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CN-121993593-A - Method and device for determining a fault of a hall sensor of a motor of a gear shift actuator

CN121993593ACN 121993593 ACN121993593 ACN 121993593ACN-121993593-A

Abstract

The application relates to a method for determining a hall sensor fault of an electric motor of a gear shift actuator of a vehicle having an electrically driven bridge system integrating the electric motor, a reduction gear and an inverter, comprising the steps of performing a hall sensor self-test diagnosis procedure for the hall sensor of the electric motor after a gear shift control unit of the vehicle has been awakened for the first time, and determining that the hall sensor has failed if the hall sensor self-test diagnosis procedure has not passed. The application also relates to a device for determining the fault of the Hall sensor of the motor of the gear shifting actuating mechanism of a vehicle and an electric drive bridge system of the vehicle, by adopting the scheme, even if the gear shifting actuating mechanism does not move, the fault of the Hall sensor of the DCA motor can be determined, and the fault diagnosis of the Hall sensor can be performed before gear shifting when the TCU is awakened for the first time, so that the possible gear shifting problem is avoided in advance.

Inventors

  • WANG YULONG
  • WU JIAPENG

Assignees

  • 罗伯特·博世有限公司

Dates

Publication Date
20260508
Application Date
20241105

Claims (14)

  1. 1. A method of determining a hall sensor fault for an electric motor of a shift actuator of a vehicle having an electric drive axle system integrating the electric motor, a speed reducer and an inverter, the method comprising the steps of: After a shift control unit of a vehicle is awakened for the first time, a hall sensor self-checking diagnosis process for a hall sensor of the motor is performed, and if the hall sensor self-checking diagnosis process is not passed, it is determined that the hall sensor fails.
  2. 2. The method of claim 1, further comprising performing a shift actuator response diagnostic process each time the shift control unit issues a shift request to the shift actuator, and determining that the hall sensor is malfunctioning if the shift actuator response diagnostic process fails.
  3. 3. The method according to claim 1 or 2, wherein the hall sensor self-test diagnostic process comprises the steps of: And rotating the rotor of the motor of the gear shifting executing mechanism along a first direction for a certain distance, judging whether the phase sequence of the motor, which is indicated by the Hall sensor signal and is received after the rotor rotates along the first direction, is changed compared with the phase sequence of the motor when a gear shifting request is sent, if so, rotating the rotor of the motor along a second direction which is different from the first direction for a certain distance, judging whether the phase sequence of the motor, which is received after the rotor rotates along the second direction, is the same as the phase sequence of the motor when the gear shifting request is sent, and if so, determining that the self-checking diagnosis process of the Hall sensor is not passed.
  4. 4. The method of claim 2, wherein the shift actuator response diagnostic process includes the steps of: The method comprises the steps of enabling a rotor of a motor of a gear shifting executing mechanism to rotate for a distance along a first direction, judging whether a motor phase sequence which is received after the rotor rotates along the first direction and is represented by a Hall sensor signal is changed compared with a motor phase sequence when a gear shifting request is sent, enabling the motor rotor to rotate for a distance along a second direction which is different from the first direction if the motor phase sequence is changed, judging whether the motor phase sequence which is received after the rotor rotates along the second direction is identical with the motor phase sequence when the gear shifting request is sent, and if the motor phase sequence is different from the motor phase sequence, determining that the gear shifting executing mechanism does not pass a response diagnosis process.
  5. 5. The method of any of claims 1-4, further comprising performing a limp control on the electric drive bridge system upon determining that the hall sensor is malfunctioning, the performing a limp control on the electric drive bridge system including maintaining a current gear unchanged.
  6. 6. The method of claim 5, wherein performing a limp control on the electro-bridge system is performed for a single electro-bridge or a dual or multiple electro-bridge.
  7. 7. The method of any of claims 3-6, wherein the rotor of the electric machine is rotated 1rpm or more in the first direction or the second direction.
  8. 8. An apparatus for determining a hall sensor fault for a motor of a shift actuator of a vehicle, comprising: a shift control request module that instructs a shift actuator to perform a shift operation, And the self-checking diagnosis module of the Hall sensor is used for executing the self-checking diagnosis process of the Hall sensor for judging whether the Hall sensor of the motor has faults or not after the gear shifting control unit of the vehicle is awakened for the first time.
  9. 9. The apparatus of claim 8, further comprising a shift actuator response diagnostic module that performs a shift actuator response diagnostic process each time the shift actuator performs a shift operation in response to an instruction of the shift control unit to determine whether a hall sensor of the motor is malfunctioning.
  10. 10. The apparatus of claim 8 or 9, wherein the hall sensor self-test diagnostic module determines whether the hall sensor is malfunctioning by rotating a rotor of the motor in a first direction by a distance and comparing a motor phase sequence, which is indicated by a hall sensor signal received after the rotation, with a motor phase sequence at the time of a shift request, moving the rotor in a second direction when the phase sequence is changed, and again determining whether the phase sequence is changed, and determining whether the hall sensor is malfunctioning based on the phase sequence change.
  11. 11. The apparatus of claim 9 wherein the shift actuator response diagnostic module determines whether the hall sensor is malfunctioning by rotating the rotor of the motor a distance in a first direction and comparing the motor phase sequence, as indicated by the hall sensor signal, received after rotation with the motor phase sequence at the time of the shift request, moving the rotor in a second direction when the phase sequence changes, and again determining whether the phase sequence changes, determining whether the hall sensor is malfunctioning based on the phase sequence change.
  12. 12. The device of claim 10 or 11, wherein the rotor is rotated 1rpm or more in the first direction or the second direction.
  13. 13. The apparatus of any of claims 8-12, wherein the motor is a brushless dc motor.
  14. 14. An electrically driven bridge system for a vehicle comprising an electric motor, an inverter, a retarder and a shift assembly, the shift assembly comprising a shift control unit that instructs a shift actuator to control the operation of the shift actuator, wherein the electrically driven bridge system further comprises an apparatus according to any of claims 8-13 for performing the method according to any of claims 1-7.

Description

Method and device for determining a fault of a hall sensor of a motor of a gear shift actuator Technical Field The present application relates to an electrically driven bridge system using a shift actuator having a hall sensor, and more particularly, to a method and apparatus for determining a hall sensor failure for a shift actuator in an electrically driven bridge system. Background With the development of modern automobiles, an electric drive axle system for an electric automobile, i.e., a drive system combining a motor, an inverter, and a decelerator, has emerged for driving the operation of the vehicle. In such a vehicle, when a shift operation is required, a transmission control unit (hereinafter may be abbreviated as TCU) issues a transmission shift instruction to a shift actuator (hereinafter may be abbreviated as DCA), and the shift actuator performs the shift operation through a fork or other structure. For a motor for a gear shift actuator, a plurality of, for example, three hall sensors are associated, which can output high and low level signals according to the sensed change of the motor magnetic field, and the phase sequence of the motor is determined according to the combined sequence of the signals thereof. However, with existing electrically driven bridge systems, the hall sensor of the shift actuator does not support the basic electrical diagnostics (OL/SCB/SCG, etc.) in electrically driven bridge systems. That is, when one or more of the plurality of hall sensors fails, for example, when the signal of the hall sensor is not changed, it cannot be determined whether the hall sensor is in the power-off stop state or in the failure state, particularly, after the TCU is first awakened, the existing vehicle directly performs the gear shift operation, the determination of the failure of the hall sensor of the gear shift motor is not performed in advance, and the direct gear shift operation under the failure of the hall sensor may damage the vehicle components. Accordingly, there is a need for a method and apparatus for accurately diagnosing whether a hall position sensor in a shift actuator is malfunctioning in an electric drive axle system of a vehicle, thereby ensuring that the motor can be operated normally to increase the safety and reliability of the vehicle. That is, the position sequence of the hall sensor needs to be monitored in real time, both when the TCU is first awakened and each time a shift occurs, in order to discover any electrical problems that may exist with the motor at any time. Disclosure of Invention The application aims to provide a device for determining the fault of a Hall sensor of a gear shifting actuating mechanism accurately in real time in an electric drive axle driving system of a vehicle when a TCU of the vehicle is awakened and each gear shifting operation is carried out. To achieve the above object, the present application provides a method of determining a hall sensor failure of a motor of a shift actuator for a vehicle having an electric drive axle system integrating the motor, a reduction gear and an inverter, the method comprising the steps of performing a hall sensor self-check diagnosis process for the hall sensor of the motor after a shift control unit of the vehicle is first awakened, and determining that the hall sensor fails if the hall sensor self-check diagnosis process is failed. The application also relates to a device for determining the fault of the Hall sensor of the motor of the gear shifting actuating mechanism of the vehicle, which comprises a gear shifting control request module, a Hall sensor self-checking diagnosis module and a Hall sensor self-checking diagnosis module, wherein the gear shifting control request module sends an instruction to the gear shifting actuating mechanism to execute gear shifting operation, and the Hall sensor self-checking diagnosis module executes the Hall sensor self-checking diagnosis process aiming at the Hall sensor after the gear shifting control unit of the vehicle is awakened for the first time so as to judge whether the Hall sensor of the motor has the fault or not. The application also relates to an electric drive axle system for a vehicle comprising an electric motor, an inverter, a retarder and a gear shifting assembly comprising a gear shifting control unit that instructs a gear shifting actuator to control the operation of the gear shifting actuator, wherein the electric drive axle system further comprises a device as described above for performing a method as described above. By adopting the scheme of the application, the possible electrical problem in the motor of the gear shifting executing mechanism can be detected in real time according to the change between the signal sequence of the Hall sensor when the gear shifting request is sent and the signal sequence after the motor rotor rotates positively and reversely, even if the gear shifting executing mechanism does not move, the fault of the Hall