Systems and methods for shaft torque security electrical vehicles

A system for protecting a powertrain of a vehicle, the system comprising:

• input circuitry configured to:
• receive a signal from a sensor coupled to a motor shaft of an electric motor, wherein the sensor indicates an amount of rotation of the motor shaft;
• control circuitry configured to:
• determine an acceleration of the electric motor, based on the signal from the sensor;
• determine an internal torque between the motor shaft and an input gear coupled to the motor shaft, based on the acceleration of the electric motor and an inertia of the electric motor and a gearbox, wherein the powertrain of the vehicle comprises the gearbox and the electric motor, and the input gear couples the electric motor to the gearbox;
• determine whether the internal torque exceeds a conditional shutdown threshold torque;
• in response to determining that the internal torque exceeds the conditional shutdown threshold torque, increment a counter;
• and
• in response to determining that the counter exceeds a counter threshold, reduce power output to the electric motor.

A vehicle comprising:

• an electric motor comprising a motor shaft and an input gear coupled to the motor shaft;
• power electronics configured to output power to the electric motor;
• a gearbox, wherein the input gear couples the electric motor to the gearbox;
• a sensor coupled to the motor shaft and configured to output a signal indicating an amount of rotation of the motor shaft;
• input circuitry configured to receive the signal from the sensor;
• and
• control circuitry configured to:
• determine an acceleration of the electric motor, based on the signal from the sensor;
• determine an internal torque between the motor shaft and the input gear, based on the acceleration of the electric motor and an inertia of the electric motor and the gearbox;
• determine whether the internal torque exceeds a conditional shutdown threshold torque;
• in response to determining that the internal torque exceeds the conditional shutdown threshold torque, incrementing a counter;
• and
• in response to determining that the counter exceeds a counter threshold, control the power electronics to reduce the power output to the electric motor.