, wherein said plurality of parameters captured real time by the VCU includes but not limited to inter-component communication in the vehicle, temperature of battery, temperature of motor, and SoC of the battery.

In an alternative embodiment of the present invention, Wherein the said deactivation of the Safe Mode requires manual selection of the rider/user. This is implemented to improve the safety of the rider. Even when the VCU has initiated deactivation of the Safe Mode operation, the vehicle continues to operate in Safe Mode until the rider provides manual input approving the deactivation.

In the safe mode operation of the present invention, restrictions on vehicle parameters including power, torque, discharge current and speed is imposed, thus the probability of the components reaching their threshold or safe operating limits is reduced, irrespective of the rider’s driving style. The restrictions are imposed with respect to corresponding pre-set thresholds for power, torque, discharge current and speed of the electric vehicle. Thereby, preventing the vehicle from complete shut-down and causing the rider to be stranded.

Brief Description of the Drawings Fig. l is a block diagram representation of a system for operating automobiles with an electric drivetrain in a safe mode operation in case of vehicle fault detection reducing the probability of the rider being stranded due to vehicle faults, in accordance with an embodiment of the present invention. Fig. 2 provides a flow diagram representative of method of operating automobiles with an electric drivetrain in a safe mode operation in case of vehicle fault detection reducing the probability of the rider being stranded due to vehicle faults, in accordance with an embodiment of the present disclosure.

Fig. 3 represents instrument cluster layout of an electric drivetrain vehicle in accordance with the present invention.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Prior to this, terms and words used in the present specification and claims should not be construed as limited to ordinary or dictionary terms, and the inventor should appropriately interpret the concept of the term appropriately to describe its own invention in the best way. The present invention should be construed as meaning and concept consistent with the technical idea of the present invention based on the principle that it can be defined. Therefore, the embodiments described in this specification and the configurations shown in the drawings are only the most preferred embodiments of the present invention and do not represent all the technical ideas of the present invention. Therefore, it should be understood that equivalents and modifications are possible.

Detailed Description of the Invention with Respect to the Drawings

The present invention as embodied by "System and method for operating automobiles with an electric drivetrain" succinctly fulfils the above-mentioned need(s) in the art. The present invention has objective(s) arising as a result of the above-mentioned need(s), said objective(s) being enumerated below. In as much as the objective(s) of the present invention are enumerated, it will be obvious to a person skilled in the art that, the enumerated objective(s) are not exhaustive of the present invention in its entirety, and are enclosed solely for the purpose of illustration. Further, the present invention encloses within its scope and purview, any structural alternative(s) and/or any functional equivalent(s) even though, such structural alternative(s) and/or any functional equivalent(s) are not mentioned explicitly herein or elsewhere, in the present disclosure. The present invention therefore encompasses also, any improvisation(s)/ modification(s) applied to the structural alternative(s)/functional alternative(s) within its scope and purview. The present invention may be embodied in other specific form(s) without departing from the essential attributes thereof.

Throughout this specification, the use of the word "comprise" and variations such as "comprises" and "comprising" may imply the inclusion of an element or elements not specifically recited.

The term “electric vehicle” or “EV” as used herein, includes vehicles having an electric motor for vehicle propulsion, such as battery electric vehicles (BEV), hybrid electric vehicles (HEV), and plug-in hybrid electric vehicles (PHEV).

The present invention provides a system and method for operating automobiles with an electric drivetrain, which activates the operation of the electric drive train in safe mode operation in case of detection of vehicle fault. It mainly focuses on a system and method for operating automobiles with an electric drivetrain in a safe mode operation in case of vehicle fault detection reducing the probability of the rider being stranded due to vehicle faults.

The present invention provides a system for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : atleast a controller (100), configured to monitor and operate the automobile with an electric drivetrain; atleast a memory unit (106), positioned within the said controller (100); an event monitoring module (108), positioned inside the said memory unit (106); a safe mode activation module (110), positioned in direct communication with the said event monitoring module (108); atleast a BUS (104), in direct communication with the said memory unit (106); atleast a processor (102), positioned in direct communication with the said BUS (104), Wherein the said memory unit (106) and processor (102) are operatively coupled to the bus (104), wherein the said event monitoring module (108) is configured to detect a predefined set of events which affects the performance of the electric drivetrain vehicle, wherein the said safe mode activation module (110) is configured to automatically activate a safe mode operation of the electric drivetrain upon detection of the said predefined set of events, wherein under the safe mode operation of the electric drivetrain vehicle is operated with restricted parameters.

In the preferred embodiment of the present invention, wherein the memory unit (106) includes a plurality of modules which instructs the said processor (102) to perform specific functions. The memory unit (106) includes an event monitoring module (108), and a safe mode activation module (110).

In the preferred embodiment of the present invention, wherein the said event monitoring module (108) includes a Vehicle Control Unit (VCU) configured to detect a predefined set of events based on the data received from the Battery Management System (BMS) and the Motor control Unit (MCU). In the preferred embodiment of the present invention, wherein the said predefined set of events includes at least one of loss of controller area network (CAN) communication between the MCU/BMS and the VCU, an event of battery overheating based on data representative of operating condition of the battery, overheating of the motor or exceeding safe operating limit of the motor, drop of State of charge (SoC) of the battery beyond a pre-set percentage of charge. In the preferred embodiment of the present invention, wherein the said processor (102) includes any type of computational circuit, such as, but not limited to, a microprocessor, a microcontroller, a complex instruction set computing microprocessor, a reduced instruction set computing microprocessor, a very long instruction word microprocessor, an explicitly parallel instruction computing microprocessor, a digital signal processor, or any other type of processing circuit, or a combination thereof.

In the preferred embodiment of the present invention, Wherein the vehicle when operated under safe mode operation the vehicle parameters including power, torque, discharge current and speed are restricted reducing the probability of the components reaching their threshold limits. In the preferred embodiment of the present invention, wherein during the said safe mode operation the power is restricted to 1 kW

In the preferred embodiment of the present invention, wherein during the said safe mode operation torque output of the traction motor is restricted to 10 Nm. In the preferred embodiment of the present invention, wherein during the said safe mode operation the speed of the vehicle is restricted to 25 km /hr thereby restricting the current discharged from the battery. .

In the preferred embodiment of the present invention, wherein during the said safe mode operation the said VCU will not accept any drive mode requests or inputs from the rider, the MCU will constantly monitor the power, torque, and speed of the vehicle and if any of the said three parameter violate their set limits, MCU will ignore the command received from the physical throttle, such as accelerator present in the vehicle, which is actuated by the rider.

In the preferred embodiment of the present invention, a rider in safe mode operation with low performance of the vehicle can reach the desired destination including home, service or charging station rather being stranded on road.

In the preferred embodiment of the present invention, wherein the said safe mode operation is automatically activated when the battery SoC drops below 20%, providing additional boost for the vehicle driving range by limiting the energy consumption from the battery.

In an embodiment of the present invention, wherein the said safe mode operation is activated manually when the battery SoC drops below 20%, by triggering the “Safe Mode” buttons provided on the handle bar switch assembly.

In another embodiment of the present invention provides, a method (200) for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : a) capturing a plurality of parameters of the vehicle in real time (202), wherein said plurality of parameters are captured by VCU; b) monitoring the said plurality of parameters captured in real-time by the VCU, wherein said monitoring is performed by the MCU; c) identifying one or more predefined events in the vehicle based on the captured plurality of parameters (204), wherein said identification is performed by the VCU ; d) activating a safe mode operation upon detection of one or more predefined events in the vehicle (206), wherein said activation is performed by the VCU; e) deactivating the safe mode operation when the captured plurality of parameters of the vehicle do not fall under predefined events and indicates normal operation of the vehicle; and f) repeating the cycle again in loop. In the preferred embodiment of the present invention, wherein said plurality of parameters captured real time by the VCU includes but not limited to inter-component communication in the vehicle, temperature of battery, temperature of motor, and SoC of the battery.

In the preferred embodiment of the present invention, Wherein said one or more predefined events include the loss of controller area network (CAN) communication between the MCU and the VCU, loss of inter-component communication in the vehicle, battery overheating, motor overheating, and low State of charge (SoC) of the battery.

In the preferred embodiment of the present invention, the safe mode activation module (110) is configured to automatically activate the safe mode upon detection of the predefined set of events by the event monitoring module (108). Once the safe mode is activated, it is communicated to the rider/user via dashboard along with the detected one or more predefined events as shown in Figure.3.

In the preferred embodiment of the present invention, wherein said monitoring of the said plurality of parameters such as the loss of CAN, breach of operational limits of battery and motor, SoC of the battery is done either continuously or within predefined time intervals. In the preferred embodiment of the present invention, wherein the said safe mode operation of the vehicle limits the power, torque, discharge current and vehicle speed, thereby operating the vehicle within its safe operating limit. In the preferred embodiment of the present invention, Wherein the said safe mode operation is deactivated when the said plurality of parameters restores to its normal operational conditions.

In an embodiment of the present invention, wherein the said event monitoring module (108) is configured to detect at least one of loss of controller area network (CAN) communication between the MCU/BMS and the VCU. The said MCU is configured to monitor the CAN signals from the VCU in order to detect the loss of CAN communication between the MCU and the VCU. If no signal is received for a predefined duration, then it is flagged as a loss of the CAN communication, wherein if the system detects the loss of CAN for the said predefined duration, then it is flagged as a predefined event. In such a predefined event of the loss of communication between the VCU and MCU, the critical information regarding the drive modes and controls of the vehicle will not be available for the MCU. The said MCU activates the safe mode operation upon detection of the said predefined event. The safe mode operation enables the vehicle to operate the motor with limited power and torque and imposes a limit on the top speed of the vehicle, even when the communication is lost. Thereby, the rider can still ride the vehicle to a nearby location for service/safe keeping instead of being stranded on the road.

In the preferred embodiment of the present invention, wherein said CAN control system is a simple two-wire differential serial bus system meant to reduce the number of wires and make it possible for different control systems to communicate, and so perform more complex tasks, a flexible and reliable control system. In the preferred embodiment of the present invention, wherein the said predefined duration is changed depending on the type and make of the vehicle, more preferably the said predefined duration is 5 seconds. In an embodiment of the present invention, wherein the said event monitoring module (108) is configured to detect at least one of loss of controller area network (CAN) communication between the MCU/BMS and the VCU. The said VCU is configured to monitor the CAN signals from the BMS for identification of loss of the CAN communication. In the preferred embodiment of the present invention, wherein during the said safe mode operation the power is restricted to 1 kW

In the preferred embodiment of the present invention, wherein during the said safe mode operation torque output of the traction motor is restricted to 10 Nm.

In the preferred embodiment of the present invention, wherein during the said safe mode operation the speed of the vehicle is restricted to 25 km/hr.

In an embodiment of the present invention, upon entering the Safe Mode operation, the VCU will consider CAN communication to be restored only when the VCU receives CAN messages for a predefined period of time, referred to as a restoration interval. The VCU does not consider the restoration interval through an actual measure of time lapsed but rather as the number of CAN messages which would have been received during that interval of time. If a cumulative number of CAN messages are received by the VCU from the MCU, then the Safe mode is deactivated and returns to normal vehicle operation with the approval of the user. If the cumulative number of CAN messages are not received by the VCU from the MCU, then the vehicle continues to operate under the safe mode. In another embodiment, the said event monitoring module (108) is configured to detect an event of battery overheating based on data representative of operating condition of the battery, wherein the data representative of operating condition of the battery is communicated to the VCU by the BMS. The battery overheating is detected when temperature of the battery or its components exceed their threshold temperature or safe operating limit. When the VCU senses that the components are nearing their threshold or safe operating limits, it activates “Safe Mode” operation automatically. The safe mode operation enables the vehicle to operate the motor with limited power and torque and imposes a limit on the top speed of the vehicle. With the power, torque and speed restrictions imposed by “Safe Mode” operation, the probability of the components reaching their threshold or safe operating limits is reduced, irrespective of the rider’s driving style. Thereby preventing the vehicle from complete shut-down and causing the rider to be stranded.

In the preferred embodiment of the present invention, wherein during the said safe mode operation the power is restricted to 1 kW

In the preferred embodiment of the present invention, wherein during the said safe mode operation the speed of the vehicle is restricted to 25 km/hr. In yet another embodiment, the event monitoring module (108) is configured to detect an event of overheating of the motor or exceeding safe operating limit of the motor. The event is detected based on operating condition of the motor monitored by the VCU. The data representative of operating condition of the motor is communicated to the VCU by the MCU When the VCU senses that the components are nearing their threshold or safe operating limits, it activates “Safe Mode” operation automatically. The safe mode operation enables the vehicle to operate the motor with limited power and torque and imposes a limit on the top speed of the vehicle. With the power, torque and speed restrictions imposed by “Safe Mode” operation, the probability of the components reaching their threshold or safe operating limits is reduced. Thereby preventing the vehicle from complete shut-down and causing the rider to be stranded. In the preferred embodiment of the present invention, wherein during the said safe mode operation the power is restricted to 1 kW

In the preferred embodiment of the present invention, wherein during the said safe mode operation the speed of the vehicle is restricted to 25 km/hr. In the preferred embodiment of the present invention, Wherein the said safe operating limit of the motor is predefined and specific to the type and capacity of the motor.

In the preferred embodiment of the present invention, Wherein the said VCU constantly monitors the temperature of the motor, MCU and the battery pack data received from the MCU and BMS via CAN messages. When any of these temperatures exceed a pre-defined limit, the VCU automatically triggers the Safe Mode operation to the MCU. This pre-defined limit is set to be lower than the safe operating limit of the components ensuring no damage to the components occur as well as extending its operating life by preventing it from reaching its safe operating limit. In the preferred embodiment of the present invention, Wherein said pre-defined limit is preferably set as 90% of their safe operating limit.

In an embodiment of the present invention, the event monitoring module (108) is configured to detect an event of drop of State of charge (SoC) of the battery below a pre-set percentage of charge. The battery management system communicates the SoC to the VCU. When the vehicle is in operation, the VCU senses the drop of the State of charge (SoC) of the battery below a preset percentage and provides an indications to the rider and the rider can manually enter the “Safe Mode”. If the SoC of the battery has dropped below the pre-set percentage during the vehicle boot-up, the VCU automatically enters into “Safe Mode” as an indication that the SoC is low. The rider can choose to exit the “Safe Mode” if the range boost is not required. The safe mode operation enables the vehicle to operate the motor with limited power and torque and imposes a limit on the top speed of the vehicle. This provides an additional boost of the vehicle’ s driving range by limiting the energy consumption from the battery. Thereby preventing the vehicle from complete shut-down and causing the rider to be stranded.

In an embodiment of the present invention, when the vehicle is in operation, the VCU senses the drop of the State of charge (SoC) of the battery below a pre-set percentage and provides an indications to the rider and the rider can manually enter the “Safe Mode”. If the SoC of the battery has dropped below the pre-set percentage during the vehicle boot-up, the VCU automatically enters into “Safe Mode” as an indication that the SoC is low. The rider can choose to exit the “Safe Mode” if the range boost is not required. This provides an additional boost of the vehicle’s driving range by limiting the energy consumption from the battery. Thereby, reducing the probability of the rider being stranded.

In the preferred embodiment of the present invention, wherein during the said safe mode operation the speed of the vehicle is restricted to 25 km/hr. In the preferred embodiment of the present invention, wherein the said pre-set percentage of charge is adjusted by user as per the requirement, more preferably the said pre-set percentage of charge is 20%.

In the preferred embodiment of the present invention, wherein the said additional boost of driving range is subject to several parameters including but not limited to road conditions, overall load present on the vehicle.

In the safe mode operation of the present invention, restrictions on vehicle parameters including power, torque, discharge current and speed is imposed, thus the probability of the components reaching their threshold or safe operating limits is reduced, irrespective of the rider’s driving style. The restrictions are imposed with respect to corresponding pre-set thresholds for power, torque, discharge current and speed of the electric vehicle. Thereby, preventing the vehicle from complete shut-down and causing the rider to be stranded. The MCU constantly monitors the vehicle parameters, and when the user violates the pre-set thresholds for the power, torque, discharge current and speed, the system ignores any manual command received from the user including a physical throttle or accelerator present in the vehicle. The safe mode operation limits the power, torque, discharge current and vehicle speed, therefore the battery and motor operate within its safe operating limit. As a result, the vehicle components are subjected to reduced stress and wear and contribute to increased operating life of the vehicle components.

While entering Safe Mode is an automated process which the VCU will initiate based on the pre-defined conditions, exit from Safe Mode requires the intervention of the rider. This is implemented intentionally considering the safety of the rider. Even though the VCU has initiated exit from Safe Mode, the vehicle continues to be in Safe Mode until the rider approves the exit process. In Safe Mode, the vehicle is essentially in a low power state, in terms of power consumption, torque generation and vehicle speed, due to which the rider would be cruising on the road. If the vehicle exits from Safe Mode automatically, unaware of the same, the rider might give a sudden throttle causing a sudden surge of power resulting in rapid acceleration of the vehicle leading to accidents and causing harm to the rider and others on the road.

The present invention effectively solves the issue with automatically taking corrective measures in the automobiles with the electric drivetrain, if any issue occurs with vehicle components, without any intervention from the user/rider. Therefore, the rider is not distracted while riding the automobile and maintain focus on the road. Further, this enhances the chances of driving the vehicle to a service station without breakdown while preventing damages to the vehicle components.

The “Safe Mode” limits the power, torque and vehicle speed, the chances that battery and motor will reach its Safe Operating Limit in minimized and the components are subjects to reduced stress and wear. Thus, contributing towards increased operating life of the components.

EXAMPLE 1

The present invention provides a system and method for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : atleast a controller (100), configured to monitor and operate the automobile with an electric drivetrain; atleast a memory unit (106) comprising of an event monitoring module (108) and a safe mode activation module (110), positioned within the said controller (100), atleast a BUS (104), in direct communication with the said memory unit (106) and a processor (102), positioned in direct communication with the said BUS (104). The said event monitoring module (108) includes a Vehicle Control Unit (VCU) configured to detect a predefined set of events based on the data received from the Battery Management System (BMS) and the Motor Control Unit (MCU). Wherein the said event monitoring module (108) is configured to detect at least one of loss of controller area network (CAN) communication between the MCU/BMS and the VCU. The said VCU is configured to monitor the CAN signals from the MCU in order to detect the loss of CAN communication between the MCU and the VCU. If no signal is received for a predefined duration of say 5 seconds, then it is flagged as a loss of the CAN communication. Wherein if the system detects the loss of CAN for the said predefined duration, then it is flagged as a predefined event. In such a predefined event of the loss of communication between the VCU and MCU, the said MCU activates the safe mode operation. The safe mode operation enables the vehicle to operate the motor with limited power of 1 kW and torque output of 10 Nm and imposes a limit on the top speed of the vehicle to 25 km/hr. Enabling the rider to still ride the vehicle to a nearby location for service/safe keeping instead of being stranded on the road. Upon entering the Safe Mode operation, the VCU will consider CAN communication to be restored only when the VCU receives CAN messages for a predefined period of time, referred to as a restoration interval. The VCU does not consider the restoration interval through an actual measure of time lapsed but rather as the number of CAN messages which would have been received during that interval of time. For instance the MCU CAN messages have a periodicity of 50 ms which is translated to 20 CAN messages received by the VCU from the MCU in an interval of 1 second. Therefore, for a Time-out interval of 5 seconds, the VCU will look for 100 CAN messages. If a cumulative of 100 CAN messages are received by the VCU from the MCU, then the Safe mode is deactivated and returns to normal vehicle operation with the approval of the user. If the cumulative number of CAN messages are not received by the VCU from the MCU, then the vehicle continues to operate under the safe mode. The aforementioned steps take place in a loop, wherein the safe mode is deactivated when the captured loss of controller area network (CAN) communication between the MCU/BMS and the VCU indicates normal operation of the vehicle.

EXAMPLE 2

The present invention provides a system and method for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : atleast a controller (100), configured to monitor and operate the automobile with an electric drivetrain; atleast a memory unit (106) comprising of an event monitoring module (108) and a safe mode activation module (110), positioned within the said controller (100), atleast a BUS (104), in direct communication with the said memory unit (106) and a processor (102), positioned in direct communication with the said BUS (104). The said event monitoring module (108) includes a Vehicle Control Unit (VCU) configured to detect a predefined set of events based on the data received from the Battery Management System (BMS) and the Motor Control Unit (VCU). The said event monitoring module (108) is configured to detect an event of battery overheating based on data representative of operating condition of the battery, wherein the data representative of operating condition of the battery is communicated to the VCU by the BMS. The battery overheating is detected when temperature of the battery or its components exceed their predefined value. Wherein said pre-defined values is 90% of their safe operating limit. When the VCU senses that the components are nearing the said predefined value or the threshold or safe operating limits, it activates “Safe Mode” operation automatically. The safe mode operation enables the vehicle to operate with the power output of 1 kW and torque output of 10 Nm and imposes a limit on the top speed of the vehicle to 25 km/hr. With the power, torque and speed restrictions imposed by “Safe Mode” operation, the probability of the components reaching their threshold or safe operating limits is reduced, irrespective of the rider’s driving style. Thereby preventing the vehicle from complete shut-down and causing the rider to be stranded. Upon entering the Safe Mode operation, the VCU constantly monitors the temperature of the battery pack data received from the BMS via CAN messages. When temperatures exceed a pre-defined limit, the VCU automatically triggers the Safe Mode operation to the MCU. During the safe mode operation when the temperature lowers to the normal operating range then the Safe mode is deactivated and EV returns to normal vehicle operation with the approval of the user. The aforementioned steps take place in a loop, wherein the safe mode is deactivated when the captured temperature indicates normal operation of the vehicle.

EXAMPLE 3

The present invention provides a system and method for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : atleast a controller (100), configured to monitor and operate the automobile with an electric drivetrain; atleast a memory unit (106) comprising of an event monitoring module (108) and a safe mode activation module (110), positioned within the said controller, atleast a BUS (104), in direct communication with the said memory unit (106) and a processor (102), positioned in direct communication with the said BUS (104). The said event monitoring module (108) includes a Vehicle Control Unit (VCU) configured to detect a predefined set of events based on the data received from the Battery Management System (BMS) and the Motor Control Unit (MCU). The said event monitoring module (108) is configured to detect an event of overheating of the motor or exceeding safe operating limit of the motor. The event is detected based on operating condition of the motor monitored by the VCU. The data representative of operating condition of the motor is communicated to the VCU by the MCU. The motor overheating is detected when temperature of the motor or its components exceed their predefined value. Wherein said pre-defined values is 90% of their safe operating limit. When the VCU senses that the components are nearing the said predefined value or the threshold or safe operating limits, it activates “Safe Mode” operation automatically. The safe mode operation enables the vehicle to operate with the power output of 1 kW and torque output of 10 Nm and imposes a limit on the top speed of the vehicle to 25 km/hr. With the power, torque and speed restrictions imposed by “Safe Mode” operation, the probability of the components reaching their threshold or safe operating limits is reduced, irrespective of the rider’s driving style. Thereby preventing the vehicle from complete shut-down and causing the rider to be stranded. Upon entering the Safe Mode operation, the VCU constantly monitors the temperature of the motor data received from the MCU via CAN messages. When temperatures exceed a pre-defined limit, the VCU automatically triggers the Safe Mode operation to the MCU. during the safe mode operation when the temperature lowers to the normal operating range then the Safe mode is deactivated and EV returns to normal vehicle operation with the approval of the user. The aforementioned steps take place in a loop, wherein the safe mode is deactivated when the captured temperature indicates normal operation of the vehicle.

EXAMPLE 4

The present invention provides a system and method for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : atleast a controller (100), configured to monitor and operate the automobile with an electric drivetrain; atleast a memory unit (106) comprising of an event monitoring module (108) and a safe mode activation module (110), positioned within the said controller (110), atleast a BUS (104), in direct communication with the said memory unit (106) and a processor (102), positioned in direct communication with the said BUS (104). The said event monitoring module (108) includes a Vehicle control units (VCU) configured to detect a predefined set of events based on the data received from the Battery Management System (BMS) and the Motor Control Unit (MCU). The said event monitoring module (108) is configured to detect an event of drop of State of charge (SoC) of the battery below a pre-set percentage of charge say 20 %. The battery management system communicates the SoC to the VCU. When the VCU senses that the drop of State of charge (SoC) of the battery below a pre-set percentage of 20 %, it activates “Safe Mode” operation automatically. The safe mode operation enables the vehicle to operate with a power output of 1 kW and torque output of 10 Nm and imposes a limit on the top speed of the vehicle to 25 km/hr. During the event of drop of State of charge (SoC) of the battery below a pre-set percentage of charge say 20% the rider has the option to manually enter the

“Safe Mode”. This provides an additional boost of the vehicle’s driving range by limiting the energy consumption from the battery. Thereby, reducing the probability of the rider being stranded. Upon entering the Safe Mode operation, the VCU constantly monitors the SoC % data received from the BMS via CAN messages. When SoC% values falls below a pre-defined limit, the VCU automatically triggers the Safe Mode operation to the MCU.

EXAMPLE 5

To avoid oscillations into and out of Safe Mode, particularly in the event of violation of operating parameters of the vehicle components, “Entry into Safe Mode” and “Exit from Safe Mode” have two different triggering instances with that of the Exit mode being lower than that of the Entry Mode. This implementation is to ensure that the respective vehicle component is well within its safe operating limit before exiting Safe Mode, thus preventing immediate return to Safe Mode

Temperature limits for the activation of the Safe may be as following.

Temperature values that may lead to deactivation of the safe mode is following:

VCU will continue to monitor the data from the MCU and BMS in Safe Mode. Once the component temperatures have dropped below the values mentioned in the table, VCU will initiate exit from Safe Mode. The above-mentioned limits are only exemplary embodiment calculated based on the particular type of components used. The values change based on the different types of components and /or technology used.

Although the proposed concept has been described as a way of example with reference to various models, it is not limited to the disclosed embodiment and that alternative designs could be constructed without deviating from the scope of invention as defined above.

It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations, and improvements without deviating from the scope of the invention may be made by a person skilled in the art.

Claims

We claim

1. A system for operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of : atleast a controller (100), configured to monitor and operate the automobile with an electric drivetrain; atleast a memory unit (106), positioned within the said controller (100); an event monitoring module (108), positioned inside the said memory unit (106); a safe mode activation module (110), positioned in direct communication with the said event monitoring module (108); atleast a BUS (104), in direct communication with the said memory unit (106); and atleast a processor (102), positioned in direct communication with the said BUS

(104),

Wherein the memory unit (106) and processor (102) are operatively coupled to the bus (104), wherein the event monitoring module (108) is configured to detect a predefined set of events which affects the performance of the electric drivetrain vehicle, wherein the safe mode activation module (110) is configured to automatically activate a safe mode operation of the electric drivetrain vehicle upon detection of the predefined set of events, wherein under the safe mode operation the electric drivetrain vehicle is operated with restricted parameters.

2. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1 , wherein the memory (106) unit includes a plurality of modules which instructs the processor (102) to perform specific functions.

3. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1, wherein the said event monitoring module (108) includes a Vehicle control unit (VCU) configured to detect a predefined set of events based on the data received from the Battery Management System (BMS) and the Motor Control Unit (MCU).

4. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1 , wherein the predefined set of events includes at least one of loss of controller area network (CAN) communication between the MCU/BMS and the VCU, an event of battery overheating based on data representative of operating condition of the battery, overheating of the motor or exceeding safe operating limit of the motor, drop of State of charge (SoC) of the battery beyond a pre-set percentage of charge.

5. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1, wherein during the safe mode operation the vehicle parameters including power, torque, discharge current and speed are restricted reducing the probability of the components reaching their threshold limits.

6. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1 , wherein during the said safe mode operation the power of the electric drivetrain is restricted to 1 kW.

7. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1, wherein during the said safe mode operation torque output of the traction motor is restricted to 10 Nm.

8. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1 , wherein during the said safe mode operation the speed of the vehicle is restricted to 25 km/hr thereby restricting discharge of current.

9. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1, wherein during the said safe mode operation the VCU will not accept any drive mode requests or inputs from the rider and the MCU ignores any command received from the physical throttle, such as accelerator present in the vehicle, which is actuated by the rider.

10. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1 , wherein a rider in safe mode operation with low performance of the vehicle reaches the desired destination including home, service or charging station rather being stranded on road.

11. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1, wherein the safe mode operation is automatically activated when the battery SoC drops below 20%, providing additional boost for the vehicle driving range by limiting the energy consumption from the battery.

12. The system for operating automobiles with an electric drivetrain with safe mode operation, as claimed in claim 1, wherein the safe mode operation is activated manually when the battery SoC drops below 20%, by triggering the “Safe Mode” buttons provided on the handle bar switch assembly.

13. A method (200) of operating automobiles with an electric drivetrain activating the safe mode operation in case of detection of vehicle fault, comprising of: a. capturing a plurality of parameters of the vehicle in real time (202), wherein said plurality of parameters are captured by VCU; b. monitoring the said plurality of parameters captured in real-time by the VCU, wherein said monitoring is performed by the MCU; c. identifying one or more predefined events in the vehicle based on the captured plurality of parameters (204), wherein said identification is performed by the MCU; d. activating a safe mode operation upon detection of one or more predefined events in the vehicle (206), wherein said activation is performed by the MCU; e. deactivating the safe mode operation when the captured plurality of parameters of the vehicle do not fall under predefined events and indicates normal operation of the vehicle; and f. repeating the cycle again in loop.

14. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 13, wherein said plurality of parameters captured real time by the VCU includes but not limited to inter-component communication in the vehicle, temperature of battery, temperature of motor, and SoC of the battery.

15. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 13, wherein said one or more predefined events include the loss of controller area network (CAN) communication between the MCU/BMS and the VCU, loss of inter-component communication in the vehicle, battery overheating, motor overheating, and low State of charge (SoC) of the battery.

16. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 13, wherein said monitoring of the said plurality of parameters is done either continuously or within predefined time intervals.

17. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 13, wherein during the safe mode operation the vehicle parameters including power, torque, discharge current and speed are restricted reducing the probability of the components reaching their threshold limits.

18. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 13, wherein during the said safe mode operation the power of the electric drivetrain is restricted to 1 kW.

19. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 13, wherein during the safe mode operation torque output of the traction motor is restricted to 10 Nm.

20. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 1, wherein during the said safe mode operation the speed of the vehicle is restricted to 25 km/hr thereby restricting discharge of current.

21. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 1, wherein the safe mode operation is deactivated when the said plurality of parameters restores to its normal operational conditions.

22. The method of operating automobiles with an electric drivetrain activating the safe mode operation, as claimed in claim 1, wherein the deactivation of the Safe Mode requires manual intervention of the rider/user, when the VCU has initiated deactivation of the Safe Mode operation the vehicle continues to operate in Safe Mode until the rider provides manual input approving the deactivation.