Fault detection and mitigation in hybrid drive system
Abstract
Fault detection and response systems and processes can be used in pumps, such as pumps/motors used in hybrid vehicles. The fault detection system determines when certain operating conditions occur that may affect proper operation of the system. The response system takes the appropriate action to trigger the fault condition. For example, different types of fault detection systems and processes include detection systems for leaks, sensor malfunctions, or operational errors.

Term
Projected expiry 11 June 2030.
- Priority
- Filed
- Published
- Today
- Projected expiry
20 claims: 6 independent, 14 dependent
- 1펌프시스템에서 배럴 누설을 검출하기 위한 검출방법에 있어서, 방법은:펌프시스템의 필터 압력센서로부터 데이터신호를 구하는 단계와;펌프시스템의 펌프 속도센서로부터 데이터신호를 구하는 단계와;펌프시스템의 펌프의 회전주파수를 결정하는 단계와;필터링된 신호를 얻기 위해 펌프의 회전주파수를 기반으로 하여 필터 압력센서로부터 수신한 데이터신호를 필터링하는 단계와;그리고 필터링된 신호가 규정된 임계치를 초과하는지를 판단하기 위해 필터링된 신호를 분석하는 단계를 포함하는 것을 특징으로 하는, 펌프시스템에서 배럴 누설을 검출하기 위한 검출방법.
- 2제1항에 있어서, 상기 데이터신호를 필터링하는 단계는:제1필터링된 신호를 구하기 위해 필터 압력펌프로부터 획득한 데이터신호를 고역통과필터를 통해 통과시키는 단계와;정류된 신호를 얻기 위해 제1필터링된 신호를 정류하는 단계와;그리고 필터링된 신호를 얻기 위해 정류된 신호를 저역통과필터를 통해 통과시키는 단계를 포함하는 것을 특징으로 하는 검출방법.
- 3제2항에 있어서, 상기 고역통과필터는 버터워스 필터인 것을 특징으로 하는 검출방법.
- 4제1항에 있어서, 상기 필터링된 신호가 규정된 임계치를 초과하면 펌프시스템의 경사판을 제로 아웃된 위치로 조정하는 단계를 더 포함하는 것을 특징으로 하는 검출방법.
- 5제1항에 있어서, 상기 필터링된 신호가 규정된 임계치를 초과하면 사용자에게 경보를 행하는 단계를 더 포함하는 것을 특징으로 하는 검출방법.
- 6액체챔버로부터 분리된 가스챔버를 가지고 저유기로부터 이격되는 축압기를 가지는 펌프시스템에서 가스누설을 검출하기 위한 검출방법에 있어서, 상기 방법은:저유기와 축압기의 액체챔버 사이에 전달되는 유체의 유체온도를 구하는 단계와;유체의 유체압력을 구하는 단계와;구한 유체온도와 구한 유체압력을 기반으로 가스압력을 추정하는 단계와;추정된 가스압력을 제1임계치와 비교한는 단계와;추정된 가스압력이 제1임계치 아래이면 제1장애를 작동시키는 단계를 포함하는 것을 특징으로 하는, 펌프시스템에서 가스누설을 검출하기 위한 검출방법.
- 7제6항에 있어서, 추정된 가스압력의 이동평균을 계산하는 단계와;이동평균을 제2임계치와 비교하는 단계와;그리고 이동평균이 제1임계치 아래이면 제2장애를 작동시키는 단계를 더 포함하는 것을 특징으로 하는 검출방법.
- 8제7항에 있어서, 상기 제2임계치는 상기 제1임계치보다 높은 것을 특징으로 하는 검출방법.
- 9제6항에 있어서, 구한 유체압력과 구한 유체온도를 기반으로 규정된 온도에서 추정된 가스압력이 어떻게 될 것인지를 계산하는 단계를 더 포함하는 것을 특징으로 하는 검출방법.
- 10제6항에 있어서, 상기 유체온도를 구하는 단계는 저유기의 온도센서로부터 유체온도를 구하는 단계를 포함하는 것을 특징으로 하는 검출방법.
- 11제6항에 있어서, 상기 유체압력을 구하는 단계는 축압기의 압력센서로부터 유체압력을 구하는 단계를 포함하는 것을 특징으로 하는 검출방법.
- 12펌프케이스 온도를 구하는 단계와;유체 저유기 온도를 구하는 단계아;펌프케이스 온도와 유체 저유기 온도를 비교하는 단계와;그리고 펌프케이스 온도와 유체 저유기 온도 간의 온도 차이를 판단하는 단계를 더 포함하는 것을 특징으로 하는 검출방법.
- 13액체챔버로부터 분리된 가스챔버를 가지고 저유기로부터 이격되는 축압기를 가지는 펌프시스템에서 오일누설을 검출하기 위한 검출방법에 있어서, 상기 방법은:저유기에서 유체의 유체온도를 나타내는 데이터신호를 구하는 단계와;축압기에서 유체의 유체압력을 나타내는 데이터신호를 구하는 단계와;구한 유체온도와 구한 유체압력을 기반으로 저유기 내 유체의 레벨을 추정하는 단계와;저유기에서 유체의 실제 레벨을 나타내는 데이터신호를 구하는 단계와;유체의 추정 레벨을 유체의 실제 레벨과 비교하는 단계와;실제 레벨이 추정 레벨보다 임계량 보다 많은 양만큼 다르면 장래를 작동시키는 단계를 포함하는 것을 특징으로 하는, 펌프시스템에서 오일누설을 검출하기 위한 검출방법.
- 14제13항에 있어서, 상기 펌프시스템은 차량에 작동적으로 연결되고, 상기 검출방법은:차량이 이동하는지를 판단하는 단계와;그리고 차량이 이동하는 것으로 판단되는지 또는 이동하지 않는 것으로 판단되는지를 기반으로 상기 임계량을 조정하는 단계를 더 포함하는 것을 특징으로 하는 검출방법.
- 15제14항에 있어서, 상기 임계량을 조정하는 단계는 차량이 정지하면 임계량을 낮추는 단계를 포함하는 것을 특징으로 하는 검출방법.
- 16제14항에 있어서, 상기 임계량은 데이터신호들을 제공하는 센서들의 공차를 적어도 부분적으로 기반으로 하여 계산하는 것을 특징으로 하는 검출방법.
- 17제1동력원과 제2동력원을 가지는 차량의 엔진의 속도를 제한하기 위한 제한방법에 있어서, 상기 방법은:차량이 엔진으로부터 제2동력원을 분리하는 것을 실패하였다는 것을 판단하는 단계와;제2동력원의 펌프의 펌프속도를 구하는 단계와;제2동력원의 펌프의 기어비를 구하는 단계와;상기 기어비를 적어도 부분적으로 기반으로 하여 최대 허용가능한 펌프속도를 판단하는 단계와;구한 펌프속도가 최대 허용가능한 펌프속도보다 크다면 차량의 엔진에 제한명령을 전송하는 단계를 포함하는 것을 특징으로 하는, 차량의 엔진의 속도를 제한하기 위한 제한방법.
- 18제17항에 있어서, 상기 차량이 엔진으로부터 제2동력원을 분리하는 것을 실패하였다는 것을 판단하는 단계는:엔진의 클러치에 전송되는 명령을 나타내는 제1데이터신호를 구하는 단계와;클러치의 현재 상태를 나타내는 제2데이터신호를 구하는 단계와;적어도 설정된 시간주기 동안에 클러치의 현재 클러치 상태가 클러치에 전송된 명령과 충분히 부합하지 않는다는 것을 판단하는 단계와;분리실패 장애를 작동시키는 단계를 포함하는 것을 특징으로 하는 제한방법.
- 19제18항에 있어서, 상기 분리실패 장애는 불능화 장애인 것을 특징으로 하는 제한방법.
- 20유체펌프와; 유체펌프에 위치하여, 유체펌프의 속도를 측정하도록 구성되는 펌프속도센서와; 펌핑할 유체의 압력을 측정하는 구성되는 압력센서와; 그리고 펌프속도센서와 필터압력센서와 연통하는 제어기를 포함하고, 상기 제어기는 프로세스와 메모리를 포함하고, 상기 제어기는:펌프속도센서와 압력센서로부터 데이터신호들을 구하고;필터링된 신호를 얻기 위해 펌프속도센서로부터 구한 데이터신호를 기반으로 압력센서로부터 구한 데이터신호를 필터링하고;압력급증 임계값에 필터링된 신호를 비교하고;그리고 필터링된 신호가 압력급증 임계값에 도달하면 장애상태를 작동시키도록 구성되는 것을 특징으로 하는 유체 펌프시스템.
Independent claims20
200 paragraphs, as filed
Fault detection and mitigation in hybrid drive systems
The present invention is a PCT international patent application filed on June 11, 2010 in the name of Eaton Corporation, a United States corporation, and Eaton Corporation has filed applications in all designated countries except the United States, and US citizen Mitchell Anthony Stoner and US citizen Thomas D. . Hawkins and Douglas Simpson, a U.S. citizen, claim priority to U.S. Provisional Patent Application No. 61/186,136, filed on June 11, 2009, as applicants only to the United States.
Highway and national highway hybrid vehicles are vehicles that include multiple power sources. As an example, a hybrid vehicle may use a conventional gas driven engine to propel the vehicle in one mode of operation and an electric motor to propel the vehicle in another mode of operation. As another example, a hybrid vehicle may use a gas driven engine to propel the vehicle in one mode of operation and a fluid motor to propel the vehicle in another mode of operation. Due to the multiple power sources, the hybrid vehicle provides cost-effective operation.
<p>The present invention relates to a fault detection and response system and processes for use, for example, in a vehicle.</p>
<p>According to some features of the present invention, an exemplary detection method for detecting a barrel leak in a pump system filters the data signal received from the filter pressure sensor or the case pressure sensor based on the rotation frequency of the pump, and ; analyzing the filtered signal to determine if it exceeds a prescribed threshold.</p><p>In accordance with other features of the present invention, an exemplary method for detecting a gas leak in a pump system includes estimating a gas pressure based on a fluid temperature and a fluid pressure.</p><p>In accordance with other aspects of the present invention, an exemplary method for detecting a fluid (eg, oil) leak in a pump system includes comparing an estimated fluid level to an estimated fluid level.</p><p>According to another aspect of the present invention, an exemplary method for detecting an oil leak in a pump system includes comparing an estimated level of fluid in a reservoir with an actual level of fluid in a reservoir.</p>
<p>According to the present invention, an exemplary method for detecting a gas leak in a pump system used in a hybrid vehicle can estimate the gas pressure based on the fluid temperature and the fluid pressure.</p>
1 is a schematic diagram of a drive system of a hybrid vehicle having a configuration that is an example of features according to the principles of the present invention; 2 is a schematic diagram of a second power source 124 having a configuration that is an example of features in accordance with the principles of the present invention. 3 is a block diagram of an exemplary control system for a hybrid drive assembly having a configuration that is an example of features in accordance with the principles of the present invention; 4 is a block diagram of an exemplary fault detection system configured to perform fault monitoring and response to a second power source control system in accordance with the principles of the present invention; 5 is a flow diagram illustrating an exemplary reset process that may operatively couple a second power source to a driveline of a vehicle in accordance with the principles of the present invention; 6 is a flow diagram illustrating an exemplary fault detection process that enables detection and adjustment of system and component failures and/or failures in accordance with the principles of the present invention; 7 is a flow diagram illustrating the operational flow for an exemplary response process that enables a second power source control system to respond when a new fault condition is detected in accordance with the principles of the present invention; 8 is a flow diagram illustrating an operational flow for an exemplary network failure detection process that enables a failure detection system to identify network failure conditions in accordance with the principles of the present invention; 9 is a flow diagram illustrating an operational flow for an exemplary out-of-range fault detection process that enables a fault detection system to identify out-of-range fault conditions in accordance with the principles of the present invention. FIG. 10 is a flow diagram illustrating an operational flow for an exemplary mismatch fault detection process that enables a fault detection system to identify fault conditions initiated by conflicting sensor readings or commands in accordance with the principles of the present invention. 11 is a flow diagram illustrating the operational flow for an exemplary filter clogging fault detection system that enables the clogged filter fault detection system to detect a clogged filter in accordance with the principles of the present invention. 12 is a flow diagram illustrating the operational flow for an exemplary foot valve failure detection process 1000 that enables a failure detection system to detect a malfunction in a proximity sensor on an accumulator in accordance with the principles of the present invention. 13 is a flow diagram illustrating an operational flow for an exemplary pressure leak fault detection process that enables a fault detection system to detect a high pressure leak in accordance with the principles of the present invention. 14 is a schematic diagram of an exemplary pump assembly that may be used in a pump/motor in accordance with the principles of the present invention; 15A is a flow diagram illustrating an operational flow for an exemplary leak detection process that enables detection of a barrel leak, such as a barrel leak, in a pump assembly in accordance with the principles of the present invention; 15B is a flow diagram illustrating an operational flow for another exemplary leak detection process that enables detection of a barrel leak, such as a barrel leak, in a pump assembly in accordance with the principles of the present invention. 15C is a flow diagram illustrating an operational flow for an exemplary monitoring process that allows monitoring of a barrel leak, such as a barrel leak, in a pump assembly in accordance with the principles of the present invention. 16 is a block diagram illustrating an exemplary detection process that allows determination of low fluid (eg, oil) levels in accordance with the principles of the present invention. 17 is a block diagram illustrating an exemplary bypass valve failure detection process that enables determination of a malfunction in a bypass valve in accordance with the principles of the present invention. 18 is a block diagram illustrating a bootstrap failure detection process that enables detection of failures for obtaining swash plate control according to the principles of the present invention; 19 is a block diagram illustrating an exemplary pump/motor failure detection process that enables the detection of malfunctions in a pump in accordance with the principles of the present invention. 20 is a block diagram illustrating exemplary obstacles to an exemplary disconnection detection process that enables future detection in a transfer case for disconnecting a second power source from a vehicle drive assembly in accordance with the principles of the present invention; 21 is a block diagram illustrating an exemplary speed limiting process that allows limiting the speed of an engine to mitigate damage to a second power source in the event of a failure in a transfer case in accordance with the principles of the present invention; 22 shows an exemplary hydraulic accumulator constructed in accordance with the principles of the present invention; 23 is a flow diagram illustrating an operational flow for an exemplary gas leak detection process that enables detection of a gas leak in an accumulator in accordance with the principles of the present invention. 24 is a flow diagram illustrating an operational flow for an exemplary initialization verification process that enables a gas leak detection process to determine whether a system has recently been initialized in accordance with the principles of the present invention; 25 is a flow diagram illustrating the operational flow for allowing a fluid leak detection process to determine whether a fluid (eg, oil) is leaking from a second power system in accordance with the principles of the present invention; 26 is a block diagram illustrating a fault detection process for an exemplary disconnect that enables detection of a fault in a transfer case for disconnecting a second power source from a vehicle in accordance with the principles of the present invention.
Exemplary features of the invention described in the accompanying drawings will be described in detail. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like structures.
Referring to FIG. 1 , a schematic diagram of a drive system 100 of a vehicle is shown. In one aspect of the present invention, the drive system 100 is suitable for use in high-speed vehicles such as trucks, sweepers, buses, and roundabouts, and non-road field vehicles such as construction and agricultural vehicles.
In the example shown in FIG. 1 , the drive system 100 includes a hybrid drive assembly 102 and a control system 104 . The hybrid drive assembly 102 is suitable for selectively propelling the vehicle while the control system 104 is adapted to control the hybrid drive assembly 102 .
In one aspect of the present invention, drive system 100 further includes one or more front wheels 106 and one or more rear wheels 108 . The brake 120 is operatively coupled to each of the front and rear wheels 106 and 108 of the drive system 100 . The brake 102 is suitable for selectively reducing the kinetic energy of the vehicle. In one aspect of the present invention, the brake 120 is a friction brake. Non-limiting examples of friction brakes suitable for use in drive system 100 include disc brakes, drum brakes, mechanically actuated brakes, hydraulically actuated brakes, pneumatically actuated brakes; electronically actuated brakes, or a combination thereof.
The hybrid drive assembly 102 of the drive system 100 includes a first power source 122 and a second power source 124 . In the illustrated example of FIG. 1 , the second power source 124 is disposed in parallel to the first power source 122 . However, in another example, the second power source 124 may be disposed in series with the first power source 122 .
In some features of the present invention, the first power source 122 of the hybrid drive assembly 102 includes a conventional prime mover 126 , such as an internal combustion engine. In general, prime mover 126 generates power in response to combustion of fuel. In one aspect of the present invention, the first power source 122 also includes a transmission 128 as a conventional transmission unit. When the second power source 124 is connected in parallel to the first power source 122 , the transmission 128 sends the output from the prime mover 126 through the drive line 120 to at least one of the wheels 106 and 108 . .
In one aspect of the present invention, the drive system 130 includes a front wheel drive shaft 132 , a rear wheel drive shaft 134 , left and right axle shafts 136 , 138 , and a differential 140 . The differential 140 is disposed between the left and right axle shafts 136 , 138 . In the example shown, the left and right axle shafts 136 , 138 are connected to the rear wheel 108 of the differential 140 . In another aspect, driveline 130 may include an axle shaft that connects front wheel 106 to a differential.
1 and 2, in certain aspects of the present invention, the second power source 124 is a hydraulic 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 features, 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 in selective fluid communication with the fluid reservoir 144 and the energy storage unit 146 .
According to one feature, the pump/motor unit 142 is of a variable displacement type. In one aspect of the invention, the pump/motor unit 142 is of the axial piston type (ie, variable displacement axial piston type). The pump/motor unit 142 includes a servo actuator coupled to a variable swashplate 148 . The servo actuator is suitable for controlling the displacement of the pump/motor unit 142 by selectively adjusting the angle of the swash plate. In one aspect of the invention, the energy storage unit 146 is an accumulator. In another aspect of the present invention, the energy storage unit 146 is a gas-charged accumulator.
The second power source 124 further includes an engagement assembly 149 . In one aspect of the present invention, the coupling assembly 149 is disposed between the front wheel drive shaft and the rear wheel drive shafts 132 , 134 . The coupling assembly 149 is suitable for selectively coupling the pump/motor unit 142 to the drive line 130 . In one aspect of the present invention, coupling assembly 149 includes a clutch configured to selectively couple pump/motor unit 142 to driveline 130 . For example, the clutch may include a clutch valve 224 ( FIGS. 2 and 4 ). In another aspect of the present invention, the coupling assembly 149 includes a transfer case (see FIG. 2 ).
In one aspect of the invention, the coupling assembly is adapted to couple the pump/motor unit 142 to the driveline 130 when the vehicle is decelerating (eg, via a clutch). During deceleration, the pump/motor unit 142 engages the driveline 130 and acts as a 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 delivered to the energy storage unit 146 , the pressure of the fluid in the energy storage unit 146 increases.
In another aspect of the invention, the coupling assembly 149 is adapted to couple the pump/motor unit 142 to the driveline 130 (eg, via a clutch) when the vehicle accelerates. During acceleration, the pump/motor unit 142 is coupled to the driveline 130 and acts as a motor. The pump/motor unit 142 receives pressurized fluid from the energy storage unit 146 , which causes the pump/motor unit 142 to transmit torque to the driveline 130 . This torque generated from the pump/motor unit 142 and transmitted to the driveline 130 is used to propel the vehicle.
In another feature, the second power source 144 is connected in series with the second power source 142 , and the prime mover 126 is connected to the pump/motor unit 142 . Pump/motor unit 142 is in fluid communication with a motor assembly (not shown) that is coupled to left and right axle shafts 1436 and 138 .
1 , an example of a control system 104 is described. In one aspect of the invention, the exemplary control system 104 includes a first power source control system 150 and a second power source control system 152 .
The first power source control system 150 is suitable for controlling the first power source 122 . In one aspect of the present 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 may be combined with a single powertrain control module, and the prime mover control module 154 and the transmission control unit 156 will be described herein as separate units. .
The prime mover control unit 154 is suitable for controlling one operative form of the prime mover 126 as will be described in detail herein. The prime mover control unit 154 is operatively connected to the prime mover 126 (see dashed line 191 in FIG. 1 ). For example, when used with an internal combustion engine, prime mover control unit 154 may determine, for example, one or more of the following: amount of fuel injected into the engine, idle speed of the engine, ignition timing, and/or engine It may be suitable for controlling valve timing.
Transmission control unit 156 is suitable for controlling operational characteristics of transmission 128 as will be described in detail herein. Transmission control unit 156 is operatively connected to transmission 128 (see dashed line 192 in FIG. 1 ). For example, the transmission control unit 156 may be used to calculate how and when to shift gears in the vehicle to optimize fuel efficiency and/or vehicle performance.
The brake control unit 158 is suitable for controlling the operational characteristics of the brake 120 . The brake control unit 158 is operatively connected to the brake 120 (see dashed line 193 in FIG. 1 ). For example, the brake control unit 158 may be adapted to provide anti-lock braking during various driving states and/or to provide a uniform relationship between pedal effort and brake effectiveness. .
The second power source control system 152 is suitable for controlling operational characteristics of the second power source 124 . In one aspect of the invention, the second power source control system 152 is adapted to selectively control the operational characteristics of the prime mover 126 of the first power source 122 . For example, the second power source control system 152 may be suitable to limit the torque output of the prime mover 126 when the second power source 124 is actively coupled to the driveline 130 .
In 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 unit 152 are connected to a communication network (shown by a solid line in FIG. 1). 184) to communicate with the vehicle parts, the associated sensors and each other. In one aspect of the invention, the communication network 184 is a controller-area network (CAN or CAN-Bus). In another aspect of the present 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 a user. For example, the user interface 190 may include a gauge, a display light, electronic information (eg, text, numerical value, etc.), a sound, and the like. In one aspect of the invention, user interface 190 is communicatively coupled to communication network 184 . In another aspect, the user interface 190 may be communicatively connected directly to the second power source control unit 152 .
3 is a block diagram of an exemplary control system 104 for a drive assembly, such as 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 communicatively connected together through a communication network 184 . According to one feature, the communication network 184 may be electrically connected. However, depending on other features, the communication network 184 may be connected wirelessly.
In one aspect of the present 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 . The processor 160 of the prime mover control unit 154 is adapted to receive electrical data signals from one or more prime mover sensors 170 . For example, two prime mover sensors 170a and 170b are shown in FIG. 3 . According to one feature, the sensors 170a and 170b are located near the prime mover 126 . However, according to another feature, a predetermined number of sensors 170 may be operatively connected to the processor 160 of the prime mover control unit 154 .
In one aspect of the present invention, the processor 160 may receive electronic data signals from the sensors 170 through the communication network 184 . In another aspect of the present invention, the processor 160 may receive electronic data signals through a direct communication connection (eg, wired) with the sensors 170a and 170b. Non-limiting examples of prime mover sensors 170 include: a throttle position sensor, an oxygen sensor, an RPM sensor, a mass airflow sensor, a manifold absolute pressure (MAP) sensor, a coolant sensor, and a knock sensor. ), a crankshaft position sensor, and/or oil temperature sensors.
The microprocessor 160 of the prime mover control unit 154 is adapted to calculate the control parameters for the prime mover 126 from an algorithm stored in the non-volatile memory component 161 . Control variables may be calculated using electronic data signals received from one or more prime mover sensors 170 and used to control the operation of prime mover 126 (eg, via control connection 191 in FIG. 1 ).
The non-volatile memory component 161 stores software, firmware, etc. used by the processor 160 to control the prime mover 126 and to calculate control variables. The nonvolatile memory component 161 may store software, firmware, and the like when power to the prime mover control unit 154 is cut off. Exemplary non-volatile memory components suitable for use with prime mover control unit 154 include, but are not limited to, EPROM, EEPROM, flash memory, and the like.
In one aspect of the present invention, the transmission control unit 156 includes a processor (eg, microprocessor) 162 and a non-volatile memory component 163 (eg, EPROM, EEPROM, flash memory, etc.). The processor 162 of the transmission control unit 156 is adapted to receive electronic data signal inputs from one or more transmission sensors 172 . In the example shown in FIG. 3 , only one transmission sensor 172 is operatively connected to the processor 162 of the transmission control unit 156 . However, according to other features, any number of sensors 172 may be operatively coupled to the processor 162 of the transmission control unit 156 .
In one aspect of the present invention, the processor 162 may receive electronic data signals through the communication network 184 . In another aspect of the present invention, the processor 162 may receive electronic data signals through a direct communication connection (eg, wired) with the sensors 172 . Non-limiting examples of transmission sensors 172 may 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 present invention, the transmission control unit 156 includes a kick down switch used to determine whether the accelerator is depressed past the full throttle, a traction control system, and cruise control. It may be suitable for receiving electronic data signal inputs from one or more of the modules.
The processor 162 of the transmission control unit 156 is adapted to calculate control parameters for the transmission 9128 from an algorithm stored in the non-volatile memory component 163 . Control variables are calculated using electronic data signals received from one or more transmission sensors 172 and are also used to control operation of transmission 128 .
In one aspect of the present 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 adapted to receive electronic data signal inputs from one or more brake sensors 174 . The processor 164 of the brake control unit 158 is adapted to calculate the control parameters for the brake 120 from an algorithm stored in the non-volatile memory component 165 . The control variables can be calculated using electronic data signals received from one or more brake sensors 174 and are also used to control the operation of the brake 120 .
In one aspect of the present invention, the processor 164 may receive electronic data signals via the communication network 184 . In another aspect of the present invention, the processor 164 may receive electronic data signals through a direct communication connection (eg, wired) with the sensors 174 . Non-limiting examples of brake sensors 174 may include one or more of wheel speed sensors, a pressure sensor for monitoring brake fluid pressure, and/or pedal position sensors.
In one aspect of the present 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 and a memory component 168 . Processor 166 is adapted to receive electronic data signal inputs from one or more sensors 176 . In one aspect of the invention, non-limiting examples of one or more sensors 176 include: an accumulator pressure sensor, a filter pressure sensor, a neutral pressure sensor, a pump/motor speed sensor; a low organic fluid temperature sensor, a pump case temperature sensor; a low organic fluid level sensor; a swash plate angle sensor and a brake pressure sensor; and/or one or more of an accumulator and transfer case proximity sensors. In the illustrated example, processor 166 is operatively coupled to three data sensors 176a, 176b, and 176c. However, depending on other features, the processor 166 may be operatively coupled to more or fewer sensors 176 .
The processor 166 of the second power source control system 152 calculates control variables 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 . suitable for Control variables are calculated using electronic data signals received from one or more sensors 176 . Non-volatile memory 167 is also configured to store operating parameters 189 and fault detection algorithm 187 for second power source control system 152 (FIG. 4). For example, memory 167 may include algorithms that trigger fault conditions, upper and lower limits used for these algorithms, and error messages indicating a failure or malfunction of one or more system components.
The fault conditions detected by the processor 166 may be stored in the non-volatile memory 167 or the volatile memory 168 . According to some characteristics, failure states can be divided into three types, non-latching, latching, and disabling. According to features, latching and non-latching fault states are stored in volatile memory 168 and disabling fault conditions are stored in non-volatile memory 167 . Accordingly, latching and non-latching fault conditions are cleared from memory 168 when the vehicle is turned off. Even after the ignition is turned off, the disabling fault states remain in the memory 167 .
4 is a block diagram of an exemplary fault detection system 200 configured to implement fault monitoring and response to the second power source control system 152 . According to one aspect, the exemplary fault detection system 200 is implemented using the processor 166 and the memory 167 of the second power source control system 152 . According to other features, the exemplary failure detection system 200 may be implemented using processors and/or memory of other systems.
For example, the fault conditions may be stored in the data recording system instead of being stored in the memory 167 of the second power source control system 152 . An exemplary data recording system is shown in FIG. 1 and is denoted by reference numeral 100 . Additional information on suitable data recorders may be found in U.S. Patent Application Serial No. 61/158,542, filed March 9, 2009, entitled "Data Recorder for Hybrid Vehicles," the contents of which are hereby incorporated by reference. can
The exemplary fault detection system 200 includes one or more monitoring modules 201 configured to receive electronic data signals from one or more sensors, as detailed herein. In the illustrated example, the exemplary failure detection system 200 includes one monitoring module 201 that receives a sensor input. In other exemplary systems, multiple monitoring modules may receive and process sensor input. For example, each of the sensors may have a corresponding monitoring module.
The monitoring module 201 is configured to analyze the data signals to determine whether a fault condition has occurred. The exemplary fault detection system 200 includes one or more response modules 206 that are configured to respond to a detected fault condition. The fault detection system 200 also includes a communication network interface 202 configured to transmit messages to, and to receive messages from, a communication network 182 of the vehicle, and a memory 167 of the in-vehicle second power source control system 152 . or a memory interface 205 configured to communicate with another memory storage unit (eg, a data recording device).
According to one feature, the monitoring module 201 receives data signals from one or more sensors. Non-limiting examples of suitable data sensors include one or more swash plate position sensors 210 indicative of the position of the swash plate in the pump/motor 142 and fluid (eg, oil) indicative of an amount of fluid in the fluid reservoir 144 . A level sensor 211, a fluid temperature sensor 212 indicating the temperature of the fluid in the reservoir 144, and a neutral pressure sensor 213 indicating a pressure in an end cover assembly 145, the system A filter pressure sensor 214 indicating the filter 147 dmk status, a high pressure sensor 215 indicating the pressure in the energy storage unit 146 , and an accumulator proximity sensor indicating whether the foot valve 236 is open or closed ( 216), a pump speed sensor 217 indicating the rotational speed per minute at which the pump/motor unit 142 rotates, and a case temperature sensor 218 indicating the temperature in the pump housing of the pump/motor 142; and a transfer case switch sensor 219 indicating whether the second power source 1240 is selectively coupled with the drive line 130. However, according to other features, the monitoring module 201 may also include other types of sensors, For example, data signals may be received from a brake pressure sensor (not shown) indicating pressure in the brake 120 of the vehicle.
Depending on the features, the monitoring module 201 may receive input messages 203 from the vehicle's communication network (eg, CAN bus) 184 via the network interface 202 . According to one feature, the input message 203 indicates the operating state of components outside the second power source 124 . Non-limiting examples of input messages 203 include engine speed, wheel-based vehicle speed, input shaft speed, output shaft speed, actual gear ratio of the engine, current gear to which the engine is configured, accelerator pedal position, and a percentage torque of the driver request to the engine, a percentage torque of nominal friction, and/or an indication of whether an anti-lock brake system (ABS) or cruise control is active.
According to one aspect, the network interface 202 also sends an output message 204 to the communication network 184 . Non-limiting examples of output message 204 include a torque limit, a speed limit indicating the maximum speed at which the vehicle can be moved, a status message indicating the state of the second power source 124 , and the occurrence of one or more fault conditions. code for the user indicator 190 , an override control mode message, and recorder data (ie, data stored in the data recorder 100 of FIG. 1 ).
According to features, memory interface 205 is configured to obtain data from and transfer data to and from a memory, such as memory 167 of FIG. 3 . For example, the memory interface 205 may obtain one or more failure detection algorithms 187 and/or failure detection parameters 189 from memory. Non-limiting examples of data that may be written to memory by memory interface 205 may include received sensor data, values of variables used in a control algorithm, system component states, and fault conditions. . According to other features, the memory interface 205 may write data to an additional memory (not shown) over the communication network 184 .
According to some features, the response module 206 sends control signals to one or more control valves to operate components of the second power source 124 in response to one or more fault conditions. In the illustrated example, the response module 9206 transmits control signals to the bypass valve 222 , the clutch valve 224 , and the swash plate control valve 226 . However, according to other features, the response module 206 may transmit control signals to any desired valve. For example, the response module 206 may operate an isolation valve 230 , a charge bypass valve 232 , and a mode valve 234 (see FIG. 2 ).
According to one feature, the control signals include electrical signals transmitted to one or more solenoids operatively coupled to the valves. For example, the swash plate control valve 226 may be operated by a motor solenoid and a pump solenoid (see FIG. 2 ). The bypass valve 222 may be operated by a bypass solenoid and the clutch valve 224 may be operated by a clutch solenoid. However, depending on other features, the valves may be operated using more or fewer solenoids or via other means known to those skilled in the art.
5 is a flow diagram illustrating an exemplary reset process 300 , wherein the second power source 124 may be operatively coupled to the vehicle's driveline 130 by the reset process. According to some features, the reset process 300 is implemented by the control system 152 each time the vehicle is started (ie, keyed on). According to some features, the reset process 300 may also be implemented upon request of other processes, as will be described in more detail herein.
The reset process 30 performs any appropriate initialization procedure and proceeds to a check operation 320 starting with the initiation module 310 . Check operation 320 accesses second power source control system 152 to determine whether predetermined fault conditions have been stored. According to one aspect, the check operation 320 accesses the non-volatile memory 167 to assure the disable fault condition 182 . According to another feature, the check operation 320 accesses the volatile memory 168 to ascertain the non-latching fault condition 182 and/or the latching fault condition 184 .
The determination module 330 determines whether predetermined fault conditions have been found in the memory. If the determination module 330 determines that no fault conditions are stored in the memory, the engage operation 340 operatively connects the second power source 124 to the vehicle. As will be described in more detail herein, regardless of whether or not the coupling operation 340 is operated, the monitor operation 350 repeatedly analyzes the sensor indication value, so that the second power source 124 must be disconnected. decide whether The reset process 300 performs any appropriate completion procedures and also ends at the stop module 360 .
6 is a flow diagram illustrating an exemplary error detection process 400 by which system and component failures and/or malfunctions may be detected and remedied. According to one aspect, the exemplary fault detection process 400 is suitable for implementation by the second power source control system 152 . The failure detection process 400 performs any appropriate initialization procedure, and proceeds to an acquire operation 404 beginning with the initiation module 402 .
Acquisition operation 404 receives or derives electronic data signals. According to one aspect, the acquiring operation 404 acquires electronic data signals from one or more sensors (eg, sensors 210 - 219 in FIG. 4 ). According to another aspect, the acquiring operation 404 acquires electronic data signals from the communication network 184 . In one aspect, the acquiring operation 404 receives an electronic data signal from the monitoring module 202 of FIG. 4 .
An analyze operation 406 processes the received electronic data signal to determine whether a failure state has started. According to some features, the analysis operation 406 processes the received electronic data signals based on the failure detection algorithm 187 and the variables 189 stored in the non-volatile memory 167 of the second power source control system 152 . (see FIG. 3).
The check operation 408 accesses the memory of the second power source control system 152 to determine whether a predetermined fault condition is stored. For example, check operation 408 accesses non-volatile memory 167 and/or volatile memory 168 .
The comparison operation 410 determines an overlap between the failure states detected from the sensor data and the failure states stored in the memory. Non-overlapping fault conditions are the occurrence of new fault conditions (ie, fault conditions determined by sensor data but not data stored in memory) or interruption of previous fault conditions (ie, stored in memory but not based on sensor data). undetermined failure states).
The first determining module 412 determines whether the non-overlapping failure state is a newly emerged failure state. If the first determination module 42 determines that a new fault condition has been detected, a response operation 414 operatively disconnects the second power source 124 from the vehicle. An exemplary response process according to an aspect is discussed herein with reference to FIG. 7 .
If the second decision module 416 determines that there are additional non-overlapping fault conditions to be handled, the fault detection process 400 loops back to the first decision module 412 and continues as described above. If the second determining module 416 determines that all non-overlapping fault conditions provided by the comparing operation 410 have been handled, the fault detection process 400 performs any appropriate processes and in the stopping module 424 . quit
However, if the first determination module 412 determines that the previously detected failure state is stopped, the third determination module 418 determines which type of failure state is stopped. For example, the third determining module 418 may determine whether a non-latching failure, a latching failure, or a disabling failure is detected. If the third determining module 418 determines that a latching fault condition or a disabling fault condition is detected, the fault detection process 400 loops to the second determining module 416 .
However, if the third determination module 418 determines that a non-latching fault condition is detected, an erase operation 420 erases the non-latching fault condition from the memory, and a reset operation ( 422 implements the reset process 300 of FIG. 5 , and the failure detection process 400 proceeds to the second decision module 416 and continues as described above.
7 is a flowchart illustrating an operational flow for an exemplary response process 500, wherein the second power source control system 152 responds according to the flowchart when a new fault condition is detected. The response process 500 performs a predetermined appropriate initialization procedure, and proceeds to an alert operation 504 beginning with the initiation module 520 .
Alert action 504 provides an indication to a user (eg, a driver) that an obstacle condition has been detected. According to some features, the alert action 504 activates one or more alert indicators 190 in the vehicle (eg, on the vehicle's dashboard). Non-limiting examples of an alert indicator 190 include a speaker 194 configured to emit an illuminated symbol 192 , text read on a display screen, and/or an audible signal. For example, according to one feature, the alert operation 504 may power a luminescent indication displayed to a user of the vehicle.
A first activate operation 506 moves the swash plate 148 ( FIG. 2 ) of the pump/motor unit 142 to a neutral (eg, vertical) position. For example, the first activation operation 506 transmits a control signal (eg, an electrical signal) from the response module 206 to the swash plate control module 224 (FIG. 4) to zero out the swash plate 148 to the neutral position ( zero out: set to zero). Zeroing out the swash plate 148 may help prevent overspeed conditions within the pump/motor unit 142 , which may damage the second power source 142 . Zeroing out the swash plate 148 may also help remove torque from the driveline 130 .
A second actuation operation 508 opens a bypass between the pump/motor high pressure port and the reservoir 144 (see FIG. 2). For example, the second activation operation 508 transmits a control signal (eg, an electrical signal) from the response module 206 to the bypass valve 222 ( FIG. 4 ) so that the fluid bypasses the pump/motor unit 142 . let it do Opening the bypass valve 222 helps to remove torque from the drive line 130 . According to some features, after the first activating operation 504 zeros out the swash plate 148 , the second activating operation 440 operates the bypass valve 222 for a defined period of time. According to another feature, the second activation operation 506 operates the bypass valve 222 behind the swash plate position sensor.
A disengage operation 510 operatively disengages the second power source 124 from the hybrid drive assembly 102 . When operationally disconnected, the second power source 124 does not provide power to the vehicle. According to some features, the separation operation 510 operates the clutch valve 224 of the coupling assembly 149 to disconnect the second power source 124 from the drive line 130 . According to one feature, the disengagement actuation 510 actuates the clutch valve 224 at substantially the same time the second actuation actuation 508 opens the bypass. However, according to other features, the disconnect operation 510 may disconnect the second power source 124 from the drive line 130 before or after implementation of the first and second activation operations 506 , 508 .
An ascertain operation 512 determines the type of fault condition detected. Depending on the characteristics, check 512 determines whether the fault condition is a non-latching fault 186 , a latching detent 184 , or a disabling fault 182 . If the determination module 514 determines that the newly detected failure state is disabled, the first storage operation 516 stores a record of the disabled failure state in a non-volatile memory such as the non-volatile memory 167 ( FIG. 3 ). . However, if the determination module 151 determines that the newly detected failure state is not a disabling failure, the second storage operation 518 stores a record of the failure state in a volatile memory such as a volatile memory ( FIG. 3 ).
The response process 500 performs any appropriate completion procedures and ends at the stop module 520 .
8 is a flowchart illustrating an operation flow for an exemplary network failure detection process 600, wherein the monitoring module 201 of the failure detection system 200 of FIG. 4 may detect a network failure state. According to one feature, the network failure condition is a non-latching failure. However, according to other features, the network failure state may be a latching or disabling failure.
The network failure detection process 600 performs an appropriate initialization procedure of the adjustment, starts at the initiation module 610 and proceeds to a listen operation 62 . The listening operation 620 checks whether data is being received from the communication network 184 . For example, the listening operation 620 determines a variable or message expected to be received.
The determination module 630 determines whether data is being received from the communication network 184 . According to some features, if the decision module 630 determines that data is not being received, the fault operation 640 triggers a process such as the response process 500 of FIG. 7 . According to one feature, the fault operation 640 may also store the network communication fault state in a memory. The network failure detection process 600 performs a predetermined appropriate completion procedure and ends at the stop module 650 .
9 is a flowchart illustrating an operational flow for an exemplary range fault detection process 700, wherein the monitoring module 201 of the fault detection system 200 of FIG. 4 detects out-of-range fault conditions. can be identified. Non-limiting examples of out-of-range fault conditions include: receiving sensor signals outside of normal operating range that may indicate component and/or system malfunctions; receiving sensor signals outside the possible detection range, which may indicate sensor and/or wiring problems; and may include a measured valve current that may indicate valve malfunctions.
The range failure detection process 700 performs a predetermined initialization procedure, starts from the start module 710 and proceeds to an acquisition operation 720 . Acquisition operation 720 receives one or more data signals from one or more sensors, such as sensors 211 to 219 of FIG. 2 .
The determination module 730 determines which of the received data signals has a value outside (eg, above or below) a prescribed threshold. According to some embodiments, the determining module 730 determines whether each data signal has a value outside a prescribed threshold stored in a memory (eg, the memory 167 of the control system 152 ). According to one feature, the determining module 730 may determine whether the data signals remain outside a threshold for a prescribed period of time.
According to some features, if the first determination module 730 determines that the received data signal is outside the prescribed threshold, the failure operation 740 activates a response process such as the response process 500 of FIG. 7 . According to one feature, the fault operation 740 may also store a network communication fault state in a memory. The range fault detection process 700 performs any appropriate completion procedures and ends at the stop module 750 .
FIG. 10 is a flow chart illustrating the operational flow for an exemplary miscompare fault detection process 800, wherein the monitoring module 201 of the fault detection system 200 of FIG. 4 conflicts sensor readings. Or it can identify a fault condition initiated by commands. Non-limiting examples of such fault conditions include: a trade-off between the speed reported by the pump speed sensor and the speed reported by the output shaft speed sensor; a conflict between swash plate directions reported by two or more swash plate sensors; a tradeoff between the swash plate orientation reported by the swash plate sensor and the commanded rake angle; and a conflict between the clutch state reported by the clutch valve sensor and the commanded clutch state.
The mismatch failure detection process 800 performs a predetermined initialization procedure, starts in the start module 810 , and proceeds to a first acquisition operation 820 . In the first acquisition operation 820 , a first data signal indicating a state of a system or a part of the system is received from a sensor such as the sensors 211 to 219 of FIG. 2 . According to one characteristic, in the first acquiring operation 820 , the first data signal may be received through the communication network 184 . According to another feature, in the first acquiring operation 820 , the first data signal may be received through a direct line connection to the sensor.
A second acquisition operation 830 obtains a second data signal representing the status of the system or a component of the system. According to some features, the second acquisition operation 830 obtains a second data signal from a sensor, such as the sensors 211 - 219 of FIG. 2 . According to some features, the second acquisition operation 830 may obtain the second data signals over the communication network 184 or from the memory. According to one feature, the second data signal may be a command or control signal provided to the valve (eg, to a solenoid controlling the valve).
The comparison operation 840 determines whether a conflict exists between the data signals received by the first acquisition operation 820 and the data signals received by the second acquisition operation 820 . For example, according to some features, the comparing operation 840 determines a difference between the data signals. For example, according to one feature, the comparing operation 840 determines a difference between a swash plate angle value reported by one swash plate sensor and a swash plate angle value reported by another swash plate sensor. According to other features, the comparing operation 840 determines whether binary values of the first data signal match binary values of the second data signal. For example, according to some features, the comparing operation 840 may determine whether the clutch valve reported status of the clutch matches the most recent command sent to the clutch valve.
The first determination module 850 determines whether any of the conflicts are sufficient to trigger the fault condition. In accordance with some embodiments, first determining module 850 determines whether each of the conflicting sets of data signals exceeds a system tolerance stored in memory (eg, memory 167 of control system 152 ). The second determination module 860 determines whether any of the conflicts exceeding the system tolerance persist for a prescribed period of time.
According to some features, if the first and second determining modules 850 and 860 determine that the conflict between the two data signals exceeds the system tolerance and persists for a prescribed period of time, the fault operation 870 is shown in FIG. A response process such as the response process 500 of 7 is operated. According to one feature, the fault operation 870 may also store the network communication fault state in a memory. The mismatch fault detection process 800 performs any appropriate completion procedures and ends at the stop module 880 .
11 is a flowchart illustrating an operation flow for an exemplary filter clogging failure detection process 900 , wherein the monitoring module 201 of the failure detection system 200 of FIG. 4 is a filter 147 of the second power source 124 . clogged filters can be detected.
The filter clogging failure detection process 900 performs a predetermined appropriate initialization procedure, starts in the start module 910 , and proceeds to a first acquisition operation 920 . In the first acquisition operation 920 , a first data signal is received from a fluid temperature sensor such as the fluid temperature sensor 212 of FIG. 2 . According to one characteristic, in the first acquiring operation 920 , the first data signal may be received through the communication network 184 . According to another feature, in the first acquiring operation 920 , the first data signal may be received through a direct line connection to the fluid temperature sensor 212 .
A second acquisition operation 930 obtains a second data signal from a pump speed sensor such as a pump speed sensor 217 indicating a pump speed. According to some features, the second acquisition operation 930 obtains the pump speed data signal directly from the pump speed sensor 217 . According to other features, the second obtaining operation 930 may obtain the pump speed data signals from the communication network 184 .
The calculation operation 940 determines the allowable filter pressure based on the fluid temperature and the pump speed provided by the first and second acquisition operations 930 and 940 . According to one characteristic, an acceptable filter pressure can be calculated based on test results obtained from experiments.
A third acquisition operation 950 obtains third data signals from a filter pressure sensor, such as the filter pressure sensor 214 of FIG. 2 . According to some features, the third acquiring operation 950 obtains the filter pressure data signals directly from the filter pressure sensor 214 . According to other features, the third obtaining operation 950 may obtain the filter pressure data signals from the communication network 814 .
The first determining module 960 compares the filter pressure provided by the third obtaining operation 950 with the allowable filter pressure provided by the calculating operation 940 . According to some features, the first determination module 960 determines whether the filter pressure exceeds the calculated allowable filter pressure by an amount sufficient to activate a fault condition. The second determination module 970 determines whether the filter pressure exceeds the calculated allowable filter pressure over a prescribed tolerance for a prescribed time period.
According to some features, if the first and second determination modules 960, 970 determine that the filter pressure exceeds the allowable filter pressure beyond the system tolerance and for longer than a prescribed time period, the fault action 980 is shown in FIG. A response process such as the response process 500 of 7 is operated. According to one feature, the fault operation 980 may also store the network communication fault state in a memory. The filter blockage failure detection process 900 performs an appropriate completion procedure and ends at the stop module 990 .
12 is a flowchart illustrating an operation flow for an exemplary foot valve failure detection process 1000. The monitoring module 201 of the failure detection system 200 of FIG. 4 is on the same axis as the proximity sensor 216 of FIG. It is possible to detect a malfunction in the proximity sensor on the pressure gauge. The foot valve failure detection process 100 performs a predetermined appropriate initialization procedure, starts in the start module 1002 , and proceeds to a first acquisition operation 1004 .
A first acquisition operation 1004 receives a first data signal from an accumulator pressure sensor, such as the accumulator pressure sensor 215 of FIG. 2 . According to one characteristic, the first acquiring operation 1004 may receive the first data signal through the communication network 184 . According to another feature, the first acquiring operation 1004 may receive the first data signal through a direct line connection to the accumulator pressure sensor 215 .
A second acquisition operation 1006 obtains a second data signal from the proximity sensor 216 . According to some features, the second acquisition operation 1006 obtains a data signal indicative of the status of the foot valve 236 directly from the proximity sensor 216 . According to another feature, the second acquisition operation 1006 may obtain the foot valve data signals from the communication network 184 .
The first determination module 1008 determines whether the accumulator pressure data signal is outside an acceptable range. For example, according to one feature, the first determining module 1008 determines whether the accumulator pressure data signal is lower than a prescribed lower limit.
If the first determination module 1008 determines that the accumulator pressure data signal is below the prescribed threshold, the second determination module 1010 determines whether the proximity sensor data signal indicates that the foot valve 236 is open. According to one characteristic, the accumulator pressure being below a prescribed threshold while the foot valve is open indicates a first fault condition.
If the second determination module 1010 determines that the proximity sensor data signal indicates that the foot valve 236 is open and indicates the first failure state, the third determination module 1012 determines the time period in which the first failure state is defined. to determine whether it persists during According to some features, if the third determining module 1012 determines that the failure state lasts longer than a prescribed time period, the failure operation 1014 triggers a response process such as the response process 500 of FIG. 7 .
However, if the first determining module 1008 determines that the accumulator pressure data signal is within the allowable range, the foot valve failure detection process 1000 proceeds to a third acquiring operation 1016 . The third acquisition operation 1016 receives a data signal from a fluid temperature sensor such as the fluid temperature sensor 212 of FIG. 2 . A calculation operation 1018 determines an allowable accumulator pressure based on the fluid temperature provided by a third acquisition operation 1016 .
The fourth determining module 1020 determines whether the accumulator pressure provided by the first acquiring operation 1004 exceeds the calculated allowable accumulator pressure provided by the calculating operation 118 . If the fourth determining module 1020 determines that the first acquiring operation 1004 exceeds the allowable accumulator pressure, the fifth determining module 1022 determines whether the proximity sensor data signal indicates that the foot valve is closed. judge According to one characteristic, the accumulator pressure being above the calculated allowable pressure while the foot valve is closed indicates a second fault condition.
If the fifth determination module 1022 determines that the foot valve 236 is closed and indicates the second failure state, the foot valve failure detection process 1000 proceeds to the third determination module 1012 and is described above. lasts as However, if it is determined that at least one of the second, third, fourth and fifth determination modules 1010, 1012, 1020, and 1022 does not have a failure state, the foot valve failure detection process 1000 performs a first acquisition operation ( 1004) to start again. The foot valve failure detection process 1000 performs any appropriate completion procedures and ends at the stop module 1024 .
13 is a flowchart illustrating an operation flow for an exemplary pressure leakage failure detection process 1100. The monitoring module 201 of the failure detection system 200 of FIG. 4 may detect a high pressure leak. The pressure leakage failure detection process 1100 performs a predetermined appropriate initialization procedure, starts at the start module 1102 , and proceeds to a first acquisition operation 1104 .
The first acquisition operation 1104 receives a first data signal from an accumulator pressure sensor, such as the accumulator pressure sensor 215 of FIG. 2 . According to one characteristic, the first acquiring operation 1104 may receive the first data signal through the communication network 184 . According to another feature, the first acquiring operation 1104 may receive the first data signal through a direct line connection to the accumulator pressure sensor 215 .
The calculation operation 1106 finds the slope of the accumulator pressure provided by the first acquisition operation 1104 as a graph against time. According to one feature, the calculation operation 1106 takes the absolute value of the slope. The first determination module 1108 determines whether the calculated slope value exceeds a prescribed threshold. If the first determination module 1108 determines that the threshold has not been exceeded, the pressure leakage failure detection process 1100 is cycled back to the first acquisition operation 1104 and starts again.
However, if the first determination module 1108 determines that the calculated slope value exceeds the prescribed threshold, the first acquisition operation 1110 is performed from the proximity sensor on the accumulator such as the proximity sensor 216 of FIG. 2 . get the data signal. According to some features, the second acquisition operation 1110 obtains the footvalve data signals directly from the footvalve sensor. According to another feature, the second acquisition operation 1110 may obtain a foot valve data signal 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, the pressure leakage failure detection process 1100 cycles back to the first acquisition operation 1104 and starts again. However, if the second determination module 1112 determines that the foot valve data signal indicates that the foot valve is open, the third acquisition operation 1114 receives a data signal indicating whether the mode valve is open or closed. According to some features, the third acquisition operation 1114 receives the modvalve data signals directly from the modvalve sensor. According to other features, the third obtaining operation 1114 may obtain the modevalve data signals 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, the pressure leakage failure detection process 1100 cycles back to the first acquisition operation 1104 and starts again. However, if the third acquisition operation 1116 determines that the mode valve data signal indicates that the mode valve is closed, the fourth determination module 1118 determines that the foot valve is opened and the mode valve is closed during a prescribed time period. while determining whether the accumulator pressure exceeds a threshold.
According to some features, if the fourth determination module 1118 determines that the failure state lasts longer than a prescribed time period, the failure operation 1120 triggers a response process such as the response process 500 of FIG. 7 . . The pressure leakage failure detection process 1100 performs a predetermined appropriate completion procedure and also ends at the stop module 1122 .
14 is a schematic diagram of an exemplary pump assembly that may be used in a pump/motor unit, such as pump/motor unit 142 of FIGS. 1 and 2 . The pump assembly 1300 includes a pump body 1310 defining a plurality of apertures 1312 within which pistons 1315 can be axially displaced by the swash plate 1320 . Each piston 131 interacts with the swash plate 1320 via a shoe 1317 . Over time, pump body 1310 (eg, from a cracked barrel) between bore 1312 and piston 1315 , piston 1315 and shoe 1317 , shoe 1317 and A leak grows between the swash plate 1320 and/or between the hole and the pump case.
According to some features, a leak in the pump body assembly 1300 creates a pulse of fluid into the pump case every rotation of the body 1310 . A pulse of fluid creates a pressure spike in the case or at the filter pressure sensor. The pressure surge produces a frequency equal to the frequency at which the barrel rotates. According to one feature, the data signal from the filter pressure sensor is filtered and analyzed to determine whether a barrel leak has occurred. According to another feature, the data signal from the case pressure sensor is filtered and analyzed to determine whether a barrel leak occurs.
15A is a flowchart illustrating an operational flow for an exemplary leak detection process 1200A, in which a barrel leak, such as a barrel leak, may be detected in the pump assembly 1300 of FIG. 14 . According to some implementations, the leak detection process 1200A is implemented on a pump used in a hybrid vehicle as described above. However, according to other implementations, the leak detection process 1200A may be used with any type of pump (eg, any axial piston pump) having suitable sensors for measuring pump speed and case pressure.
The leak detection process 1200A performs a predetermined appropriate initialization procedure, starts at the start module 1202 , and proceeds to a first acquisition operation 1204 . According to one feature, the first acquiring operation 1204 determines the pressure of the fluid associated with the second power source 124 . For example, in one implementation, the first acquisition operation 1204 receives a data signal from a filter pressure sensor, such as the filter pressure sensor 214 of FIG. 2 . According to another feature, the first acquiring operation 1204 receives a data signal from the case pressure sensor.
The second acquisition operation 1206 determines the frequency of the pump/motor. For example, in one implementation, the second acquisition operation 1206 receives a data signal from a pump speed sensor, such as the pump speed sensor 217 of FIG. 2 . According to another feature, the second acquiring operation 1206 converts the pump speed data signal into a frequency value (eg, converting the pump speed to Hz by dividing the pump speed by 60). In other implementations, the second acquiring operation 1206 may determine the frequency of the pump.
A filter operation 1208 removes the pressure pulses from the acquired signal to obtain a filtered signal. For example, in accordance with some features, filter operation 1208 filters out pulses that do not occur at a constant speed if the pump rotates at a constant speed. According to other features, filter operation 1208 removes pressure pulses that occur at a frequency different from the frequency at which the pump rotates. For example, filter operation 1208 may filter out pulses that generate frequencies above and/or below the pump frequency. In certain implementations, filter operation 1208 removes these pulses using a roll off filter.
For example, in accordance with some embodiments, the filter operation 1208 passes the data signal from the first acquisition operation 1204 through a high pass filter (eg, a Butterworth filter) to the standard Noise from leaks, stop-and-go cycles, etc. can be mitigated. Filter operation 1208 may also rectify the signal obtained from the high pass filter to obtain a substantially discrete signal. In certain implementations, filter operation 1208 may also pass a pressure sensor signal (eg, a rectified signal) through a low pass filter. According to one characteristic, the high-pass and low-pass filters can be adjusted based on an experimentally determined value for the pump frequency.
In other implementations, the data signal from the first acquisition operation 1204 may be passed through a bandpass filter to obtain a filtered signal. The bandpass filter may be configured based on the configuration of the pump, the strength of ripples in the acquired signal, and/or other frequencies (eg, vibration or other noise) resulting from other parts of the system. For example, in one implementation, filter operation 1208 may filter out other frequencies that are about 20% above or below the pump frequency. In another implementation, filter operation 1208 may roll off other frequencies that are about 10% above or below the pump frequency. In certain implementations, filter operation 1208 uses only a lowpass filter. For example, according to some features, if the pump is operating below a threshold rotational speed (eg, about 500 RPM), the filter operation 1208 may roll off the high frequency pulses using only the low pass filter.
Optional (see broken line) pump speed determination module 1210 determines whether the pump rotation reaches a prescribed frequency. In some implementations, the pressure pulses from the leak occur too quickly above a certain pump speed to sample accurately. In such implementations, the pump speed determination module 1210 protects against annoying disturbances when the pump is rotating at a speed that is outside the detectable range. Accordingly, if the first determination module 1210 determines that the pump speed from the second acquisition operation 1206 is greater than the maximum speed threshold, the leak detection operation 1200 loops back to the first acquisition operation 1204 again. Start.
However, if the first determination module 1210 determines that the pump speed is less than the maximum speed threshold, the leak detection operation 1200 proceeds to the second determination module 1212 . In other implementations, the sensor (eg, filter sensor 214 in FIG. 2 ) is accurate enough that pump speed determination module 1210 is not needed. In this implementation, the leak detection process 1200A proceeds from filter operation 1208 to pressure spike determination module 1212 .
The pressure surge determination module 1212 determines whether the filtered signal exceeds a prescribed threshold. According to some features, the threshold is determined empirically and stored electronically (eg, in memory 167 of second power source control system 152 of FIG. 3 ). For example, in one implementation, the second determination module 1212 may obtain the threshold value from memory via the CAN bus 184 .
For example, in some implementations, the surge threshold may be selected by operating a pump with a known leak and mapping the surge during operation. In certain implementations, the threshold may be set as a limiting magnitude or plus a tolerance to an experimentally measured pressure surge. In other implementations, the threshold is set as an experimentally measured percentage of the magnitude of the pressure surge (eg, 10%, 15%, 25%, 50%, 75%, etc.). In other implementations, the threshold is selected based on pressure surges that may occur in a pump operating under ideal conditions. For example, the threshold may be chosen to be some pulse percentage (25%, 50%, 75%, 100%, 150%, etc.) of pressure surges experimentally obtained under ideal conditions.
According to some features, pressure surges occurring at the pump frequency can be mapped for different operating conditions. Thus, the pressure surge threshold can be mapped for different operating conditions as well. For example, pressure surges may be mapped for different swash plate angular positions and/or for different pressure readings. The mapping value can be used to determine the threshold to be used for a given operating variable. In this case, the leak detection process 1200A determines the operating parameters and the pressure surge threshold module 1212 compares the filtered signal to thresholds for these operating parameters. Another alternative process is shown in FIG. 15B and is also discussed herein.
If the pressure surge determination module 1212 determines that the filtered signal does not exceed the pressure surge threshold, the leak detection process 1200A cycles back to the first acquisition operation 1204 and starts again. However, if the pressure surge determination module 1212 determines that the filtered signal exceeds the pressure surge threshold, the failure operation 1214 activates a response process such as the response process 500 of FIG. 7 . According to one aspect, the fault action 1214 determines whether the leak constitutes a disabling fault. The leak detection process 1200A performs any appropriate completion procedures and also ends at the stop module 126 .
FIG. 15B is a flowchart illustrating an operation flow for another exemplary leak detection process 1200B. In the pump assembly 1300 of FIG. 14 , a barrel leak such as a barrel leak may be detected. According to some implementations, the leak detection process 1200B is implemented in a pump used in a hybrid vehicle as described above. However, according to other implementations, the leak detection process 1200B may be used with any type of pump (eg, any axial piston pump) having suitable sensors for measuring pump speed and case pressure. The leak detection process 1200B may be used as an alternative to the leak detection process 1200A of FIG. 15A. The leak detection process 1200B differs from the leak detection process 1200A in that it stores the pressure surge threshold for only certain operating variables (instead of a 3D map for substantially all of the operating variables).
The leak detection process 1200B performs a predetermined appropriate initialization procedure, starts at the start module 1202 , and proceeds to the first determination module 1201 . The first determination module 1201 determines whether the current operating parameters of the pump (ie, or the vehicle) fall within a tolerable range. For example, according to some implementations, the first determination module 1201 obtains data signals from appropriate sensors to determine the current operating state of the pump and/or vehicle. For example, in a particular implementation, the first determining module 1201 obtains data signals representing a current swash plate angle and/or a current filter pressure. The first determination module 1201 also determines whether a pressure surge threshold associated with the current operating state is stored, for example, in the memory 167 of the second power source control system 152 of FIG. 3 . Operating states that do not have an associated threshold are out of tolerance.
If the first determination module 1201 determines that no pressure surge threshold is stored for the current operating states, the leak detection process 1200B cycles back to the start operation 1202 and starts again. Accordingly, the first decision module 1201 protects against annoying failures. However, if the first determination module 1201 determines that the pressure surge value is stored in the current operation states, the leak detection process 1200B proceeds to a first acquisition operation 1204 . The implementation of operation 1204 via leak detection process 1200B is substantially the same as operation 1204 of operation 1214 via leak detection process 1200A.
In the leak detection process 1200B, the pressure surge determination module 1212 determines whether the filtered signal exceeds a prescribed threshold associated with the operating states determined by the first determination module 1201. According to some features, the pressure surge threshold is determined empirically (eg, using one of the processes described above with respect to FIG. 15A ) and also (memory 167 of the second power source control system 152 of FIG. 3 ) e) stored electronically. For example, in one implementation, the second determination module 1212 may obtain the threshold value from the memory via the CAN bus 184 .
If the second determination module 1212 determines that the filtered signal does not exceed the pressure surge threshold, the leak detection process 1200 loops back to the first acquisition operation 1204 and starts again. However, if the second determination module 1212 determines that the filtered signal exceeds the pressure surge threshold, the failure operation 1214 activates a response process such as the response process 500 of FIG. 7 . According to one aspect, the fault action 1214 determines whether the leak constitutes a disabling fault. The leak detection process 1200B performs any appropriate completion procedures and also ends at the stop module 1216 .
15C is a flow diagram illustrating an exemplary monitoring process 1200C, wherein changes in pump operation can be monitored to map changes in filter pressure spikes over time. According to some implementations, monitoring process 1200C continues with leak detection processes 1200A, 1200B of FIGS. 15A and 15B . For example, in one implementation, the monitoring process 1200C may be implemented if the second determination module 1212 has the filter pressure signal within a tolerance range (eg, below a threshold) before cycling back to the start of the process. In other implementations, the monitoring process 1200C may be implemented after the fault operation 1214 is activated.
The monitoring process 1200C performs a predetermined appropriate initialization procedure and proceeds to the acquisition operation 1220 starting from the start module 1218 . Acquisition operation 1220 determines whether a previous pressure surge value has been stored in memory, for example, in memory 167 of second power source control system 52 of FIG. 3 . If such a value has been stored, the get operation 1220 retrieves the value from memory. In some implementations, the acquire operation 1220 retrieves one or more discrete pressure spike values stored in memory. In other implementations, the obtain operation 1220 derives a running average value based on previously stored values.
The determination module 1222 compares the filtered data signals obtained in the leak detection processes 1500A and 1500B with stored pressure surge values. If the decision module 1222 deviates from the values stored for the pressure surges by a threshold amount of the pressure surges in the filtered data signal, the fail action 1224 is actuated. In one implementation, failure 1224 triggers a response process, such as response process 500 of FIG. 7 .
The storage operation 1226 stores the values of the pressure surges of the filtered data signal, for example, in the memory 167 of the second power source control system 152 of FIG. 3 . In some implementations, store operation 1226 uses the value(s) from the filtered data signal to compute a moving average based on values already stored in memory. The monitoring process 1200C performs any appropriate completion procedures and also ends at the stop module 1228 .
If the determination module 1222 determines that the pressure surges in the filtered data signal do not deviate by a threshold amount from the values stored for the pressure surges, the monitoring process 1200C0 may proceed to a storage operation 1226. However, in other implementations, monitoring Process 1200C may instead proceed directly to quiescent module 1228 .
According to some features, monitoring process 1200C may be used to determine when the performance of the pump begins to degrade over time, even if the performance of the pump has not yet degraded sufficiently to trigger a failure. According to other features, the monitoring process 1200C may be used to map the performance of the pump over time to help provide a prognosis for the pump.
16 is a block diagram illustrating an exemplary detection process 1400, and a low fluid (eg, oil) level may be determined. According to some features, the detection process 1400 receives inputs from a transmission output speed sensor, an oil level sensor, a foot valve sensor, and an accumulator pressure sensor. If the transmission output speed is equal to about 0 RPM and a foot valve sensor such as the foot valve 236 of FIG. 2 indicates that the foot valve is open, the detection process 1400 performs both the accumulator pressure sensor and the oil level sensor of the reservoir. Determine whether the multiplier indicates that the fluid level is below a specified threshold for a specified period of time. According to one feature, the fault condition from the detection process 1400 is a disabling fault.
17 is a block diagram illustrating an exemplary bypass valve failure detection process 1500, and a malfunction may be determined in the bypass valve. If the pump does not reach the proper pressure within a prescribed time period (eg, about 10 seconds), the detection process 1500 refers to the actual calculated flow and also indicates a failure.
According to some features, the detection process 1500 receives inputs from the swash plate angle sensor, the pump rotation speed sensor, and the accumulator pressure sensor. The data received from the swash plate angle sensor and the pump rotation speed sensor allow the calculation of the absolute value of the pump/motor flow. For example, the pump/motor flow can be calculated using the following equation:
Pump/motor flow = [(displacement at max swash plate angle)*(rotation speed)*tan(actual swash plate angle)]/(231*tan(max swash plate angle).
The detection process 1500 determines whether a latching fault condition has occurred when the calculated flow exceeds a prescribed limit and the pressure in the accumulator fails to reach a prescribed threshold for a prescribed period of time. The detection process 1500 determines whether the disabling state has occurred when the latching failure state is detected more than a set number of times (eg, 5 or more times). According to one feature, the number of times the latching failure state is detected may be stored in a memory such as the volatile memory 168 of FIG. 3 .
18 is a block diagram illustrating an exemplary bootstrap failure detection process 1600, and a malfunction may be determined in the bypass valve. If the pump does not reach the proper pressure within a prescribed time period (eg, about 10 seconds), the detection process 1600 is commanded to refer to the calculated flow to indicate a failure.
According to some features, the detection process 1600 receives inputs from the pump speed rotation sensor and the accumulator pressure sensor. The detection process 1600 also determines whether the most recent command has been sent to the swash plate control valve. The absolute value of the pump/motor flow can be calculated based on the pump rotation speed and the angle at which the swash plate is commanded to be angled:
=[(displacement at maximum swash plate angle)*rotation speed*tan(commanded swash plate angle)]/(231*tan(maximum swash plate angle).
The detection process 1600 determines whether a latching fault condition has occurred when the calculated flow exceeds a prescribed limit and the pressure in the accumulator fails to reach a prescribed threshold for a prescribed period of time. The detection process 1600 determines whether a disabling failure state has occurred when the latching failure state is detected five or more times. According to one feature, the number of times a latching failure state is detected may be stored in a memory such as the volatile memory 168 of FIG. 3 .
19 is a block diagram illustrating an exemplary pump/motor failure detection process 1700, in which a malfunction in the pump may be determined. According to some features, the detection process 1700 receives inputs from the swash plate angle sensor, the pump rotation speed sensor, and the accumulator pressure sensor. The absolute value of the pump/motor flow is calculated based on the equation provided with respect to FIG. 17 .
The detection process 1700 determines whether a disabling fault condition has occurred when the calculated flow exceeds a prescribed limit and the pressure in the accumulator does not reach a prescribed threshold for a prescribed period of time. According to one feature, the prescribed threshold for the accumulator pressure is lower than the prescribed threshold used by the detection process 1500 to determine bypass valve failure.
20 is a block for explaining an exemplary failure of the separation failure failure detection process 1800, and the failure may be determined in a transfer case for disconnecting the second power source 124 from the vehicle. According to some features, the detection process 1800 receives input from a clutch valve sensor. The detection process 1800 also determines the most recent command sent to the clutch valve. The detection process 1800 determines whether a disabling fault has occurred when the difference between the commanded clutch state and the actual clutch state differs by a threshold amount for a period of time greater than a prescribed period of time. According to one aspect, the detection process 1800 activates a rate limiting process in response to detecting a disabling fault condition.
21 is a flowchart illustrating an operation flow for an exemplary speed limiting process 1900, in which damage to the second power source may be mitigated by limiting the speed of the engine in case of a failure in the transfer case. In general, if disconnection of the second power source 124 from the first power source fails, the speed limiting process 1900 sends an appropriate speed limiting command (eg, J1939 command) to the engine to prevent the pump from rotating too fast. do.
The rate limiting process 1900 performs a predetermined appropriate initialization procedure, starts at the start module 1902 , and proceeds to the first decision module 1904 . The first determination module 1904 determines whether a separation failure fault has been activated. For example, in one implementation, the first determining module 1904 verifies whether such a fault is stored in the non-volatile memory 167 of the second power source control system 152 of FIG. 3 . An exemplary process that may trigger such a failure is discussed above with reference to FIG. 20 . Of course, the fault may be stored in other forms or forms of electronic memory.
If the first decision module 1904 determines that this fault has not been activated, the speed limiting process 1900 performs a predetermined appropriate completion procedure and also ends at the stop module 1916 . However, if the first determining module 1904 determines that the separation failure fault has been activated, the speed limiting process 1900 proceeds to a first acquiring operation 1906 . A first acquisition operation 1906 receives a data signal (eg, in RPM) indicative of the pump speed. For example, the first acquisition operation 1906 may obtain a data signal from a pump speed sensor such as the speed sensor 217 of FIG. 2 .
A second acquisition operation 1908 receives a data signal representing the gear ratio of the pump. For example, in one implementation, the second acquisition operation 1908 may receive a data signal from the processor 166 and the non-volatile memory 167 of the second power source control system 152 of FIG. 3 . In another exemplary implementation, the second acquiring operation 1908 may receive a data signal from the processor 160 and the non-volatile memory 161 of the prime mover control unit 154 of FIG. 3 . In another implementation, the second acquiring operation 1908 may receive a gear ratio data signal from a user input or via an upload signal from a remote computer.
Calculation operation 1910 determines the maximum allowable engine speed at which the second power source can be coupled with the vehicle. In some implementations, the calculating operation 1910 determines a maximum allowable engine speed based, at least in part, on the obtained gear ratio. In certain implementations, the calculating operation 1910 determines a maximum allowable engine speed based, at least in part, on the obtained pump speed. For example, in one implementation, calculating operation 1910 may calculate the maximum allowable engine speed according to the following equation:
=Maximum allowable transmission output speed*gear ratio
In other implementations, calculation operation 1910 may determine the maximum allowable engine speed by retrieving a stored value from a memory, such as non-volatile memory 167 or non-volatile memory 161 of FIG. 3 .
The second determination module 1912 determines whether the pump moves faster than the calculated maximum allowable speed. If the second determination module 1912 determines that the pump is not moving quickly, the speed limiting process 1900 returns to the first acquiring operation 1904 to monitor the current pump speed. However, if the second determination module 1912 determines that the pump moves faster than the maximum allowed speed, the speed limiting process 1900 proceeds to a limiting operation 1914 .
The limiting operation 1914 sends an appropriate command to limit the speed of the engine. For example, the limit operation 1914 transmits a limit command through the communication network 184 . In one implementation, constrain operation 1914 sends a J1939 command to the engine. The speed limiting process 1900 performs any appropriate completion procedures and also ends at the stop module 196 .
22 is a schematic diagram of an exemplary hydraulic accumulator 2000 suitable for use as the high pressure accumulator 146 of FIG. 2 . Hydraulic accumulator 2000 includes a rigid outer shell (or "housing") defining an inner chamber. A separator 2020 divides the inner chamber into a liquid chamber 2015 and a gas chamber 2025 . As described above, oil may be transferred (eg, via a high-pressure valve) between the oil reservoir 144 and the liquid chamber 2015 of the accumulator 146 . Gas in the gas chamber 2025 may be accommodated through a gas pressure valve. In some implementations, the gas is in the form of a relatively inert gas, such as nitrogen gas. It should be understood that the detailed description of the present invention is not limited to the use of any particular type of gas.
In some implementations, housing 2010 includes hydraulic ports and conduits 2012 through which liquid chamber 2020 communicates with components external to the accumulator. In various implementations, the hydraulic port and conduit may or may not include a valve assembly. In some example implementations, the internal gas chamber 2025 can receive high pressure gas from a pressurized gas source, such as through a gas port 2022 and a gas release valve. However, in other exemplary implementations, the accumulator 2000 may include only one hydraulic or gas valve. Implementations of the present invention are not limited to any particular type of hydraulic or gas valve, or where both valves are present.
In certain implementations, separator 2020 between liquid chamber 2015 and gas chamber 2025 includes a piston (eg, sealed with an elastomeric sealing ring). In other implementations, the separator 2020 may include some kind of bellows arrangement. In other implementations, separator 2020 includes an elastomeric bladder. Some exemplary materials for use in constructing such bladders are permeable, or at least "semi-permeable" (i.e., over time the material will cause some of the nitrogen gas to penetrate through the bladder material into an adjacent liquid chamber. allow it). In one exemplary implementation, bladder 2020 is formed from nitrile rubber.
One process that can detect a gas leak from the internal gas chamber 2025 includes monitoring the temperature and pressure of the gas in the bladder 2020 . However, according to some implementations, leakage of gas from the internal gas chamber 2020 cannot be detected based on the measured characteristics of the gas. Indeed, in some implementations, the accumulator 2000 does not include at least one of a gas pressure sensor and a gas temperature sensor within the bladder 2020 of the accumulator 2000 . According to certain features, the accumulator 2000 does not include a gas pressure sensor or a gas temperature sensor within the bladder 2020 of the accumulator.
23 is a flowchart illustrating an operation flow for an exemplary gas leak detection process 2300, in which a gas leak may be detected in the accumulator. For example, the gas leak detection process 2300 may determine whether gas is leaking from the gas chamber 2025 of the accumulator 2000 of FIG. 22 . According to some features, the gas leak detection process 2300 detects a gas leak without directly measuring properties of the gas. For example, in certain implementations, 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 starts up (eg, daily or after several reset cycles). Accordingly, the gas leak detection process 2300 performs a predetermined appropriate initialization procedure, starts in the start module, and proceeds to the first determination module 2302 . The first determination module 2302 determines whether the accumulator is newly started.
If the first determination module 2302 determines that the accumulator is newly started, the gas leak detection process 2300 proceeds to a first acquisition operation 2304 . However, if the first determination module 2302 determines that the accumulator is not newly started, the gas leak detection process 2300 performs a predetermined completion procedure and ends in the stop module. One exemplary process for enabling the first decision module 2302 to make a decision is shown in FIG. 24 .
According to one aspect, the first acquiring operation 2304 receives a data signal from the liquid temperature sensor. For example, in one implementation, the first acquiring operation 2304 may receive a data signal from the low organic temperature sensor 212 of FIG. 2 . The data signal represents the temperature of a liquid (eg, oil) in a reservoir such as the reservoir 144 of FIG. 2 . This liquid is delivered to the fluid chamber of the accumulator, such as the fluid chamber 2015 of the accumulator 2000 of FIG. 22 . In another implementation, the first acquiring operation 2304 may receive a data signal from a predetermined temperature sensor configured to measure a temperature of a liquid flowing between the reservoir and the accumulator.
A second acquisition operation 2306 receives a data signal from a fluid pressure sensor in the accumulator. For example, in one implementation, the second acquisition operation 2306 receives a data signal from the accumulator pressure sensor 215 of FIG. 2 . The data signal represents the pressure of the liquid (eg oil) in the accumulator. For example, in one implementation, the data signal represents the pressure of the liquid in the fluid chamber 2015 of the accumulator 2000 of FIG. 22 . In other implementations, the second acquisition operation 2306 may receive data signals from a predetermined pressure sensor configured to measure the pressure of a liquid flowing between the reservoir and the accumulator.
An estimate operation 2308 calculates the temperature of the gas in the accumulator, such as nitrogen in the internal gas chamber 2025 of the accumulator 2000 of FIG. 22 . For example, in some implementations, the estimating operation 2308 calculates a pressure of the gas in the accumulator based on the pressure of the fluid in the accumulator. In this implementation, the estimating operation 2308 determines an approximated gas pressure based on the data signals received in the second acquiring operation 2306 .
In certain implementations, the estimating operation 2308 determines what the pressure of the gas in the accumulator may be at a particular temperature. For example, in one implementation, the estimating operation 2308 determines what the pressure of the gas in the accumulator would be if the gas temperature was 20°C. Of course, the estimating operation 2308 may calculate a pressure at a predetermined desired temperature. The estimating operation 2308 is determined based on the measured fluid pressure and the measured fluid temperature in the liquid chamber of the reservoir or the accumulator. can do. For example, the estimation operation 2308 may inversely calculate the pressure of the liquid based on the data signals received in the first and second acquisition operations 2302 and 2304 . From the inverse calculated liquid pressure, the estimating operation 2308 may calculate an approximation of the gas pressure at the desired temperature.
The second determination module 2310 determines whether the approximate gas pressure is within a tolerance value. In some implementations, the second determination module 2310 may determine whether the approximate gas pressure is below a prescribed threshold value at a particular temperature. In certain implementations, the threshold is set based on a standard operating pressure for a particular accumulator, which can be determined experimentally. In some implementations, the second determination module 2310 compares the inversely calculated estimated gas pressure to a threshold value. The temperature at which the estimating operation 2308 inversely calculates the gas pressure is based on a threshold, according to some features.
In some implementations, the threshold for the second determination module 2310 is based on a percentage of the standard operating gas pressure at the standard operating temperature for the particular accumulator. For example, in a particular implementation, the second determination module 2318 determines whether the approximate pressure is within 10% of the standard operating range for the particular accumulator. In another implementation, the second determination module 2310 determines whether the approximate pressure is within 15% of the standard operating range. In yet another implementation, the second determination module 2318 determines whether the approximate pressure is within 20% of the standard operating range. In yet another implementation, the second determination module 2318 determines whether the approximate pressure is within 25% of the standard operating range. For example, in certain implementations, the standard operating pressure for gas in an accumulator is about 124 bar at 20°C. In one such implementation, the second determination module 2310 determines whether the approximate gas pressure is less than or equal to about 100 bar at 20°C.
If the second determination module 2310 determines that the approximate gas pressure is outside the tolerance value for the gas pressure, the gas leak detection process 2300 activates the failure operation 2312 . For example, the second determination module 2310 may break that the approximate gas pressure is below a set threshold value. The failure operation 2312 operates a response process such as the response process 500 of FIG. 7 . According to one feature, the fault action 2312 determines that the leak constitutes a disabling fault. The leak detection process 2300 performs a predetermined completion procedure and ends in the stop module.
If the second determination module 2310 determines that the approximate gas pressure is within the tolerance for the gas pressure (eg, is below a set threshold), the gas leak detection process 2300 proceeds to a storage operation 2314 . The storage operation 2314 stores the approximate gas pressure value in a memory, such as the non-volatile memory 167 (see FIG. 3) of the second power source. In certain implementations, the store operation 2314 also deletes previously stored values, such as the oldest gas pressure values stored in memory. In another implementation, the store operation 2314 does not delete the stored values.
An average operation 2316 calculates a moving average of the estimated gas pressure values stored in the memory. In some implementations, the averaging operation 2316 may compute a moving average based on the most recent values stored in memory. For example, in one implementation, the averaging operation 2316 computes a moving average of at least five approximate gas pressure values stored in memory. However, in other implementations, the averaging operation 2316 may perform a calculation based on the most recent three values, eight values, ten values, fifteen values, twenty values, fifty values.
The third determination module 2318 determines whether the moving average of the approximate gas pressure values is within the tolerance value. In some implementations, the third determining module 2318 may determine whether the moving average is below a prescribed threshold associated with a particular temperature. In a specific implementation, the tolerance values for the moving average are closer to the desired operating variables than the tolerance values used by the second determination module 2310 .
In some implementations, the threshold for third determination module 2318 is based on a percentage of the standard operating gas pressure at the standard operating temperature for the particular accumulator. For example, in a particular implementation, the third determination module 2318 determines whether the moving average is within 10% of the standard operating range for the particular accumulator. In another implementation, the third determining module 2318 determines whether the moving average is within 5% of the operating range in the table. In yet another implementation, the third determining module 2318 determines whether the moving average is within 15% of the standard operating range. In yet another implementation, the third determining module 2318 determines whether the moving average is within 20% of the standard operating range. For example, in one implementation, the third determination module 2318 determines whether the moving average of the approximate gas pressure values is less than about 115 bars at 20°C when the standard operating value is about 124 bars at 20°C.
If the third determination module 2318 determines that the moving average is out of the tolerance value, the gas leak detection process 2300 activates a failure operation 2312 . For example, the third determination module 2318 may determine that the moving average is below a set threshold. The failure operation 2312 activates a response process such as the response process 500 of FIG. 7 . In one implementation, the fault action 2312 determines that the leak constitutes a disabling fault. In another implementation, failover 2312 determines that the leak constitutes a latching future. In another implementation, fault action 2312 displays a service indication without triggering a fault response. The leak detection process 2300 performs a predetermined appropriate completion procedure and also ends at the stop module.
If the third determination module 2318 determines that the moving average is within the tolerance value for the gas pressure (eg, is below a set threshold), the gas leak detection process 2300 activates the failure operation 2312. It ends at the stop module without any work.
24 is a flowchart illustrating an operation flow for an exemplary initialization confirmation process 2400, wherein the gas leak detection process 2300 may determine whether the system has been recently initialized. The initialization confirmation process 2400 performs a predetermined appropriate initialization procedure, starts in the start module, and a first determination module 2402 determines whether a foot valve such as the foot valve 236 of FIG. 2 has changed the state to the open position. ) to proceed.
If the foot valve has not changed state or has not been opened, the initialization confirmation process 2400 proceeds to a first return operation 2412 in which a value of "no" or false is returned. The initialization confirmation process 2400 performs a predetermined appropriate completion procedure and also ends at the stop module. However, if the first determination module 2402 determines that the foot valve has changed the state to open, the initialization confirmation process 2400 proceeds to a first acquisition operation 2402 .
The first acquisition operation 2402 receives a data signal from the first temperature sensor indicating the temperature of the pump case. For example, the first acquisition operation 2402 may receive a data signal from the case temperature sensor 218 . The second acquisition operation 2404 receives a data signal from a second temperature sensor indicating the temperature of the fluid reservoir, such as the fluid reservoir 144 (see FIGS. 1 and 2 ). For example, the second acquisition operation 2404 may receive a data signal from the low organic temperature sensor 212 .
The comparison operation 2406 determines a difference between the data signals received in the first and second acquisition operations 2402 and 2404 . The second determination module 2408 determines whether the difference calculated by the comparison operation 2406 is within a prescribed range. For example, in one implementation, the second determination module 2408 determines whether the temperature of the pump case and the temperature of the fluid reservoir are within 10 degrees of each other. In another implementation, the second determining module 2408 may determine whether the case temperature and the low organic temperature are within 2 degrees, 5 degrees, 8 degrees, 15 degrees, and 12 degrees of each other.
If the second determination module 2408 determines that the temperature of the case is different from the fluid storage organic temperature, the initialization confirmation process 2400 proceeds to a first return operation 2412 in which a "no" or false value is returned. . If the second determination module 2408 determines that the temperature of the case is within the tolerance range from the fluid storage organic temperature, the initialization confirmation process 2400 proceeds to a second operation 2414 of returning a value of "yes" or true. proceed The initialization confirmation process 2400 performs a predetermined completion procedure and ends in the stop module.
25 is a flowchart illustrating an operation flow of the fluid leak detection process 2500 capable of determining whether a fluid (eg, oil) leaks from the second power source. For example, the fluid leak detection process 2500 may detect a fluid leaking from the reservoir, the liquid chamber of the accumulator, or a conduit system therebetween. In general, the fluid leak detection process 2500 compares the measured fluid level in the reservoir with the estimated fluid level. The fluid leak detection process 2500 performs a predetermined initialization procedure, starts in the start module, and proceeds to the first determination module 2502 .
The first determination module 2502 determines whether the foot valve is open. For example, in one implementation, the first determination module 2502 may obtain an indication from the accumulation proximity sensor 216 of FIG. 2 indicating whether the foot valve is open or closed. If the first determination module 2502 determines that the foot valve is not opened, the fluid leak detection process 2500 performs a predetermined completion procedure and also ends in the stop module. However, if the first determination module 2502 determines that the foot valve is open, the fluid leak detection process 2500 proceeds to a first acquisition operation 2504 .
In the first acquiring operation 2504, a data signal is received from a temperature sensor indicating the temperature of the fluid in the reservoir. For example, in one implementation, the first acquiring operation 2504 may receive a data signal from the low organic temperature sensor 212 of FIG. 2 . The data signal represents the temperature of a liquid (eg, oil) in a reservoir such as the reservoir 144 of FIG. 2 . In another implementation, the first acquiring operation 2504 may receive data signals from a predetermined temperature sensor configured to measure a temperature of a liquid flowing between the reservoir and the accumulator.
A second acquisition operation 2506 receives a data signal from a fluid pressure sensor in the accumulator. For example, in one implementation, the second acquisition operation 2506 receives a data signal from the accumulator pressure sensor 215 of FIG. 2 . The data signal represents the pressure of the liquid (eg oil) in the accumulator. For example, in one implementation, the data signal represents the pressure of the liquid in the fluid chamber 2015 of the accumulator 2000 of FIG. 22 . In another implementation, the second acquisition operation 2506 may receive data signals from a predetermined pressure sensor configured to measure the pressure of a liquid flowing between the reservoir and the accumulator.
Estimating operation 2508 calculates an estimated fluid level in the accumulator. According to some implementations, the estimating operation 2508 calculates an estimated fluid level based on the readings obtained in the first and second acquiring operations 2504 and 2506 and the amount of fluid that should be in the reservoir. .
In the third acquiring operation 2510, the actual fluid level in the reservoir is measured. For example, in one implementation, the third acquisition operation 2510 receives a data signal from the level sensor 211 of FIG. 2 . The data signal indicates the level of the fluid in the reservoir 144 of FIG. 2 .
The second determination module 2512 determines whether the vehicle is moving. According to features of the present invention, fluid may clump around the reservoir when the vehicle is moving. Thus, fluid level measurements made when the vehicle is moving have higher inaccuracies than when the vehicle is stationary during the reading. If the second determination module 2512 determines that the vehicle is not moving, the fluid leak detection process 2500 performs a comparison operation (evaluating the measured fluid level and the estimated fluid level to determine a difference between the two values) 2516).
However, if the second determination module 2512 determines that the vehicle is moving, the fluid leak detection process 2500 proceeds to an adjust operation 2514 . Adjustment 2514 increases the measured fluid level by an amount that may differ from the estimated fluid level. In a particular implementation, the amount by which the adjustment 2514 changes the measurement or tolerance depends on how the movement of the vehicle affects the low organic fluid. Accordingly, in certain implementations, the amount of adjustment may be empirically determined for a particular reservoir and/or accumulator.
In some implementations, adjusting 2514 raises or lowers the estimated fluid level by a prescribed amount. For example, in one implementation, the adjustment 2514 subtracts 2 gallons from the estimated fluid level before comparing the measured level with the estimated level. In another implementation, the estimating operation 2514 subtracts 1 to 5 gallons from the estimated fluid level before comparing the measured and estimated levels. In yet another implementation, adjustment 2514 may subtract less than a gallon (eg, ¼ gallon, ½ gallon, etc.).
In another implementation, the adjustment 2514 increases the tolerance range for the comparison. For example, in one implementation, adjustment 2514 may increase the tolerance range by about 2 gallons. In other implementations, adjustment 2514 may add 1 to 5 gallons to the tolerance range before comparing the measured and estimated levels. In yet another implementation, adjustment 2514 may add less than a gallon (eg, ¼ gallon, ½ gallon, etc.) to the tolerance range. In this implementation, the adjustment operation 2514 is implemented before the compare operation 2516 . However, in other implementations, the adjustment operation 2514 may be implemented after the compare 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 implementations, the third determining module 2518 determines whether a difference between the estimated fluid level and the measured fluid level is less than a prescribed threshold. In another implementation, the third determining module 2518 determines whether the difference between the adjusted estimated level and the measured level is less than a prescribed threshold.
In some implementations, the threshold is set based at least in part on an amount of tolerance in the system. For example, a threshold may account for percentage errors in fluid temperature readings, percentage errors in fluid pressure readings, and percentage errors in fluid level readings. In one implementation, the fluid temperature sensor may have an error of 2%, the fluid pressure sensor may have an error of 1%, and the fluid level sensor may have an error of 7%. In one such implementation, the tolerance threshold may be set at a value of at least 9% of the measured value. However, in other implementations, the tolerance threshold may be set at high or low percentage tolerances.
In some implementations, the threshold may be set, at least in part, based on laws, regulations, or guidelines. For example, the threshold may be set at least in part based on EPA (US Environmental Protection Agency) reporting guidelines. For example, in one implementation, the third determination module 2518 determines whether the difference between the estimated fluid level and the measured fluid level is less than about 10 gallons. In another implementation, the third determination module 2518 determines whether the difference between the estimated fluid level and the measured fluid level is less than about 5 gallons. In another implementation, the third determination module 2518 determines whether the difference between the estimated fluid level and the measured fluid level is less than about 3 gallons. In another implementation, the third determination module 2518 determines whether the difference between the estimated fluid level and the measured fluid level is less than about 1 gallon. In another implementation, the third determination module 2518 determines whether the difference between the estimated fluid level and the measured fluid level is less than about 1/2 gallon.
If the third determination module 2518 determines that the difference between the estimated fluid level and the measured fluid level is within the tolerance range, the fluid leak detection process 2500 performs a predetermined appropriate completion procedure and also ends in the stop module. do. However, if it is determined that the third determination module 2518 is outside the tolerance range, the fluid leak detection process 2500 activates the failure operation 2520 . The failure operation 2520 operates a response process such as the response process 500 of FIG. 7 . According to one feature, the fault action 2520 determines that the fluid leak constitutes a disabling future. The fluid leak detection process 2500 completes any appropriate procedures and also ends at the stop module.
26 is a block diagram illustrating another exemplary separation failure detection process 2600, in which an obstacle may be broken in a transfer case for disconnecting the second power source 124 from the vehicle. In accordance with some aspects of the present invention, the exemplary separation failure detection process 2600 may be used as an alternative to the exemplary separation failure detection process 1800 shown in FIG. However, in accordance with another aspect of the present invention, the exemplary separation failure detection process 2600 may be used in combination with the exemplary separation failure detection process 1800 of FIG. 20 .
In general, the detection process 2600 determines whether the pump is still pumping after the clutch has been presumably disengaged. The detection process 2600 may determine whether the difference between the pump speed and the output shaft speed is logically impossible. According to some features, the detection process 2600 receives an input from the clutch valve sensor to determine whether the clutch is engaged or disengaged.
The detection process 2600 also receives input from the pump speed sensor to determine the speed of the pump. The detection process 2600 also estimates the pump speed using the speed of the output shaft and the transfer case ratio. In one exemplary implementation, the detection process 2600 obtains the output shaft speed from the engine controller via the CAN bus 184 . For example, in one implementation, the detection process 2600 may compare the pump speed to the output shaft speed using the following equation:
=Pump speed - (output shaft speed * transfer case ratio)
If the clutch is engaged and the difference between the pump speed and the comparable output shaft speed exceeds the tolerance amount for a period of time greater than a prescribed period of time, the detection process 2600 triggers a fault. In various example implementations, the detection process 2600 can trigger a disabling fault when the tolerance rate limit is exceeded for about 3 seconds, 5 seconds, 8 seconds, 30 seconds, 1 minute, 2 minutes, 5 minutes, or 30 minutes. have.
In some implementations, the detection process 2600 can trigger a non-latching fault. In another implementation, the detection process 2600 activates a latching fault. In yet another implementation, the detection process 2600 triggers a disabling future. According to one aspect, the detection process 2600 activates a rate limiting process in response to detecting a disabling fault condition. According to another feature, the detection process 2600 triggers a service alert in response to detecting a fault condition.
The detection process 2600 also triggers a fault if the clutch status sensor indicates that the clutch is disengaged and the pump speed exceeds a threshold speed for a period of time greater than a prescribed period of time. In various example implementations, the detection process 2600 can trigger a disabling fault when the speed threshold is exceeded for about 3 seconds, 5 seconds, 8 seconds, 15 seconds, 30 seconds, 1 minute, 2 minutes, or 5 minutes. .
In some implementations, the detection process 2600 activates a non-latching future. In another implementation, the detection process 2600 activates a latching fault. In yet another implementation, the detection process 2600 activates a disabling fault. According to one aspect, the detection process 2600 activates a rate limiting process in response to detecting a disabling fault condition. According to another feature, the detection process 2600 triggers a service alert in response to detecting a fault condition.
Various modifications and alternatives of the present invention will become apparent to those skilled in the art without departing from the scope and spirit of the present invention. For example, each flowchart represents an exemplary sequence of operations. At least some of the operations in the flowchart may be performed in a different order than shown. The scope of the invention is not limited to the illustrative embodiments given herein.
29 sheets
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Every citation, both ways
| Document | Relation | Office | Cited during |
|---|---|---|---|
| DE102013105030A1 | Cited by | Germany | Applicant |
27 members in 9 offices
Priority claims5
| Document | Office | Kind | Date |
|---|---|---|---|
| 18613609 | United States of America | P | |
| 18613609 | United States of America | P | |
| 61186136 | United States of America | – | |
| 2009186136 | – | – | – |
| US20090186136P | – | – | – |
Members27
| Document | Office | Kind | |
|---|---|---|---|
| CA2765159A1 | Canada | A1 | |
| US2010313849A1 | United States of America | A1 | |
| WO2010144793A2 | World Intellectual Property Organization (WIPO) | A2 | |
| EP2440902A2 | European Patent Office (EPO) | A2 | |
| KR20120052926AThis record | Republic of Korea | A | |
| WO2010144793A9 | World Intellectual Property Organization (WIPO) | A9 | |
| MX2011013252A | Mexico | A | |
| CN102725619A | China | A | |
| WO2010144793A3 | World Intellectual Property Organization (WIPO) | A3 | |
| JP2012530247A | Japan | A | |
| US8499616B2 | United States of America | B2 | |
| US2013317716A1 | United States of America | A1 | |
| JP2014197007A | Japan | A | |
| US8950249B2 | United States of America | B2 | |
| JP5682016B2 | Japan | B2 | |
| US2015152861A1 | United States of America | A1 | |
| CN102725619B | China | B | |
| CN104972884A | China | A | |
| JP2015187500A | Japan | A | |
| JP2015199494A | Japan | A | |
| JP5841192B2 | Japan | B2 | |
| BRPI1009667A2 | Brazil | A2 | |
| MX338307B | Mexico | B | |
| JP6104313B2 | Japan | B2 | |
| JP6169126B2 | Japan | B2 | |
| US10030648B2 | United States of America | B2 | |
| CN104972884B | China | B |
1 legal event, as the office reported them to INPADOC
Events
| Event | Code | |
|---|---|---|
| Application deemed withdrawn, e.g. because no request for examination was filed or no examination fee was paidWithdrawnWITN | WITN |
Numbers
- Publication
- 1020120052926
- Publication, DOCDB
- 20120052926
- Publication, EPODOC
- KR20120052926
- Application
- 1020127000014
- Application, DOCDB
- 20127000014
- Application, EPODOC
- KR20127000014
Titles4
- Korean
- 하이브리드 구동시스템에서 장애 검출 및 완화
- English
- FAULT DETECTION AND MITIGATION IN HYBRID DRIVE SYSTEM
- Unlabeled
- 하이브리드 구동시스템에서 장애 검출 및 완화{FAULT DETECTION AND MITIGATION IN HYBRID DRIVE SYSTEM}
- Unlabeled
- Fault detection and mitigation in hybrid drive systems
Classification
- CPC, 18
- B60K6/12
- G01M3/26
- F04B51/00
- B60W20/50
- F02D41/22
- F02D2041/1432
- F02D2041/224
- F02D2041/225
- F02D2041/227
- F04B49/103
- G01M3/002
- Y02T10/62
- B60W10/30
- B60K6/26
- B60W10/02
- F02D29/02
- G01M3/00
- G01M17/00
- IPC, 3
- G01M3 26
- B60L50 16
- B60W10 30