Fault detection and mitigation in hybrid drive system

(Related application) This application is filed by Eaton Corporation of the United States, which is an applicant in all designated countries except the United States, and Michael Anthony Stner and Thomas Dee, who are applicants of the United States only. Hawkins, Douglas Simpson's name or name, filed as a PCT international patent application on June 11, 2010, and filed on June 11, 2009, US Provisional Patent Application No. 61 / 186,136. Claims the interests of. The invention according to the present application relates to a fault detection and response system for a vehicle.

On-highway (public road) hybrid vehicles and off-highway (field work) hybrid vehicles are vehicles that include multiple power sources. As an example, a hybrid vehicle can use a normal gas-powered engine to propel the vehicle in one mode of operation and also use an electric motor to propel the vehicle in another mode of operation. can do. As another example, a hybrid vehicle can use a conventional gas-powered engine to propel the vehicle in one mode of operation and also use a fluid motor to propel the vehicle in another mode of operation. can do. By providing multiple power sources, the hybrid vehicle provides cost-effective operation.

Aspects of the present invention relate, for example, to fault detection and response systems used in vehicles and fault detection processes (methods) used in vehicles.

According to some aspects of the invention, detection methods for detecting barrel leaks in pump systems include filtering data signals received from a filter pressure sensor or case pressure sensor based on pump speed and filtering. Includes analyzing the filtered signal to determine if the processed signal exceeds a predetermined threshold.

According to another aspect of the invention, detection methods for detecting gas leaks in pump systems include estimating gas pressure based on fluid temperature and fluid pressure.

According to yet another aspect of the present invention, a detection method for detecting a fluid (eg, oil) leak in a pump system involves comparing an estimated fluid level with an estimated fluid level.

According to yet another aspect of the invention, detection methods for detecting oil leaks in pump systems include comparing the estimated fluid level in the reservoir with the actual fluid level in the reservoir.

<figref num="1">FIG. 1 is a schematic diagram of a hybrid vehicle drive system having exemplary features of embodiments that follow the principles of the present invention.</figref>

<figref num="2">FIG. 2 is a schematic view of a second power source 124 having exemplary features of embodiments that follow the principles of the present invention.</figref>

<figref num="3">FIG. 3 is a block diagram showing an example of a control system for a hybrid drive assembly having exemplary features of embodiments that follow the principles of the present invention.</figref>

<figref num="4">FIG. 4 is a block diagram of an exemplary failure detection system configured to perform failure monitoring and response of a second power source control system according to the principles of the present invention.</figref>

<figref num="5">FIG. 5 is a flow chart illustrating an exemplary reset process by a second power source that can be operably connected to the drive line of the vehicle according to the principles of the present invention.</figref>

<figref num="6">FIG. 6 is a flow chart illustrating an exemplary failure detection process capable of detecting and adjusting system and component failures and / or malfunctions according to the principles of the present invention.</figref>

<figref num="7">FIG. 7 is a flowchart showing an operation flow of an exemplary response process in which the second power source control system responds when a new failure state is detected according to the principle of the present invention.</figref>

<figref num="8">FIG. 8 is a flowchart showing an operation flow of an exemplary network failure detection process for identifying a network failure state by a failure detection system according to the principle of the present invention.</figref>

<figref num="9">FIG. 9 is a flowchart showing an operation flow of an exemplary range failure detection process for identifying a failure state outside the range by a failure detection system according to the principle of the present invention.</figref>

<figref num="10">FIG. 10 is a flowchart showing an exemplary mismatched failure detection operation flow that identifies a failure state triggered by a competing sensor reading or command by a failure detection system according to the principles of the present invention.</figref>

<figref num="11">FIG. 11 is a flowchart showing an operation flow of an exemplary filter clogging failure detection process for identifying a clogged filter by a failure detection system according to the principle of the present invention.</figref>

<figref num="12">FIG. 12 is a flowchart showing an operation flow of an exemplary valve failure detection process 1000 for detecting a malfunction of a proximity sensor of an accumulator by a failure detection system according to the principle of the present invention.</figref>

<figref num="13">FIG. 13 is a flowchart showing an operation flow of an exemplary pressure leak failure detection process for detecting a high pressure leak by a failure detection system according to the principle of the present invention.</figref>

<figref num="14">FIG. 14 is a schematic representation of an exemplary pump assembly that can be used in a pump / motor unit according to the principles of the present invention.</figref>

<figref num="15A">FIG. 15A is a flowchart showing an operation flow of an exemplary leak detection process for detecting a barrel leak, such as a barrel leak in a pump assembly, according to the principles of the present invention.</figref>

<figref num="15B">FIG. 15B is a flow chart showing the operating flow of another exemplary leak detection process that detects a barrel leak, such as a barrel leak in a pump assembly, according to the principles of the present invention.</figref>

<figref num="15C">FIG. 15C is a flow chart showing the operating flow of an exemplary monitoring process for monitoring barrel leaks, such as barrel leaks in pump assemblies, according to the principles of the present invention.</figref>

<figref num="16">FIG. 16 is a block diagram showing an exemplary detection process for determining low levels of fluid (eg, oil) according to the principles of the present invention.</figref>

<figref num="17">FIG. 17 is a block diagram showing an exemplary bypass valve failure detection process for determining a bypass valve malfunction according to the principles of the present invention.</figref>

<figref num="18">FIG. 18 is a block diagram illustrating an exemplary bootstrap failure detection process for detecting failure to acquire swashplate control according to the principles of the present invention.</figref>

<figref num="19">FIG. 19 is a block diagram showing an exemplary pump / motor failure detection process for detecting pump malfunction according to the principles of the present invention.</figref>

<figref num="20">FIG. 20 is a block diagram showing an exemplary disconnection failure detection process for determining a failure of a transfer case that disconnects a second power source from a vehicle drive assembly according to the principles of the present invention.</figref>

<figref num="21">FIG. 21 is a block diagram illustrating an exemplary speed limiting process that limits engine speed in the event of a transfer case failure according to the principles of the present invention to reduce damage to the second power source.</figref>

<figref num="22">FIG. 22 shows an example of an exemplary fluid accumulator constructed according to the principles of the present invention.</figref>

<figref num="23">FIG. 23 is a flowchart showing an operation flow of an exemplary gas leak detection process for detecting a gas leak in an accumulator according to the principle of the present invention.</figref>

<figref num="24">FIG. 24 is a flowchart showing an operation flow of an exemplary initialization check process for determining whether a system has recently been initialized by a gas leak detection process according to the principles of the present invention.</figref>

<figref num="25">FIG. 25 is a flowchart showing an operation flow of an exemplary fluid leak detection process that determines whether a fluid (eg, oil) is leaking from a second power source by a fluid leak detection process according to the principles of the present invention. is there.</figref>

<figref num="26">FIG. 26 is a block diagram showing another exemplary disconnection failure detection process for determining a failure of a transfer case that disconnects a second power source from a vehicle according to the principles of the present invention.</figref>

Aspects of the present invention will be described in detail with reference to the accompanying drawings. Wherever possible, similar reference numerals are used as references to similar components throughout each figure.

With reference to FIG. 1, a schematic diagram of the vehicle drive system designated by reference numeral 100 is shown. In one aspect of the invention, the drive system 100 applies to on-highway vehicles such as trucks, garbage trucks, buses or automobiles, or off-highway vehicles such as construction vehicles and agricultural vehicles.

In the example shown in FIG. 1, the drive system 100 includes a hybrid drive assembly designated by reference numeral 102 and a control system designated by reference numeral 104. The hybrid drive assembly 102 is adapted to selectively propel the vehicle while the control system 104 controls the hybrid drive assembly 102.

In one aspect of the invention, the drive system 100 further includes one or more front wheels 106 and one or more rear wheels 108. A brake 120 is operably assembled on each of the front wheels and the rear wheels 106 and 108 of the drive system 100. The brake 120 is applied to selectively reduce the kinetic energy of the vehicle. In one aspect of the invention, the brake 120 is a friction brake. Although not limited to this friction brake, friction brakes suitable for use in the drive system 100 include disc brakes, drum brakes, mechanically operated brakes, fluid operated brakes, pneumatic brakes, and electrically operated brakes. Or a brake that combines them is included.

The hybrid drive assembly 102 of the drive system 100 includes a first power source designated by reference numeral 122 and a second power source designated by reference numeral 124. In the example shown in FIG. 1, the second power source 124 is arranged in parallel with the first power source 122. However, in another example, the second power source 124 can be arranged in series with the first power source 122.

In some aspects of the invention, the first power source 122 of the hybrid drive assembly 102 includes a conventional prime mover, such as an internal combustion engine. In general, the prime mover 126 generates force in response to the combustion of fuel. In one aspect of the invention, the first power source 122 includes a transmission 128, such as a conventional transmission unit. When the second power source 124 is connected in parallel with the first power source 122, the transmission 128 applies force from the prime mover 126 to at least one wheel 106, 108 via the drive line designated by reference numeral 130. introduce.

In one aspect of the invention, the drive line 130 includes a front drive shaft 132, a rear drive shaft 134, left and right axles 136, 138 and a differential 140. The differential 140 is arranged between the left and right axles 136 and 138. In the example shown, the left and right axles 136 and 138 connect the rear wheels 108 to the differential 140. In another aspect, the drive line 130 may include an axle that differentially connects the front wheels 106.

With reference to FIGS. 1 and 2, in a particular aspect of the invention, the second power source 124 is a fluid power source. For example, the second power source 124 includes a pump-motor assembly 143, a fluid reservoir 144 and an energy storage unit 146. According to some embodiments, the second power source 124 also includes a system filter 147 (FIG. 2). The pump-motor assembly 143 includes a pump / motor unit 142 and an end cover assembly 145 (FIG. 2). The pump-motor assembly 143 is arranged to be selectively fluid-coupled to the fluid reservoir 144 and the energy storage unit 146.

According to one embodiment, the pump / motor unit 142 is a variable displacement pump / motor unit. In one aspect of the invention, the pump / motor unit 142 is an axial piston type pump / motor unit (eg, variable displacement axial piston type). The pump / motor unit 142 includes a servo actuator that can engage the variable swash plate 148. This servo actuator is applied to selectively adjust the swash plate 148 that adjusts the displacement of the pump / motor unit 142. In one aspect of the invention, the energy storage unit 146 is an actuator. In another aspect of the invention, the energy storage unit 146 is a gas-filled accumulator.

The second power source 124 further includes a coupling assembly 149. In one aspect of the invention, the coupling assembly 149 is disposed between the front drive shaft 132 and the rear drive shaft 134. The connecting assembly 149 is applied to selectively connect the pump / motor unit 142 to the drive line 130. In one aspect of the invention, the coupling assembly 149 includes a clutch configured to selectively couple the pump / motor unit 142 to the drive line 130. For example, the clutch can include a clutch valve 224 (FIGS. 2 and 4). In another aspect of the invention, the connecting assembly 149 includes a transfer case (see FIG. 2).

In one aspect of the invention, the coupling assembly 149 is applied to connect the pump / motor unit 142 to the drive line 130 (eg, via a clutch) when the vehicle decelerates. During deceleration, the pump / motor unit 142 is connected to the drive line 130 to operate the pump. The pump / motor unit 142 transfers (eg, pumps) fluid from the fluid reservoir 144 to the energy storage unit 146. When the fluid is transferred to the energy storage unit 146, the fluid pressure in the energy storage unit 146 increases.

In another aspect of the invention, the energy storage unit 149 is applied to connect the pump / motor unit 142 to the drive line 130 when the vehicle accelerates. During acceleration, the pump / motor unit 142 is connected to the drive line 130 to operate the motor. The pump / motor unit 142 receives the pressurized fluid from the energy storage unit 146 so that the pump / motor unit 142 transmits torque to the drive line 130. This torque is generated from the pump / motor unit 142, and the torque transmitted to the drive line 130 is used to propel the vehicle.

In another aspect, the second power source 144 is coupled in series with the first power source 142 and the prime mover 126 is coupled to the pump / motor unit 142. The pump / motor unit 142 is fluidly connected to a motor assembly (not shown) coupled to the left and right axles 136 and 138.

Continuing with reference to FIG. 1, an example of the control system 104 is shown. In one aspect of the invention, the illustrated control system 104 includes a first power source control system designated by reference numeral 150 and a second power source control system designated by reference numeral 152.

The first power source control system 150 is applied to control the first power source 122. In one aspect of the invention, the first power source control system 150 includes a prime mover control unit 154, a transmission control unit 156 and a brake control unit 158. The prime mover control unit 154 and the transmission control unit 156 can be incorporated into a single powertrain control module, but here the prime mover control unit 154 and the transmission control unit 156 are described as separate units.

The prime mover control unit 154 is applied to control the operating surface of the prime mover 126, as described in detail herein. The prime mover control unit 154 is operably coupled to the prime mover 126 (see dashed line 191 in FIG. 1). For example, when using an internal combustion engine, the prime mover control unit 154 may use, for example, one or more of the injection rate into the engine, the idle speed of the engine, the ignition timing of the engine and / or the timing of the engine valve. Can be applied to control.

The transmission control unit 156 is applied to control the operating surface of the transmission 128, as described in detail herein. The transmission control unit 156 is operably coupled to the transmission 128 (see dashed line 192 in FIG. 1). For example, the transmission control unit 156 can be used to calculate what to do with and when to change gears in a vehicle in order to optimize fuel efficiency and / or vehicle performance.

The brake control unit 158 is applied to control the operating surface of the brake 120. The brake control unit 158 is operably coupled to the brake 120 (see dashed line 193 in FIG. 1). For example, the brake control unit 158 may provide antilock braking during various driving conditions and / or provide a constant relationship between the force applied to the pedals and the effectiveness of the brakes. Can be applied.

The second power source control system 152 is applied to control the operating surface of the second power source 124. In one aspect of the invention, the second power source control system 152 is also applied to selectively control the operating surface of the prime mover 126 of the first power source 122. For example, the second power source control system 152 can be applied to limit the output of torque from the prime mover 126 when the second power source 124 is connected to the drive line 130.

According to one aspect of the present invention, the prime mover control unit 154, the transmission control unit 156, the brake control unit 158, and the second power source control system 152 communicate with each of the vehicle components and related sensors in a communication network 184 (FIG. 1). (As shown by the solid line). According to one aspect of the invention, the communication network 184 is a controller area network (CAN or CAN bus). According to another aspect of the invention, the communication network 184 has a network protocol (eg, J1939, HDOBD, OBD-II, EOBD, JOBD).

In the illustrated example, the vehicle also includes a user interface 190 configured to display information to the user. For example, the user interface 190 can include an instrument, an indicator light, electronic reading information (for example, text reading information, numerical reading information, etc.), sound, and the like. In one aspect of the invention, the user interface 190 is communicably coupled to the communication network 184. In another aspect, the user interface 190 can be communicably directly coupled to the second power source control unit 152.

FIG. 3 is a block diagram showing an example of a control system 104 used for a drive assembly such as the drive assembly 102 of FIGS. 1 and 2. The control assembly 104 of FIG. 3 includes a first power source control unit 150 and a second power source control unit 152 that are communicably coupled to each other via a communication network 184. According to one embodiment, the communication network 184 can be electrically connected. However, according to other aspects, the communication network 184 can be connected wirelessly.

In one aspect of the invention, the prime mover control unit 154 of the first power source control unit 150 includes a processor (eg, microprocessor) 160 and a non-volatile memory component 161. Processor 160 of the prime mover control unit 154 is applied to receive electronic data signals from one or more prime mover sensors 170. For example, two prime mover sensors 170A and 170B are shown in FIG. According to one aspect, these sensors 170A, 170B are arranged adjacent to the prime mover 126. However, according to other aspects, any number of sensors 170 can be operably coupled to the processor 160 of the prime mover control unit 154.

In one aspect of the invention, the processor 160 can receive electronic data signals from a plurality of sensors 170 via a communication network 184. In another aspect of the invention, the processor 160 can receive electronic data signals via a direct communication link (eg, wiring) with the plurality of sensors 170A, 170B. As a non-limiting example of the prime mover sensor 170, a throttle position sensor, O_２Sensors, RPM sensors, manifold absolute pressure (MAP) sensors, coolant sensors, knock sensors, crankshaft position sensors, and / or one or more of oil temperature sensors can be included.

The microprocessor 160 of the prime mover control unit 154 is applied to calculate the control parameters for the prime mover 126 from the algorithm stored in the non-volatile memory component 161. This control parameter is calculated using electronic data signals received from one or more prime mover sensors 170 and is used to control the operation of prime mover 126 (eg, via the control connection line of FIG. 1). ).

The non-volatile memory component 161 stores software, firmware, and the like that are used by the processor 160 to control the prime mover 126 and calculate control parameters. The non-volatile memory component 161 can store software, firmware, and the like when the prime mover control unit 154 does not function. Examples of non-volatile memory components suitable for use in the prime mover control unit 154 are erasable and writable read-only memory (EPROM: Erasable Programmable Read-Only Memory), electrical erasure and writable read-only memory (EPROM: Electrically Erasable). EEPROM Read-Only Memory), flash memory and the like are included.

In one aspect of the invention, the transmission control unit 156 includes a processor (eg, microprocessor) 162 and a non-volatile memory component (eg, EPROM, EEPROM, flash memory, etc.) 163. The processor 162 of the transmission control unit 156 is applied to receive electronic data signals input from one or more transmission sensors 172. In the example shown in FIG. 3, only one transmission sensor 172 is operably coupled to the processor 162 of the transmission control unit 156. However, according to other aspects, any number of sensors 172 can be operably coupled to processor 162 of transmission control unit 156.

In one aspect of the invention, the processor 162 is capable of receiving electronic data signals via the communication network 184. In another aspect of the invention, the processor 162 is capable of receiving electronic data signals via a direct communication link (eg, wiring) with the plurality of sensors 172. Non-limiting examples of the transmission sensor 172 can include one or more of an input speed sensor, an output speed sensor, a wheel speed sensor, a throttle position sensor, and / or a transmission fluid temperature sensor. In another aspect of the invention, the transmission control unit 156 is among the kickdown switches, traction control systems, cruise control modules, etc. used to determine that the accelerator has been pushed through full throttle. It can be applied to receive electronic data signals input from one or more.

The processor 162 of the transmission control unit 156 is applied to calculate the control parameters for the transmission 128 from the algorithm stored in the non-volatile memory component 163. This control parameter is calculated using electronic data signals received from one or more transmission sensors 172 and is used to control the operation of transmission 128.

In one aspect of the invention, the brake control unit 158 includes a processor (eg, microprocessor) 164 and a non-volatile memory component 165 (eg, EPROM, EEPROM, flash memory, etc.). The processor 164 of the brake control unit 158 is applied to receive electronic data signals input from one or more brake sensors 174. The processor 164 of the brake control unit 158 is applied to calculate the control parameters for the brake 120 from the algorithm stored in the non-volatile memory component 165. This control parameter is calculated using electronic data signals received from one or more brake sensors 174 and is used to control the operation of the brake 120.

In one aspect of the invention, the processor 164 can receive electronic data signals via the communication network 182. In another aspect of the invention, the processor 164 can receive electronic data signals via a direct communication link (eg, wiring) with the plurality of sensors 174. Non-limiting examples of the brake sensor 174 can include a wheel speed sensor, a pressure sensor that monitors the pressure of the brake fluid, and / or one or more of the pedal position sensors.

In one aspect of the invention, the second power source control system 152 includes a processor (eg, microprocessor) 166, a non-volatile memory component 167 (eg, EPROM, EEPROM, flash memory, etc.) and a volatile memory component 168. Is included. Processor 166 is applied to receive electronic data signals from one or more sensors 176. In one aspect of the invention, as a non-limiting example of the sensor 176, an accumulator pressure sensor, a filter pressure sensor, a neutral pressure sensor, a pump / motor speed sensor, a reservoir fluid temperature sensor, a pump case temperature sensor, a reservoir fluid level sensor, an oblique. A plate angle sensor, a brake pressure sensor, and / or one or more of the accumulator and transfer case proximity sensors can be included. In the example shown, processor 166 is operably coupled to three data sensors 176A, 176B and 176C. However, in other embodiments, the processor 166 can be operably coupled to more or less sensors 176.

The processor 166 of the second power source control system 152 is applied to calculate the control parameters for the second power source 124 from the control algorithm 185 stored in the non-volatile memory component 167 of the second power source control system 152. .. This control parameter is calculated using electronic data signals received from one or more sensors 176. The non-volatile memory component 167 is also configured to store the failure detection algorithm 187 and the operating parameter 189 for the second power source control system 152 (FIG. 4). For example, memory 167 can store an algorithm according to an error message indicating that a failure condition has been invoked, the upper and lower limits used for the algorithm, and one or more system components failing or malfunctioning. ..

The failure state detected by the processor 166 can be stored in either the non-volatile memory 167 or the volatile memory 168. According to some aspects, failure conditions can be divided into three types: non-latching, latching and dysfunction. According to these aspects, the latching and non-latching failure states are stored in the volatile memory 168 and the dysfunction failure states are stored in the non-volatile memory 167. Therefore, the latching and non-latching failure states are cleared when the vehicle is unlocked. The dysfunction failure state remains in the memory 167 even if it is unlocked / locked.

FIG. 4 is a block diagram of an example of a failure detection system 200 configured to perform failure monitoring and response used in the second power source control system 152. According to one embodiment, the illustrated failure detection system 200 is executed using the processor 166 and memory 167 of the second power source control system 152. According to other aspects, the illustrated failure detection system 200 can be run using the processors and / or memory of the other system.

For example, the failure state can be stored in the data logger system in place of or in addition to the storage device of the memory 167 of the second power source control system 152. An example of a data logger system is shown in FIG. 1 and is designated by reference numeral 101. The indicated data logger 101 is operably coupled to the communication network 184. Additional information related to proper data loggers, under the name Hybrid Vehicle Data Logger, can be found in U.S. Patent Application No. 61/158542 filed March 9, 2009, which discloses the disclosure of this patent application. Incorporated into this description by reference.

The illustrated failure detection system 200 includes one or more monitoring modules 201 configured to receive electronic data signals from one or more of the sensors described in detail herein. In the illustrated example, the illustrated failure detection system 200 includes one monitoring module 201 that receives the input of the sensor. In other illustrated systems, multiple monitoring modules can receive and process sensor inputs. For example, each sensor has a corresponding monitoring module.

The monitoring module 201 is configured to analyze (analyze) the received data signal in order to determine whether or not a failure state has occurred. The illustrated failure detection system 200 includes one or more response modules 206 configured to react to the detected failure condition. Further, the failure detection system 200 includes a communication network interface 202 configured to send and receive messages to and from the vehicle communication network, and a second power source control system 152 and / or the vehicle. Included is a memory interface 205 configured to interact with other high capacity solid storage devices (MSUs: memory system units, such as data loggers) within.

According to one aspect, the plurality of monitoring modules 201 receive data signals from one or more sensors. Non-limiting examples of suitable data sensors include a swash plate position sensor 210 indicating the position of the swash plate of the pump / motor 142, a fluid (eg, oil) level sensor 211 indicating the amount of fluid in the fluid reservoir 144, and a fluid in the reservoir 144. A fluid temperature sensor 212 that indicates the temperature, a neutral pressure sensor 213 that indicates the pressure of the end cover assembly 145, and a filter pressure that measures the system pressure and indicates the state of the system filter 147 upstream of the system filter that filters the fluid from the case drain. Sensor 214, high pressure sensor 215 indicating the pressure of the energy storage unit 146, accumulator proximity sensor 216 indicating whether the foot valve 236 has been opened or closed, pump speed sensor 217 indicating the number of rotations per minute of the rotating pump / motor 142, A case temperature sensor 218 indicating the temperature of the pump housing of the pump / motor 142 and one or more of the transfer case switch sensors 219 are included. However, according to other aspects, the monitoring module 201 can also receive data signals from other types of sensors, such as a brake pressure sensor (not shown) that indicates the pressure of the vehicle brake 120.

According to some aspects, the plurality of monitoring modules 210 can also receive the input message 203 from the vehicle's communication network (eg, CAN bus) 184 via the network interface 202. According to one aspect, the input message 203 indicates the operating state of the components except the second power source 124. Non-limiting examples of input message 203 include engine speed, wheel-based vehicle speed, input shaft speed, output shaft speed, actual gear ratio of the engine, current gear ratio of the engine, accelerator pedal position, and engine required by the driver. It can include percent torque, percent torque of nominal friction, and / or an indication as to whether the anti-lock braking system (ABS) or cruise control is operating.

According to one embodiment, the network interface 202 also sends an output message 204 to the communication network 184. Non-limiting examples of the output message 204 include a torque limit, a speed limit indicating the maximum speed at which the vehicle can move, a status message indicating the state of the second power source 124, and one or more failure states. The code for the user indicator 190, the override control mode message, and the logger data (ie, the data stored in the data logger 100 of FIG. 1) can be included.

According to some aspects, the memory interface 205 is configured to acquire data from the memory and transmit the data to the memory, as in the memory 167 of FIG. For example, the memory interface 205 can acquire one or more failure detection algorithms 187 and / or failure detection parameters 189 from memory. Non-limiting examples of data written to memory by memory interface 205 can include received sensor data, values of parameters used in control algorithms, system component status, and fault status status. According to another aspect, the memory interface 205 can write data to the additional memory (not shown) via the communication network 184.

According to some aspects, the plurality of response modules 206 control signals to one or more control valves to activate the components of the second power source 124 in response to one or more failure conditions. To send. In the illustrated example, the response module 206 transmits control signals to the bypass valve 222, the clutch valve 224 and the swash plate control valve 226. However, according to another aspect, the response module 206 can transmit a control signal to any valve. For example, the response module 206 can operate the shutoff valve 230, the charge bypass valve 232 and the mode valve 234 (see FIG. 2).

According to one aspect, the control signal includes an electrical signal transmitted to one or more solenoids operably coupled to the valve. For example, the swash plate control valve 226 can be operated by a motor solenoid and a pump solenoid (see FIG. 2). The bypass valve 222 can be actuated by a bypass solenoid, and the clutch valve 224 can be actuated by a clutch solenoid. However, according to other aspects, these valves can be operated using more or fewer solenoids, or via other means, as known to those of skill in the art. ..

FIG. 5 is a flow chart illustrating an exemplary reset process 300 by a second power source 124 that can be operably coupled to the drive line 130 of the vehicle. According to some aspects, the reset process 300 is performed by the control system 152 each time the vehicle starts (ie, has a key attached). Also, according to other aspects, the reset process 300 can be executed when called by another processor, as described in more detail.

The reset process 300 is executed by an arbitrary initialization procedure and starts at the start module 310 to start the check operation 320. The check operation 320 accesses the memory of the second power source control system 152 in order to determine whether or not the failure state is stored. According to one embodiment, the check operation 320 accesses the non-volatile memory 167 to check the dysfunction failure state 182. According to another aspect, the check operation 320 accesses the volatile memory 168 to check the non-latching failure state 186 and / or the latching failure state 184.

The determination module 330 determines whether or not an arbitrary failure state exists in the memory. When the determination module 330 determines that the failure state is not stored in the memory, the second power source 124 is operably connected to the vehicle in the connection operation 340. As described in detail here, regardless of whether the concatenation operation 340 is invoked, the monitoring operation 350 analyzes the readings of the sensor to determine if the second power source 124 should be disconnected. .. The reset process 300 executes an arbitrary completion procedure and ends at the stop module 360.

FIG. 6 is a flow chart illustrating an exemplary failure detection process 400 capable of detecting and / or adjusting system and component failures and / or malfunctions. According to one embodiment, the exemplary failure detection process 400 is applied to execution by the second power source control system 152. The failure detection process 400 executes any suitable initialization procedure, starts with the start module 402, and continues the acquisition operation 404.

In the acquisition operation 404, the electronic data signal is received, that is, the electronic data signal is extracted. According to one aspect, the acquisition operation 404 acquires an electronic data signal from one or more sensors (eg, sensors 210-219 in FIG. 4). According to another aspect, the acquisition operation 404 acquires an electronic data signal from the communication network 184. In one aspect, in the acquisition operation 404, the monitoring module 201 of FIG. 4 receives an electronic data signal.

Analytical operation 406 processes the received electronic data signal to determine if a fault condition has been triggered. According to some aspects, in analysis operation 406, the received electronic data signal is based on the failure detection algorithm 187 and the operating parameter 189 stored in the non-volatile memory 167 of the second power source control system 152 (see FIG. 3). To process.

The check operation 408 accesses the memory of the second power source control system 152 in order to determine what failure state is stored. For example, in check operation 408, the non-volatile memory 167 and / or the volatile memory 168 can be accessed.

In the comparison operation 410, the overlapping portion between the failure state detected from the sensor data and the failure state stored in the memory is determined. The failure state of the non-overlapping part is the occurrence of a new failure state (that is, the failure state determined by the sensor data and not stored in the memory), or the failure state of the previous failure state. It indicates whether or not it is stopped (that is, a failure state stored in the memory but not determined by sensor data).

The first determination module 412 determines whether or not the failure state of the non-overlapping portion is a newly generated failure state. When the first determination module 412 determines that a new failure state has been detected, the response operation 414 subsequently disconnects the second power source 124 from the vehicle. An example of a response process that follows one embodiment is described in connection with FIG.

If the second determination module 416 determines that there is a failure state for the additional non-overlapping portion to be processed, then the failure detection process 400 returns to the first determination module 412 and continues as described above. Will be done. If the second determination module 416 determines that the failure states of all non-overlapping parts have been provided by the processed comparison operation 410, then the failure detection process 400 executes any suitable process. , It ends with the stop module 424.

However, when the first determination module 412 determines that the previously detected failure state has stopped, the third determination module 418 subsequently determines which type of failure state has stopped. For example, the third determination module 418 can determine whether a non-latching failure, a latching failure, or a dysfunctional failure has been detected. When the third determination module 418 determines that a latching failure state or a dysfunction failure state has been detected, the failure detection process 400 subsequently repeats the second determination module 416.

However, when the third determination module 418 determines that the non-latching failure state is detected, the erase operation 420 subsequently erases the non-latching failure state from the memory, and the reset operation 422 shows FIG. The reset process 300 is executed, and in the failure detection process 400, the second determination module 416 is repeated and continued as described above.

FIG. 7 is a flowchart showing an operation flow of an exemplary response process 500 that follows the response of the second power source control system 152 when a new failure state is detected. In response process 500, any suitable initialization procedure is performed to start with start module 502 and continue with warning operation 504.

Warning operation 504 provides the user (eg, driver) with instructions that a failure condition has occurred. According to some aspects, warning operation 504 activates one or more vehicle warning indicators (eg, on the vehicle dashboard). Non-limiting examples of the warning indicator 190 can include a light emitting symbol 192, a text reading on a display screen, and / or a speaker 194 configured to emit an audible signal. For example, according to one aspect, the warning operation 504 can power the light emitting indicator displayed to the user of the vehicle.

In the first operation operation 506, the swash plate 148 of the pump / motor unit 142 (FIG. 2) is moved to a neutral position (for example, a vertical position). For example, in the first operation operation 506, the response module 206 (FIG. 4) can transmit a control signal to the swash plate control valve 226 to set the swash plate 148 to the neutral position to zero. Setting the swash plate 148 to zero can help suppress the overspeed condition of the pump / motor unit 142 that damages the second power source 142. Further, setting the swash plate 148 to zero can be useful for removing torque from the drive line 130.

In the second actuation operation 508, a bypass is opened between the high pressure port of the pump / motor and the fluid reservoir 144 (FIG. 2). For example, in the second actuation operation 508, a control signal (eg, an electronic signal) can be transmitted from the response module 206 to the bypass valve 222 (FIG. 4) to bypass the fluid to the pump / motor unit 142. Opening the bypass valve 222 can help remove torque from the drive line 130. According to some aspects, in the second actuation operation 508, in the first actuation operation 504, after setting the swash plate 148 to zero, the bypass valve 222 is actuated for a predetermined time period. According to another aspect, in the second operation operation 508, the bypass valve 222 is operated after detecting the position of the swash plate.

In the disconnection operation 510, the second power source 124 is operationally disconnected from the hybrid drive assembly 102. When operationalally disconnected, the second power source 124 does not power the vehicle. According to some embodiments, the disconnection operation 510 activates the clutch valve 224 of the coupling assembly 149 to disconnect the second power source 124 from the drive line 130. According to one embodiment, the disengagement operation 510 activates the clutch valve 224 approximately simultaneously with opening the bypass in the second actuation operation 508. However, according to another aspect, in the detachment operation 510, the second power source 124 is driven from the drive line 130 before or after the first and second actuation operations 506 and 508 are performed. Can be separated.

The confirmation operation 512 determines the type of detected failure condition. According to some aspects, confirmation operation 512 determines whether the failure state is a non-latching failure 186, a latching failure 184, or a dysfunctional failure 182. When the determination module 514 determines that the newly detected failure state is a dysfunction failure, subsequently, in the first storage operation 516, the dysfunction failure state is set to the non-volatile memory such as the non-volatile memory 167 (FIG. 3). Save to. When the determination module 514 determines that the newly detected failure state is not a functional failure failure, the second storage operation 518 subsequently records the failure state in a non-volatile memory such as the non-volatile memory 168 (FIG. 3). Save to.

Response process 500 executes any suitable completion procedure and terminates at stop module 520.

FIG. 8 is a flowchart showing an operation flow of an exemplary network failure detection process 600 by the monitoring module 201 of the failure detection system 200 of FIG. 4, which can identify the failure state of the network by the failure detection system. According to one embodiment, the network failure state is a non-latching failure. However, according to other aspects, the fault state of the network is a latching fault or a dysfunctional fault.

In the network failure detection process 600, any suitable initialization procedure is performed to start with the start module 610 and continue the listen operation 620. The listening operation 620 checks whether data has been received from the communication network 184. For example, listening operation 620 can determine that an expected parameter or message has been received.

The determination module 630 determines whether or not the data has been received from the communication network 184. According to some aspects, if the determination module 630 determines that no data has been received, the failure operation 640 initiates a response process such as the response process 500 of FIG. According to one embodiment, and in the failure operation 640, the network communication failure state can be stored in the memory. The network failure detection process 600 executes an arbitrary completion procedure and ends at the stop module 650.

FIG. 9 is a flowchart showing an operation flow of an exemplary range failure detection process 700 for identifying a failure state outside the range in the monitoring module 201 of the failure detection system 200 of FIG. As a non-limiting example of an out-of-range failure condition, the received sensor signal is out of the normal operating range that can indicate a component malfunction and / or a system malfunction, and the received sensor signal is a sensor. And / or wiring problems are out of the detectable range that can be indicated, and can include measured valve currents that can indicate valve malfunction.

The range fault detection process 700 executes any suitable initialization procedure, is started by the start module 710, and continues the acquisition operation 720. In the acquisition operation 720, one or more sensor signals are received from one or more sensors such as the sensors 211 to 219 of FIG.

The determination module 730 determines which received data signal has a value outside a predetermined threshold (for example, greater than or equal to or less than or equal to). According to some embodiments, the determination module 730 determines which data signal has a value outside a predetermined threshold stored in the memory (memory 167 of the control system 152). According to one aspect, the determination module 730 can determine whether the data signal remains outside the threshold for a predetermined time period.

According to some aspects, if the determination module 730 determines that the received data signal is outside a predetermined threshold, the failure operation 740 initiates a response process such as the response process 500 of FIG. Let me. According to one aspect, and in the failure operation 740, the network communication failure state can be stored in the memory. The range fault detection process 700 executes any suitable completion procedure and ends at the stop module 750.

FIG. 10 is a flowchart showing an operation flow of an exemplary mismatch failure detection process 800 that identifies a failure state activated by a reading or command of a competing sensor in the failure detection system 200 of FIG. Non-limiting examples of such failure conditions include competition between speeds reported by the pump speed sensor and output shaft speed sensor, and competition between swash plate attitudes reported by two or more swash plate sensors. Conflicts between the swash plate sensor and the swash plate attitude reported by the commanded swash plate angle, and between the clutch valve sensor and the clutch state reported by the commanded clutch state can be included.

The mismatch failure detection process 800 is started at the start module 810 and continues the acquisition operation 820 by performing any suitable initialization procedure. The mismatch failure detection process 800 receives a first data signal indicating the state of the system or component from sensors such as the sensors 211 to 219 of FIG. According to one aspect, in the first acquisition operation 820, the first data signal can be received via the communication network 184. In another aspect, the first acquisition operation 820 can receive the first data signal directly from the sensor.

The second acquisition operation 830 acquires a second data signal indicating the state of the system or component. According to some aspects, in the second acquisition operation 830, the second data signal is acquired from a sensor such as the sensors 211 to 219 of FIG. According to another aspect, in the second acquisition operation 830, the second data signal can be acquired from the communication network 184 or the memory. According to one embodiment, the second data signal is a command or control signal supplied to the valve (eg, to the solenoid that controls the valve).

In the comparison operation 840, it is determined whether or not there is a conflict between the data signal received in the first acquisition operation 820 and the data signal received in the second acquisition operation 830. For example, according to some aspects, comparison operation 840 can determine differences between data signals. For example, according to one aspect, the comparative operation 840 determines the difference between the swash plate angle value reported by one swash plate sensor and the swash plate angle value reported by another swash plate sensor. be able to. According to another aspect, the comparison operation 840 determines whether the binary value of the first data signal matches the binary value of the second data signal. For example, according to some aspects, comparative operation 840 can determine if the clutch condition reported by the clutch valve matches the latest command sent to the clutch valve.

The first determination module 850 determines which conflict is sufficient to activate the failure state. According to some aspects, the first determination module 850 determines whether the difference between the competing data signals exceeds the permissible range of the system stored in the memory (eg, memory 167 of the control system 152). The second determination module 860 determines which conflicts that are out of the system's permissible range have survived for a predetermined time period.

According to another aspect, when the first and second determination modules 850 and 860 determine that the conflict between the two data signals exceeds the tolerance of the system and continues for a predetermined time period. In the failure operation 870, activates a response process such as the response process 500 of FIG. According to one embodiment, and in the failure operation 870, the failure state of the network can be stored in the memory. The mismatch failure detection process 800 executes any suitable completion procedure and ends at the stop module 880.

FIG. 11 is a flowchart showing an operation flow of an exemplary filter clogging failure detection process 900 in which the monitoring module 201 of the failure detection system 200 of FIG. 4 detects a clogged filter such as the filter 147 of the second power source 124. is there.

In the filter clogging failure detection process 900, any suitable initialization procedure is performed to start with the start module 910 and continue with the first acquisition operation 920. In the first acquisition operation 920, the first data signal is received from the fluid temperature sensor such as the fluid temperature sensor 212 of FIG. According to one aspect, in the first acquisition operation 920, the first data signal can be received via the communication network 184. According to another aspect, in the first acquisition operation 920, the first data signal can be received directly from the fluid temperature sensor 212.

In the second acquisition operation 930, a second data signal is acquired from a pump speed sensor such as the pump speed sensor 217 that indicates the pump speed. According to some aspects, the second acquisition operation 930 acquires the pump speed data signal directly from the pump speed sensor 217. According to another aspect, in the second acquisition operation 930, the pump speed data signal can be acquired from the communication network 184.

Computational operation 940 determines the acceptable filter pressure based on the fluid temperature and pump speed provided in the first and second acquisition operations 930,940. According to one embodiment, the acceptable filter pressure is calculated based on the test results obtained in the experiment.

In the third acquisition operation 950, the third data signal is acquired from the filter pressure sensor such as the filter pressure sensor 214 of FIG. According to some embodiments, in the third acquisition operation 950, the filter pressure data signal is acquired directly from the filter pressure sensor 214. According to another aspect, in the third acquisition operation 950, the filter pressure data signal can be acquired from the communication network 184.

The first determination module 960 compares the filter pressure provided in the third acquisition operation 950 with the acceptable filter pressure provided in the calculation operation 940. According to some embodiments, the first determination module 960 also determines whether the filter pressure exceeds the calculated acceptable filter pressure in an amount sufficient to initiate a fault condition. The second determination module 970 determines whether the filter pressure exceeds the calculated acceptable filter pressure within a predetermined allowable range for a predetermined time period.

According to another aspect, the first and second determination modules 960,970 determine that the filter pressure is greater than the system's permissible range and longer than the predetermined time period and exceeds the permissible filter pressure. In this case, the failure operation 980 initiates a response process such as the response process 500 of FIG. According to one embodiment, and in the failure operation 980, the failure state of the network can be stored in the memory. The filter clogging failure detection process 900 executes any suitable completion procedure and terminates at the stop module 990.

FIG. 12 is a flowchart showing an operation flow of an exemplary foot valve failure detection process 1000 in which the monitoring module 201 of the failure detection system 200 of FIG. 4 detects a malfunction of the proximity sensor of the accumulator such as the proximity sensor 216 of FIG. Is. In the foot valve failure detection process 1000, any suitable initialization procedure is performed to start with the start module 1002 and continue with the first acquisition operation 1004.

In the first acquisition operation 1004, the first data signal is received from an accumulator pressure sensor such as the accumulator pressure sensor 215 of FIG. According to one aspect, in the first acquisition operation 1004, the first data signal can be received via the communication network 184. According to another aspect, in the first acquisition operation 1004, the first data signal can be received directly from the accumulator pressure sensor 215.

In the second acquisition operation 1006, the second data signal is acquired from the proximity sensor 216. According to some aspects, the second acquisition operation 1006 acquires a data signal representing the state of the foot valve 236 directly from the proximity sensor 216. According to another aspect, in the second acquisition operation 1006, the foot valve data signal can be acquired from the communication network 184.

The first determination module 1008 determines whether the accumulator pressure data signal is outside the acceptable range. For example, according to one aspect, the first determination module 1008 determines whether the accumulator pressure data signal is lower than a predetermined lower limit.

When the first determination module 1008 determines that the accumulator pressure data signal is lower than a predetermined threshold value, the second determination module 1010 subsequently opens the data signal of the proximity sensor and the foot valve 236. It is determined whether or not it indicates that. According to one embodiment, the accumulator pressure below a predetermined threshold while the foot valve is open indicates a first failure condition.

In the second determination module 1010, when it is determined that the data signal of the proximity sensor indicates that the foot valve 236 is open and thereby indicates the first failure state, the third determination is subsequently made. Module 1012 determines whether the fault condition persists for a predetermined time period. According to some aspects, if the third determination module 1012 determines that the failure state has persisted for longer than a predetermined time period, the failure operation 1014 may be similar to the response process 500 of FIG. Start the response process.

However, if the first determination module 1008 determines that the accumulator pressure data signal is within an acceptable range, the foot valve failure detection process 1000 subsequently executes a third acquisition operation 1016. In the third acquisition operation 1016, a data signal is received from a fluid temperature sensor such as the fluid temperature sensor 212 of FIG. Computational operation 1018 determines the acceptable accumulator pressure based on the fluid temperature provided in third acquisition operation 1016.

The fourth determination module 1020 determines whether the accumulator pressure provided in the first acquisition operation 1004 exceeds the calculated acceptable accumulator pressure provided in the calculation operation 1018. When the fourth determination module 1020 determines that the first acquisition operation 1004 exceeds the allowable accumulator pressure, the fifth determination module 1022 subsequently determines that the data signal of the proximity sensor is that the foot valve is closed. Determine if it indicates that there is. According to one embodiment, the accumulator pressure above the calculated acceptable pressure while the foot valve is closed indicates a second failure condition.

The fifth determination module 1022 indicates that the foot valve 236 is closed, and when it is determined that the second failure state is indicated, the foot valve failure detection process 1000 subsequently determines that the foot valve 236 is closed. 3 Execute the determination module 1012 and continue as described above. However, if it is determined that one or more of the second, third, fourth, and fifth determination modules 1010, 1012, 1020, and 1022 does not satisfy the failure conditions, the foot is subsequently determined. The valve failure detection process 1000 returns to the first acquisition operation 1004, is repeated, and is started again. The foot valve failure detection process 1000 executes any suitable completion procedure and ends at the stop module 1024.

FIG. 13 is a flowchart showing an operation flow of an exemplary pressure leak failure detection process 1100 in which the monitoring module 201 of the failure detection system 200 of FIG. 4 detects a high voltage leak. In the pressure leak failure detection process 1100, any suitable initialization procedure is performed to start with the start module 1102 and continue with the first acquisition operation 1104.

In the first acquisition operation 1104, the first data signal is received from an accumulator pressure sensor such as the accumulator pressure sensor 215 of FIG. According to one aspect, in the first acquisition operation 1104, the first data signal can be received via the communication network 184. According to another aspect, in the first acquisition operation 1104, the first data signal can be received directly from the accumulator pressure sensor 215.

Computational operation 1106 finds the slope of the plotted (filled in) accumulator pressure with respect to time provided by the first acquisition operation 1104. According to one embodiment, and in calculation operation 1106, the absolute value of the slope is obtained. The first determination module 1108 determines whether or not the calculated slope value exceeds a predetermined threshold value. When the first determination module 1108 determines that the threshold value has not been exceeded, the pressure leak failure detection process 1100 then returns to the first acquisition operation 1104, is repeated, and is restarted.

However, when the first determination module 1108 determines that the calculated inclination value exceeds a predetermined threshold value, subsequently, in the second acquisition operation 1110, as in the proximity sensor 216 of FIG. The second data signal is acquired from the proximity sensor of the accumulator. According to some aspects, the second acquisition operation acquires the foot valve data signal directly from the foot valve sensor. According to another aspect, in the second acquisition operation, the data signal of the foot valve can be acquired from the communication network 184.

The second determination module 1112 determines whether the foot valve data signal provided by the second acquisition operation 1110 indicates that the foot valve is open. If the second determination module 1112 determines that the foot valve data signal indicates that the foot valve is closed, then the pressure leak failure detection process 1100 returns to the first acquisition operation 1104. Is repeated and started again. However, if the second determination module 1112 determines that the foot valve data signal indicates that the foot valve is open, then in the third acquisition operation 1114, the mode valve is open. Or receive a data signal indicating whether it is closed or not. According to some aspects, the third acquisition operation acquires the mode valve data signal directly from the mode valve sensor. According to another aspect, the third acquisition operation 1114 can acquire the mode valve data signal from the communication network 184.

If the third determination module 1116 determines that the mode valve data signal indicates that the mode valve is open, then the pressure leak failure detection process 1100 returns to the first acquisition operation 1104. Is repeated and started again. However, if the third determination module 1116 determines that the mode valve data signal indicates that the mode valve is closed, the fourth determination module 1118 subsequently determines that the mode valve is closed for a predetermined time period. Determines if the accumulator pressure exceeds the threshold while the valve is open and the mode valve is closed.

According to some aspects, if the fourth determination module 1118 determines that the failure state lasts longer than a predetermined time period, the failure operation 1120 will respond as in response process 500 of FIG. Start the process. The pressure leak failure detection process 1100 terminates at stop module 1122 by performing any suitable completion procedure.

FIG. 14 is a schematic representation of an exemplary pump assembly 1300 that can be used with pump / motor units such as the pump / motor unit 142 of FIGS. 1 and 2. The pump assembly 1300 includes a pump body 1310 in which a plurality of bores (cylinder openings) 1312 are formed through which the swash plate 1320 allows the piston 1315 to be axially displaced. Each piston 1315 interacts with the swash plate 1320 via the shoe 1317. Over time, the pump body 1310 has been pumped between each bore 1312 and each piston 1315, between each piston 1315 and each shoe 1317, between each shoe 1317 and the swash plate 1320, and / or between the bore and the pump. Leakage can occur between the case and (eg, from a damaged barrel (cylinder)).

According to some embodiments, the leak in the pump body assembly 1300 causes a pulsation of fluid in the pump case once per rotation of the pump body 1310. The pulsation of the fluid causes pressure spikes in the case or at the filter pressure sensor. Pressure spikes occur as often as the barrel rotation cycle. According to one embodiment, the data signal from the filter pressure sensor is filtered and analyzed to determine if a barrel leak has occurred. According to another aspect, the data signal from the case pressure sensor is filtered and analyzed to determine if a barrel leak has occurred.

FIG. 15A is a flowchart showing an operation flow of an exemplary leak detection process 1200A capable of detecting a barrel leak such as the barrel leak in the pump assembly 1300 of FIG. According to some embodiments, the leak detection process 1200A is carried out on the pump used in the hybrid vehicle described above. However, according to other embodiments, the leak detection process 1200A can be used with any type of pump (eg, axial piston pump) equipped with suitable sensors to measure pump speed and case pressure.

In the leak detection process 1200A, any suitable initialization procedure is performed to start with the start module 1202 and continue with the first acquisition operation 1204. According to one embodiment, the first acquisition operation 1204 determines the pressure of the fluid associated with the second power source 124. For example, in one embodiment, the first acquisition operation 1204 receives a data signal from a filter pressure sensor such as the filter pressure sensor 214 of FIG. According to another aspect, in the first acquisition operation 1204, a data signal is received from the case pressure sensor.

In the second acquisition operation 1206, the pump / motor frequency is determined. For example, in one embodiment, the second acquisition operation 1206 receives a data signal from a pump speed sensor such as the pump speed sensor 217 of FIG. According to one embodiment, in the second acquisition operation 1206, the pump speed data signal is converted to a frequency value (eg, RPM is converted to Hz by dividing the pump speed by 60). In another embodiment, in second acquisition operation 1206, the frequency of the pump can be determined in another way.

Filter operation 1208 removes pressure pulses from the acquired signal in order to acquire the filtered signal. For example, according to some aspects, filter operation 1208 removes pulses that do not occur at a constant speed when the pump is rotating at a constant speed. According to another aspect, filter operation 1208 removes pressure pulses generated at a frequency different from the frequency at which the pump is rotating. For example, filter operation 1208 can remove pulses that occur at frequencies higher and / or lower than the pump frequency. In one embodiment, filter operation 1208 uses a roll-off filter to remove such pulses.

For example, according to some embodiments, in filter operation 1208, first acquisition operation 1204 through a high-pass filter (eg, a Butterworth filter) to reduce noise from standard leaks, slow run cycles, and so on. The data signal can be passed from. Further, in filter operation 1208, the signal acquired from the high-pass filter can be modified in order to acquire a substantially discrete signal. In certain embodiments, filter operation 1208 also allows the signal (ie, or correction signal) of the pressure sensor to pass through a lowpass filter. According to one embodiment, the high-pass and low-pass filters can be adjusted based on experimentally determined values for the pump frequency.

In another embodiment, the data signal from the first acquisition operation 1204 can be passed through a bandpass filter to acquire the filtered signal. Bandpass filters can be configured based on the shape of the pump, the strength of the ripple of the acquired signal, and / or other frequencies (eg, vibration or other noise) derived from other components of the system. .. For example, in one embodiment, filter operation 1208 can remove frequencies approximately 20% above and below the pump frequency. In another embodiment, filter operation 1208 rolls off a frequency about 10% above and below the pump frequency. In some embodiments, only lowpass filters can be used in filter operation 1208. For example, according to some embodiments, if the pump is operating below the critical speed (about 500 RPM), filter operation 1208 uses only a lowpass filter to roll off high frequency pulses. Can be done.

An additional pump speed determination module 1210 (shown by a broken line) determines whether the rotation of the pump has reached a predetermined frequency. In some embodiments, the pressure pulse from the leak occurs too fast above a particular pump speed sampled accurately. In this embodiment, the pump speed determination module 1210 prevents annoying failures when the pump is rotating at a speed outside the detection range. Therefore, if the pump speed determination module 1210 determines that the pump speed from the second acquisition operation 1206 is greater than the maximum limit speed, then the leak detection process 1200 returns to the first acquisition operation 1204 and is repeated. It will start again.

However, when the pump speed determination module 1210 determines that the pump speed is smaller than the maximum limit speed, the leak detection process 1200 subsequently executes the second determination module 1212. In another embodiment, the sensor (eg, the filter sensor of FIG. 2) is accurate enough to eliminate the need for the pump speed determination module 1210. In this embodiment, the leak detection process 1200A executes the pressure spike determination module 1212 from filter operation 1208.

The pressure spike determination module 1212 determines whether the filtered signal exceeds a predetermined threshold. According to some embodiments, the threshold is determined experimentally and stored electronically (eg, in memory 167 of the second power source control system 152 in FIG. 3). For example, in one embodiment, the second determination module 1212 can acquire the threshold value from the memory on the CAN bus 184.

For example, in some embodiments, the pressure spike threshold can be selected by operating a pump with known leaks and mapping pressure spikes during operation. it can. In certain embodiments, the threshold can be set as the magnitude of the experimentally measured pressure spike plus or minus the tolerance. In other embodiments, the threshold can be set as a percentage of the experimentally measured pressure spike magnitude (eg, 10%, 15%, 25%, 50%, 75%, etc.). In another embodiment, the threshold is selected based on the pressure spikes generated by the pump operating under ideal conditions. For example, the threshold can be selected by adding the percentage (25%, 50%, 75%, 100%, 150%, etc.) to the pressure spike experimentally obtained under ideal conditions.

According to some aspects, the pressure spikes that occur at the pump frequency are mapped for different operating conditions. Therefore, the pressure spike thresholds can be associated with different operating conditions. For example, pressure spikes can be associated with different swash plate angular positions and / or different pressure readings. The map can be used to determine the threshold value used for a given operating parameter. In this case, the leak detection process 1200A determines the operating parameters, and the pressure spike threshold module 1212 compares the filtered signal with the threshold for these operating parameters. Other processes are shown in Figure 15B and are described here.

If the pressure spike determination module 1212 determines that the filtered signal does not exceed the pressure spike threshold, then the leak detection process 1200A returns to the first acquisition operation 1204 and is repeated and restarted. .. However, if the pressure spike determination module 1212 determines that the filtered signal exceeds the pressure spike threshold, then in failure operation 1214, a response process such as response process 500 in FIG. 7 is performed. Start it. According to one aspect, failure operation 1214 determines that the leak constitutes a dysfunctional failure. In the leak detection process 1200A, an arbitrary completion procedure is executed and the process ends at the stop module 1216.

FIG. 15B is a flowchart showing an operation flow of another exemplary leak detection process 1200B that detects a barrel leak, such as the barrel leak of the pump assembly 1300 of FIG. According to some embodiments, the leak detection process 1200B is performed on the pump used in the hybrid vehicle, as described above. However, according to other embodiments, the leak detection process 1200B can be used with any type of pump (eg, any axial piston pump) having suitable sensors to measure pump speed and case pressure. it can. The leak detection process 1200B can be used in place of the leak detection process 1200A of FIG. 15A. The leak detection process 1200B differs from the leak detection process 1200A by storing pressure spike thresholds only for specific operating parameters (instead of a 3D map for substantially all operating parameters).

In the leak detection process 1200B, any appropriate initialization procedure is executed to start with the start module 1202 and continue with the first determination module 1201. The first determination module 1201 determines if the current operating parameters of the pump (ie or vehicle) are within acceptable limits. For example, in some embodiments, the first determination module 1201 acquires data signals from suitable sensors to determine the current operating parameters of the pump and / or vehicle. For example, in one embodiment, the first determination module 1201 acquires a data signal representing the current swash plate angle and / or the current filter pressure. Further, the first determination module 1201 determines whether or not the pressure spike threshold value corresponding to the current operating state is stored in the memory 167 of the second power source control system 152 of FIG. 3, for example. Operating conditions that do not have a corresponding threshold are out of tolerance.

If the first determination module 1201 determines that the pressure spike threshold is not stored for the current operating conditions, then the leak detection process 1200B is repeated back to the start operation 1202 and again. It will be started. Therefore, the first determination module 1201 prevents annoying failures. However, if the first determination module 1201 determines that the pressure spike threshold is stored for the current operating conditions, then the leak detection process 1200B executes the first acquisition operation 1204. .. Performing operations 1204 to 1214 of the leak detection process 1200B is substantially the same as executing operations 1204 to 1214 of the leak detection process 1200A.

In the leak detection process 1200B, the pressure spike determination module 1212 determines whether or not the filter signal exceeds a predetermined threshold value corresponding to the operating conditions determined by the first determination module 1201. According to some embodiments, the pressure spike threshold is determined experimentally (eg, using any of the processes described above in connection with FIG. 15A) and (eg, the second power source control of FIG. 3). It is stored electronically (in memory 167 of system 152). For example, in one embodiment, the second determination module 1212 can acquire the threshold value from the memory on the CAN bus 184.

If the second determination module 1212 determines that the filter signal does not exceed the pressure spike threshold, then the leak detection process 1200 is repeated back to the first acquisition operation 1204 and started again. .. However, when the second determination module 1212 determines that the filter signal exceeds the pressure spike threshold, the failure operation 1214 subsequently initiates a response process such as the response process 500 of FIG. .. According to one aspect, failure operation 1214 determines that the leak constitutes a dysfunctional failure. The leak detection process 1200B executes an arbitrary completion procedure and ends at the stop module 1216.

FIG. 15C is a flowchart showing an operation flow of an exemplary monitoring process in which changes in pump tone are monitored over a long period of time and associated with changes in filter pressure spikes. According to some embodiments, the monitoring process 1200C is followed by the leak detection processes 1200A, 1200B of FIGS. 15A, 15B. For example, in one embodiment, the monitoring process 1200C determines that the pressure signal of the filter is within an acceptable range (eg, below a threshold) before returning to the start of the process and repeating. 2 The determination module 1212 can be executed. In another embodiment, the monitoring process 1200C can be performed after the fault operation 1214 has been invoked.

In the monitoring process 1200C, any suitable initialization procedure is performed to start with the start module 1218 and continue with the acquisition operation 1220. Acquisition operation 1220 determines if the previous pressure spike value was stored (eg, in memory 167 of the second power source control system 152 of FIG. 3). If such a value is stored, acquisition operation 1220 retrieves the value from memory. In some embodiments, acquisition operation 1220 derives one or more pressure spike discrete values stored in memory. In another embodiment, acquisition operation 1220 derives a moving average value based on a previously stored value.

The determination module 1222 compares the filtered data signal acquired in the leak detection processes 1500A and 1500B with the stored pressure spike value. When the determination module 1222 determines that the pressure spike of the filtered data signal deviates from the value stored for the pressure spike by the amount of the threshold value, the failure operation 1224 is subsequently activated. In one embodiment, failure operation 1224 initiates a response process, such as response process 500 in FIG.

In the storage operation 1226, for example, the value of the pressure spike of the filtered data signal is stored in the memory 167 of the second power source control system 152 of FIG. In some embodiments, storage operation 1226 uses the values of the filtered data signal to calculate the moving average based on the values already stored in memory. In the monitoring process 1200C, an arbitrary completion procedure is executed and the process ends at the stop module 1228.

If the determination module 1222 determines that the pressure spike of the filtered data signal does not deviate from the value stored for the pressure spike by the amount of the threshold value, then in the monitoring process 1200C, the storage operation 1226 You can proceed to. However, in other embodiments, the monitoring process 1200C can instead execute the stop module 1228 directly.

According to some embodiments, in the monitoring process 1200C, to determine if the pump's function begins to decline over time, even if it has not deteriorated enough to trigger a failure. Can be used. According to other embodiments, the monitoring process 1200C can be used to plan the function of the pump in detail over the long term to help provide the prognosis of the pump.

FIG. 16 is a block diagram showing an exemplary detection process 1400 for determining low levels of fluid (eg, oil). According to some aspects, the detection process 1400 receives inputs from the transmission output speed sensor, the oil level sensor, the foot valve sensor and the accumulator pressure sensor. If the transmission output speed is approximately equal to zero RPM and the foot valve sensor indicates that the foot valve is open, as in the foot valve 236 of FIG. 2, in detection process 1400, the accumulator pressure sensor And the oil level sensor in the reservoir determine if the fluid level is below a given threshold for a given time period. According to one aspect, the failure condition resulting from the detection process 1400 is a dysfunction failure.

FIG. 17 is a block diagram showing an exemplary bypass valve failure detection process 1500 for determining a bypass valve malfunction. The detection process 1500 examines the actual calculated flow rate and posts a failure if the pump does not reach the appropriate pressure within a predetermined time period (eg, about 10 seconds).

According to some aspects, the detection process 1500 receives input signals from the swash plate angle sensor, pump rotation speed sensor and accumulator pressure sensor. The absolute value of the pump / motor flow rate can be calculated from the data received from the swash plate angle sensor and the pump rotation speed sensor. For example, the pump / motor flow rate can be calculated using the following equation.

Pump / motor flow rate = [(displacement amount of maximum slope angle) * (rotation speed) * tan (actual slope angle)] / (231 * (maximum slope angle))

In the detection process 1500, when the calculated flow rate exceeds a predetermined limit value and the accumulator pressure does not reach a predetermined threshold value within a predetermined time period, it is determined that a latching failure state has occurred. .. In the detection process 1500, when the latching failure state is detected more than a predetermined number of times (for example, 5 times or more), it is determined that the dysfunction failure state has occurred. According to one embodiment, the number of detected latching failure states can be stored in a memory such as the volatile memory 168 of FIG.

FIG. 18 is a block diagram showing an exemplary bootstrap failure detection process 1600 for detecting a malfunction of the bypass valve. The detection process 1600 examines the commanded calculated flow rate and posts a failure if the pump does not reach the appropriate pressure within a predetermined time period (eg, about 10 seconds).

According to some aspects, the detection process 1600 receives input signals from the pump rotation speed sensor and the accumulator pressure sensor. Further, in the detection process 1600, it is determined that the latest command has been transmitted to the swash plate control valve. The absolute value of the pump / motor flow rate can be calculated based on the pump rotation speed and the angle of the swash plate instructed to place. For example, the pump / motor flow rate can be calculated using the following equation.

Pump / motor flow rate = [(displacement amount of maximum slope angle) * (rotation speed) * tan (commanded slope angle)] / (231 * (maximum slope angle))

In the detection process 1600, when the calculated flow rate exceeds a predetermined limit value and the accumulator pressure does not reach a predetermined threshold value within a predetermined time period, it is determined that a latching failure state has occurred. .. In the detection process 1600, when the latching failure state is detected five times or more, it is determined that the dysfunction failure state has occurred. According to one embodiment, the number of detected latching failure states can be stored in a memory such as the volatile memory 168 of FIG.

FIG. 19 is a block diagram showing an exemplary pump / motor failure detection process 1700 for detecting pump malfunction. According to some aspects, the detection process 1700 receives input signals from the swash plate angle sensor, pump rotation speed sensor and accumulator pressure sensor. The absolute value of the pump / motor flow rate can be calculated based on the equation provided in connection with FIG.

In the detection process 1700, when the calculated flow rate exceeds a predetermined limit value and the accumulator pressure does not reach a predetermined threshold value within a predetermined time period, it is determined that a malfunction failure state has occurred. To do. According to one embodiment, the predetermined threshold for accumulator pressure is lower than the predetermined threshold used in the detection process 1500 to determine the failure of the bypass valve.

FIG. 20 is a block diagram showing an exemplary disconnection failure detection process 1800 for determining a failure of a transfer case that disconnects the second power source 124 from the vehicle. According to some aspects, the detection process 1800 receives an input signal from the clutch valve sensor. Further, in the detection process 1800, the latest command transferred to the clutch valve is determined. In the detection process 1800, it is determined that a malfunction has occurred when the difference between the commanded clutch state and the actual clutch state is larger than a predetermined time period by a threshold value. According to one aspect, the detection process 1800 initiates a speed limiting process in response to the detection of a malfunction failure state.

FIG. 21 is a flowchart showing an operation flow of an exemplary speed limiting process 1900 that limits the engine speed in the event of a transfer case failure to reduce damage to the second power source. Generally, in the speed limiting process 1900, if an appropriate speed limiting command (eg, J1939 command) is sent to the engine and the second power source 124 fails to disconnect from the first power source, the pump will fail. Prevents rotation.

The speed limiting process 1900 performs any suitable initialization procedure, starting with the start module 1902 and continuing with the first determination module 1904. The first determination module 1904 determines whether or not a disconnection failure failure has been activated. For example, in one embodiment, the first determination module 1904 checks whether such a failure is stored in the non-volatile memory 167 of the second power source control system 152 of FIG. An exemplary process in which such a failure is invoked is described above in connection with FIG. Of course, the failure can be stored in other types or types of electronic memory.

If the first determination module 1904 determines that such a failure has not been triggered, then the speed limiting process 1900 executes an arbitrary completion procedure and ends at the stop module 1916. However, when the first determination module 1904 determines that the disconnection failure failure has been activated, the speed limiting process 1900 subsequently executes the first acquisition operation 1906. In the first acquisition operation 1906, a data signal representing the pump speed (eg RPM) is received. For example, in the first acquisition operation 1906, a data signal can be acquired from a pump speed sensor such as the speed sensor 217 of FIG.

In the second acquisition operation 1908, a data signal representing the gear ratio of the pump is received. For example, in one embodiment, the second acquisition operation 1908 can receive data signals from the processor 166 of FIG. 3 and the non-volatile memory 167 of the second power source control system 152. In another exemplary embodiment, the second acquisition operation 1908 can receive a data signal from the non-volatile memory 161 of the processor 160 and the prime mover control unit 154 of FIG. In another embodiment, in the second acquisition operation 1908, the gear ratio data signal can be received at the user's input or via the upload signal from the remote computer.

Computational operation 1910 determines the maximum permissible engine speed when the second power source is connected to the vehicle. In some embodiments, computational operation 1910 determines the maximum permissible engine speed based on at least a portion of the acquired gear ratio. In one embodiment, computational operation 1910 determines the maximum permissible engine speed based on at least a portion of the acquired pump speed. For example, in one embodiment, calculation operation 1910 can calculate the maximum permissible engine speed according to the following equation. Maximum allowable engine speed = Maximum allowable transmission output speed * Gear ratio In another embodiment, the calculation operation 1910 determines the maximum permissible engine speed by reading a stored value from a memory such as the non-volatile memory 167 or non-volatile memory 161 of FIG.

The second determination module 1912 determines whether the pump is moving faster than the calculated maximum permissible speed. In the second determination module 1912, if the pump is not moving faster than the maximum permissible speed, then the speed limiting process 1900 returns to the first acquisition operation 1906 to monitor the current pump speed. However, if the second determination module 1912 determines that the pump is moving faster than the maximum permissible speed, then the speed limiting process 1900 executes the limiting operation 1914.

Restriction operation 1914 sends an appropriate command to limit the speed of the engine. For example, in the restriction operation 1914, a restriction command is transmitted via the communication network 184. In one embodiment, the restriction operation 1914 sends a J1939 command to the engine. The speed limiting process 1900 executes an arbitrary completion procedure and ends at the stop module 1916.

FIG. 22 is a schematic diagram of an exemplary fluid accumulator 2000 suitable for use as the high pressure accumulator 146 of FIG. The fluid accumulator 2000 includes a rigid outer shell (ie, housing) that forms the inner chamber. The separator 2020 divides the internal chamber into a liquid chamber 2015 and a gas chamber 2025. As mentioned above, the oil can be moved between the reservoir 144 and the liquid chamber 2015 of the accumulator 146 (eg, via a high pressure valve). The gas in the gas chamber 2025 can be received via the gas pressure valve. In some embodiments, the gas is some kind of inert gas, such as nitrogen gas. It should be understood that this disclosure does not limit the use of any particular type of gas.

In some embodiments, the housing 2101 includes a fluid port and a conduit 2012 that communicate the liquid chamber 2020 with the outer components of the accumulator. In various embodiments, the fluid port and conduit may or may not include a valve assembly. In some exemplary embodiments, the internal gas chamber 2025 can receive high pressure gas from a pressurized gas source, for example via a gas port 2022 and a gas charge valve. In other embodiments, the accumulator 2000 can include a single fluid valve or gas valve. Embodiments of the present invention are not limited to a particular type of fluid valve, i.e., even if such a valve exists, a particular type of fluid valve.

In some embodiments, the separator 2020 between the liquid chamber 2015 and the gas chamber 2025 can include a piston (eg, sealed with an elastic seal ring). In another embodiment, the separator 2020 can include some kind of bellows arrangement. In yet another embodiment, the separator 2020 can include an elastic bladder. Some of the exemplary materials used to form such bladder are permeable or at least semipermeable (ie, for many years, one piece of nitrogen gas in an adjacent liquid chamber through the bladder material. It is a material that does not pass through the part.) In one exemplary embodiment, the bladder 2020 is made of nitrile rubber.

One process of detecting a gas leak from the internal gas chamber 2025 involves monitoring the temperature and pressure of the gas in the bladder 2020. However, according to some embodiments, gas leaks from the internal gas chamber 2020 are not detected based on the measured properties of the gas. In fact, in some embodiments, the accumulator 2000 does not include at least one of the gas pressure sensors or gas temperature sensors in the accumulator 2000 bladder 2020. According to certain embodiments, the accumulator 2000 includes neither a gas pressure sensor nor a gas temperature sensor in the accumulator bladder 2020.

FIG. 23 is a flowchart showing an operation flow of an exemplary gas leak detection process 2300 capable of detecting a gas leak in the accumulator. For example, in the gas leak detection process 2300, it can be determined whether or not gas is leaking (leaking) from the gas chamber 2025 of the accumulator 2000 in FIG. 22. According to some aspects, the gas leak detection process 2300 detects gas leaks without directly measuring the properties of the gas. For example, in one embodiment, the gas leak detection process 2300 detects a gas leak without directly measuring the temperature and / or pressure of the gas.

Generally, the gas leak detection process 2300 is performed only when the second power source system is started (eg, daily or after a downtime). As described above, the gas leak detection process 2300 executes an arbitrary appropriate initialization procedure, starts at the start module, and continues with the first determination module 2302. The first determination module 2302 determines whether or not the accumulator has been newly started.

When the first determination module 2302 determines that the accumulator has newly started, the gas leak process 2300 subsequently executes the first acquisition operation 2304. However, if the first determination module 2302 determines that the accumulator has not started anew, then the gas leak process 2300 executes an arbitrary completion procedure and ends at the stop module. An example of the process of the first determination module 2302 capable of making a determination is shown in FIG.

According to one embodiment, the first acquisition operation 2304 receives a data signal from the liquid temperature sensor. For example, in one embodiment, the first acquisition operation 2304 can receive a data signal from the reservoir temperature sensor 212 of FIG. This data signal represents the temperature of a liquid (eg, oil) in a reservoir such as the reservoir 144 of FIG. This liquid is transferred to an accumulator chamber such as the fluid chamber 2015 of accumulator 2000 in FIG. In another embodiment, in first acquisition operation 2304, a data signal can be received from any temperature sensor configured to measure the temperature of the liquid flowing between the reservoir and the accumulator.

In the second acquisition operation 2306, a data signal is received from the fluid pressure sensor of the accumulator. For example, in one embodiment, the second acquisition operation 2306 receives a data signal from the accumulator pressure sensor 215 of FIG. This data signal represents the pressure of a liquid (eg, oil) in the accumulator. For example, in one embodiment, the data signal represents the pressure of the fluid in the fluid chamber 2015 of the accumulator 2000 in FIG. In another embodiment, in second acquisition operation 2306, a data signal can be received from any pressure sensor configured to measure the pressure of the liquid flowing between the reservoir and the accumulator.

Estimating operation 2308 calculates the pressure of a gas in the accumulator, such as nitrogen in the internal gas chamber 2025 of the accumulator 2000 in FIG. For example, in some embodiments, estimation operation 2308 calculates the pressure of the gas in the accumulator based on the pressure of the fluid in the accumulator. In this embodiment, the estimation operation 2308 determines the approximate gas pressure based on the data signal received in the second acquisition operation 2306.

In one embodiment, estimation operation 2308 determines that the pressure of the gas in the accumulator will reach a particular temperature. For example, in one embodiment, in estimation operation 2308, the pressure of the gas in the accumulator determines that the temperature of the gas may have been about 20 ° C. Of course, in estimation operation 2308, the pressure can be calculated at any desired temperature. In estimation operation 2308, decisions can be made based on the measured fluid temperature and measured fluid pressure in the accumulator reservoir or liquid chamber. For example, in estimation operation 2308, the pressure of the fluid can be calculated back based on the data signals received in the first and second acquisition operations 2302 and 2304. From the back-calculated fluid pressure, the estimation operation 2308 can estimate the gas pressure at the desired temperature.

The second determination module 2310 determines whether or not the estimated gas pressure is within the permissible value. In some embodiments, the second determination module 2310 can determine if the estimated gas pressure is less than a predetermined threshold at a particular temperature. In some embodiments, the threshold is set based on a standard working pressure that can be experimentally determined for a particular accumulator. In some embodiments, the second determination module 2310 compares the back-calculated estimated pressure value with the threshold. According to another aspect, the temperature relative to the gas pressure calculated back in estimation operation 2308 is based on the threshold.

In some embodiments, the threshold for the second determination module 2310 is based on the percentage value of the standard working gas pressure at the standard operating temperature for a particular accumulator. For example, in one embodiment, the second determination module 2310 determines if the approximate pressure is within 10% of the standard operating range for a particular accumulator. In another embodiment, the second determination module 2310 determines if the estimated pressure is within 15% of the standard operating range. In yet another embodiment, the second determination module 2310 determines if the estimated pressure is within 20% of the standard operating range. In yet another embodiment, the second determination module 2310 determines if the estimated pressure is within 25% of the standard operating range. For example, in one embodiment, the standard working pressure of the gas in the accumulator is about 124 bar at 20 ° C. In one such embodiment, the second determination module 2310 determines if the estimated gas pressure is less than or equal to 100 bar at 20 ° C.

When the second determination module 2310 determines that the estimated gas pressure is out of the allowable range of the gas pressure, the gas leak detection process 2300 subsequently activates the failure operation 2312. For example, in the second determination module 2310, it can be determined that the estimated gas pressure is equal to or less than the set threshold value. In the failure operation 2312, a response process such as the response process 500 of FIG. 7 is started. According to one embodiment, failure operation 2312 determines that the leak constitutes a dysfunctional failure. The leak detection process 2300 executes an arbitrary completion procedure and ends with a stop module.

When the second determination module 2310 determines that the estimated gas pressure is within the permissible value of the gas pressure (for example, not below the set threshold value), the gas leak detection process 2300 subsequently determines. Perform storage operation 2314. In the storage operation 2314, the estimated gas pressure value is stored in a memory such as the non-volatile memory 167 of the second power source (see FIG. 3). In some embodiments, storage operation 2314 also erases previously stored values, such as the oldest gas pressure value stored in memory. In another embodiment, the value stored in the storage operation 2314 is not erased.

In average operation 2316, a moving average of estimated gas pressure values stored in memory is calculated. In some embodiments, average operation 2316 can calculate a moving average based on the latest value stored in memory. For example, in one embodiment, average operation 2316 calculates a moving average of the five latest estimated gas pressure values stored in memory. However, in another embodiment, in average operation 2316, calculations can be made based on the latest three values, eight values, ten values, fifteen values, twenty values, fifty values, and the like.

The third determination module 2318 determines whether or not the moving average of the approximate gas pressure value is within the permissible range. In some embodiments, the third determination module 2318 can determine if the moving average is less than a predetermined threshold associated with a particular temperature. In some embodiments, the tolerance for the moving average is closer to the desired operating parameter than the tolerance used in the second determination module 2310.

In some embodiments, the threshold for the third determination module 2318 is based on the percentage of standard working gas pressure at standard operating temperature for a particular accumulator. For example, in one embodiment, the third determination module 2318 determines if the moving average is within 10% of the standard operating range for a particular accumulator. In another embodiment, the third determination module 2318 determines if the moving average is within 5% of the standard operating range. In yet another embodiment, the third determination module 2318 determines if the moving average is within 15% of the standard operating range. In yet another embodiment, the third determination module 2318 determines if the moving average is within 20% of the standard operating range. For example, in one embodiment, in the third determination module 2318, if the standard operating value is about 124 bar at 20 ° C, the moving average of the approximate gas pressure value is less than 115 bar at 20 ° C. judge.

When the third determination module 2318 determines that the moving average is out of the allowable value range, the gas leak detection process 2300 subsequently activates the failure operation 2312. For example, in the third determination module 2318, it can be determined that the moving average is equal to or less than the set threshold value. In the failure operation 2312, a response process such as the response process 500 of FIG. 7 is started. According to one aspect, failure operation 2312 determines that a leak constitutes a dysfunctional failure. In another embodiment, failure operation 2312 determines that a leak constitutes a latching failure. In another embodiment, failure operation 2312 issues a service indicator without invoking a failure response in particular. The leak detection process 2300 executes an arbitrary completion procedure and ends with a stop module.

When the third determination module 2318 determines that the moving average is within the allowable value range of the gas pressure (for example, not below the set threshold value), the gas leak detection process 2300 subsequently performs a failure operation. It ends with a stop module without starting 2312.

FIG. 24 is a flowchart showing an operation flow of an exemplary initialization check process 2400 that determines whether the system has recently been initialized by the gas leak detection process 2300. In the initialization check process 2400, an arbitrary initialization procedure is executed to start with the start module, and it is determined whether or not the foot valve such as the foot valve 236 of FIG. 2 has been changed to the open position. The determination module 2402 is started.

If the state of the foot valve has not changed, i.e. not in the open position, then the initialization check process 2400 initiates a first return operation 2412 that returns to a "No" or false value. .. The initialization check process 2400 executes an arbitrary completion procedure and ends with a stop module. However, if the initialization check process 2400 determines that the foot valve has been changed to the open state, the initialization check process 2400 subsequently starts the first acquisition operation 2402.

In the first acquisition operation 2402, a data signal is received from the first temperature sensor indicating the temperature of the pump case. For example, in the first acquisition operation 2404, a data signal can be received from the case temperature sensor 218. In the second acquisition operation 2406, a data signal is received from a second temperature sensor indicating the temperature of the fluid reservoir, such as reservoir 144 (see FIGS. 1 and 2). For example, in the second acquisition operation 2406, a data signal can be received from the reservoir temperature sensor 212.

In the comparison operation 2408, the difference between the data signal received in the first acquisition operation 2404 and the data signal received in the second acquisition operation 2406 is determined. The second determination module 2408 determines whether the difference calculated in the comparison operation 2406 is within a predetermined range. For example, in one embodiment, the second determination module 2408 determines if the temperature of the pump case and the temperature of the fluid reservoir are within 10 degrees of each other. In another embodiment, the second determination module 2408 determines whether the temperature of the pump case and the temperature of the fluid reservoir are within 2 degrees, 5 degrees, 8 degrees, 15 degrees, 20 degrees, etc. of each other.

If the second determination module 2410 determines that the case temperature is different from the fluid reservoir temperature, then the initialization check process 2400 returns to a "No" or false value for the first return operation. 2412 is started. If the second determination module 2410 determines that the case temperature is within the allowable range of the fluid reservoir temperature, then the initialization check process 2400 returns to a "Yes" or true value. The second return operation 2414 is started. The initialization check process 2400 executes an arbitrary completion procedure and ends with a stop module.

FIG. 25 is a flowchart showing an operation flow of an exemplary fluid leak detection process 2500 for determining whether a fluid (eg, oil) is leaking from a second power source. For example, the fluid leak detection process 2500 can detect fluid leaking from the reservoir, the liquid chamber of the accumulator, or the conduit between them. In general, the fluid leak detection process 2500 compares the fluid level in the reservoir with the estimated fluid level. The fluid leak detection process 2500 executes an arbitrary initialization procedure, starts with the start module, and starts the first determination module 2502.

The first determination module 2502 determines whether or not the foot valve is opened. For example, in one embodiment, the first determination module 2502 can acquire a reading from the proximity sensor 216 of the accumulator of FIG. 2, which indicates the opening and closing of the foot valve. When the first determination module 2502 determines that the foot valve is not open, the first determination module 2502 subsequently executes an arbitrary completion procedure and ends at the stop module. However, if the first determination module 2502 determines that the foot valve is open, the fluid leak detection process 2500 subsequently initiates the first acquisition operation 2504.

In the first acquisition operation 2504, a data signal is received from a temperature sensor indicating the temperature of the fluid in the reservoir. For example, in one embodiment, the first acquisition operation 2504 can receive a data signal from the temperature sensor 212 of the reservoir of FIG. This data signal indicates the temperature of a fluid (eg, oil) in a reservoir such as the reservoir 144 of FIG. In another embodiment, in first acquisition operation 2504, a data signal can be received from any temperature sensor configured to measure the temperature of the liquid flowing between the reservoir and the accumulator.

In the second acquisition operation 2506, a data signal is received from the fluid pressure sensor of the accumulator. For example, in one embodiment, the second acquisition operation 2506 receives a data signal from the pressure sensor 215 of the accumulator of FIG. This data signal indicates the pressure of a liquid (eg, oil) in the accumulator. For example, in one embodiment, the data signal indicates the pressure of the liquid in the fluid chamber 2015 of the accumulator 2000 in FIG. In another embodiment, the second acquisition operation 2506 can receive a data signal from any pressure sensor configured to measure the pressure of the liquid flowing between the reservoir and the accumulator.

Estimating operation 2508 calculates the estimated fluid level in the accumulator. According to some embodiments, the estimation operation 2508 calculates the estimated fluid level based on the amount of fluid that should be in the reservoir and the readings obtained in the first and second acquisition operations 2504 and 2506.

In the third acquisition operation 2510, the actual fluid level of the reservoir is measured. For example, in one embodiment, the third acquisition operation 2510 receives a data signal from the level sensor 211 of FIG. This data signal indicates the level of fluid in the reservoir 144 of FIG.

The second determination module 2512 determines whether or not the vehicle is moving. According to aspects of the present disclosure, the fluid bounces around the reservoir when the vehicle is moving. Therefore, fluid level measurements obtained when the vehicle is moving are likely to be more inaccurate than readings when the vehicle is stopped. When the second determination module 2512 determines that the vehicle is not moving, the fluid leak detection process 2500 subsequently evaluates the measured fluid level and the estimated fluid level and determines the difference between the two values. The determination comparison operation 2516 is started.

However, if the second determination module 2512 determines that the vehicle is moving, the fluid leak detection process 2500 subsequently initiates the adjustment operation 2514. In adjustment operation 2514, the amount is increased so that the measured fluid level differs from the estimated fluid level. In one embodiment, the amount by adjustment operation 2514 modifies the measurements or tolerances that will affect the fluid in the reservoir depending on how the vehicle is driven. Thus, in certain embodiments, the adjustment amount can be determined experimentally for a particular reservoir and / or accumulator.

In some embodiments, adjustment operation 2514 raises or lowers the estimated fluid level by a predetermined amount. For example, in one embodiment, adjustment operation 2514 subtracts 2 gallons from the estimated fluid level before comparing the measured fluid level with the estimated fluid level. In another embodiment, adjustment operation 2514 subtracts 1-5 gallons from the estimated fluid level before comparing the measured fluid level with the estimated fluid level. In addition, in other embodiments, one gallon or less (eg, a quarter gallon, a half gallon, etc.) can be subtracted.

In another embodiment, adjustment operation 2514 increases the tolerance for comparison. For example, in one embodiment, the adjustment operation 2514 can increase the tolerance by about 2 gallons. In another embodiment, adjustment operation 2514 adds 1-5 gallons to the tolerance before comparing the measured fluid level with the estimated fluid level. In yet another embodiment, adjustment operation 2514 can add no more than a gallon (eg, a quarter gallon, a half gallon, etc.) to the permissible range. In this embodiment, coordination operation 2514 is performed prior to comparison operation 2516. However, in other embodiments, the coordination operation 2514 can be performed after the comparison operation 2516.

The third determination module 2518 determines whether the estimated fluid level is sufficiently close to the measured fluid level in the reservoir. In some embodiments, the third determination module 2518 determines if the difference between the estimated fluid level and the measured fluid level is less than or equal to a predetermined threshold. In another embodiment, the third determination module 2518 determines if the difference between the adjusted estimated fluid level and the measured fluid level is less than or equal to a predetermined threshold.

In some embodiments, the threshold is set at least partially based on the amount of the system's tolerance. For example, the threshold can take into account the percent error of the fluid temperature reading, the percent error of the fluid pressure reading, and the percent error of the fluid level reading. In one embodiment, the fluid temperature sensor can have a 2% error, the fluid pressure sensor can have a 1% error, and the fluid level sensor can have a 7% error. In this one embodiment, the permissible threshold can be set to a value of at least 9% of the measured value. However, in other embodiments, the tolerance threshold can be set to a higher or lower tolerance.

In some embodiments, the threshold is set at least partially based on a law, rule or guideline. For example, thresholds are set at least partially based on EPA (US Environmental Protection Agency) guidelines. For example, in one embodiment, the third determination module 2518 determines if the difference between the estimated fluid level and the measured fluid level is about 10 gallons or less. In another embodiment, the third determination module 2518 determines if the difference between the estimated fluid level and the measured fluid level is about 5 gallons or less. In another embodiment, the third determination module 2518 determines if the difference between the estimated fluid level and the measured fluid level is about 3 gallons or less. In another embodiment, the third determination module 2518 determines if the difference between the estimated fluid level and the measured fluid level is about 1 gallon or less. In another embodiment, the third determination module 2518 determines if the difference between the estimated fluid level and the measured fluid level is about half a gallon or less.

If the third determination module 2518 determines that the difference between the estimated fluid level and the measured fluid level is within the permissible range, then the fluid leak detection process 2500 executes an arbitrary completion procedure and stops. Exit with a module. However, if the third determination module 2518 determines that the difference is out of the permissible range, the fluid leak detection process 2500 subsequently initiates the failure operation 2520. In this failure operation 2520, a response process such as the response process 500 of FIG. 7 is started. According to one aspect, failure operation 2520 determines that a fluid leak constitutes a malfunction failure. The fluid leak detection process 2500 executes an arbitrary completion procedure and ends with a stop module.

FIG. 26 is a block diagram showing another exemplary disconnection failure detection process 2600 that determines a failure of the transfer case that disconnects the second power source 124 from the vehicle. According to some embodiments of the present disclosure, the exemplary disconnection failure detection process 2600 can be used in place of the exemplary disconnection failure detection process 1800 shown in FIG. However, according to other embodiments of the present disclosure, the exemplary disconnection failure detection process 2600 can be used in conjunction with the exemplary disconnection failure detection process 1800 shown in FIG.

Generally, the detection process 2600 determines if the pump is still operating after it is estimated that the clutch has been disengaged. Further, in the determination process 2600, it is possible to determine the case where the difference between the pump speed and the output shaft speed is logically impossible. According to some embodiments, the detection process 2600 receives an input signal from the clutch valve sensor to determine if the clutch has been engaged or disengaged.

Further, in the detection process 2600, an input signal is received from the pump speed sensor in order to determine the speed of the pump. Further, in the detection process 2600, the pump speed is estimated by using the ratio of the output shaft speed and the transfer case. In one exemplary embodiment, the detection process 2600 obtains the output shaft velocity from the engine controller via the CAN bus 184. For example, in one embodiment, in the detection process 2600, the pump speed and the output shaft speed can be compared using the following equation. = | Pump speed- (output shaft speed * ratio to chest of drawers) |

In the detection process 2600, a failure is triggered when the clutch is engaged and the difference between the pump speed and the output shaft speed to be compared exceeds the permissible amount for a longer than a predetermined time period. In various exemplary embodiments, in the detection process 2600, the permissible speed limit exceeds about 3 seconds, 5 seconds, 8 seconds, 30 seconds, 1 minute, 2 minutes, 5 minutes or 30 minutes. In case of dysfunction failure can be activated.

In some embodiments, the detection process 2600 initiates a non-latching failure. In another embodiment, the detection process 2600 initiates a latching failure. In yet another embodiment, the detection process 2600 initiates a dysfunction failure. According to one embodiment, the detection process 2600 initiates a speed limiting process in response to detection of a dysfunctional failure condition. According to other embodiments, the detection process 2600 invokes a service alert in response to detection of a failure condition.

Further, in the detection process 2600, when the clutch state sensor indicates that the clutch is disengaged and the pump speed exceeds the threshold speed for a longer period than a predetermined time period, the threshold speed is exceeded. Initiate a failure. In various embodiments, in the detection process 2600, the dysfunction failure occurs when the speed threshold exceeds about 3 seconds, 5 seconds, 8 seconds, 15 seconds, 30 seconds, 1 minute, 2 minutes or 5 minutes. Can be started.

In some embodiments, the detection process 2600 initiates a non-latching failure. In another embodiment, the detection process 2600 initiates a latching failure. In yet another embodiment, the detection process 2600 initiates a dysfunction failure. According to one embodiment, the detection process 2600 initiates a speed limiting process in response to detection of a dysfunctional failure condition. According to other embodiments, the detection process 2600 invokes a service alert in response to detection of a failure condition.

Any amendments or changes to the disclosed content will be apparent to those skilled in the art without departing from the scope and spirit of this disclosure. For example, each flowchart represents an example of a series of operations. At least one of these flowchart operations can be performed in a different order. It should be understood that the scope of the present disclosure is not unreasonably limited to the embodiments described herein.