# US 12,005,808 B2 · Methods and apparatus for propulsion system prognostics due to boosted operation > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,005,808 B2 - Document ID: US12005808B2 - Status: Granted - Kind: B2 - Application number: 17/318,949 - Filed: 2021-05-12 - Published: 2022-11-17 - Granted: 2024-06-11 - Earliest claimed: 2021-05-12 - Assignees: GM Global Technology Operations LLC - Applicants: GM Global Technology Operations LLC - Inventors: Shiming Duan; Yiran Hu; Shifang Li; Brent S. Gagas - Web page: https://patentgrep.com/patent/US12005808B2 ## CPC - B60L 50/61: by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles - B60L 58/16: responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH] - B60L 15/20: for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed - B60L 58/12: responding to state of charge [SoC] - B60L 2240/423: Torque - B60L 2240/427: Voltage - B60L 2240/429: Current - B60L 2240/547: Voltage - B60L 2240/549: Current - B60L 2260/167: of motors or generators - B60L 2260/50: by future state prediction - B60L 2270/142: acoustic - B60L 2270/145: Structure borne vibrations - B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES ## Abstract A diagnostic system for a vehicle includes a vehicle system configured to operate the vehicle in a normal operating mode and a boosted mode. In the boosted mode, the vehicle system increases at least one of a maximum motor torque, a maximum engine torque, and a maximum battery power available to the vehicle. A wear estimation module is configured to collect wear data associated with a component of the vehicle while being operated in the boosted mode, estimate, based on the collected wear data, wear of the component caused by being operated in the boosted mode, and generate a prediction of a remaining lifetime of the component based on the estimated wear of the component. ## Claims ### Claim 1 A diagnostic system for a vehicle, the diagnostic system comprising: a vehicle system configured to operate the vehicle in a normal operating mode and a boosted mode, wherein, in the boosted mode, the vehicle system increases at least one of a maximum motor torque, a maximum engine torque, and a maximum battery power available to the vehicle; and a wear estimation module configured to (i) collect wear data associated with a component of the vehicle while being operated in the boosted mode, (ii) estimate, based on the collected wear data, wear of the component caused by being operated in the boosted mode including applying a different weighting factor during the boosted mode than during the normal operating mode, wherein the weight factor increases during the boosted mode relative to the normal operating mode, and (iii) generate a prediction of a remaining lifetime of the component based on the estimated wear of the component, wherein the vehicle system is configured to adjust at least one of criteria for transitioning to the boosted mode and control during the boosted mode based on the prediction of the remaining lifetime of the component. ### Claim 2 (depends on 1) The diagnostic system of claim 1, wherein the wear estimation module is configured to execute at least one component wear model that models component wear as a function of operating conditions during the boosted mode. ### Claim 3 (depends on 2) The diagnostic system of claim 2, wherein the at least one model includes a health model configured to generate a health parameter H based on performance indicators of the component during the boosted mode. ### Claim 4 (depends on 3) The diagnostic system of claim 3, wherein the component is a battery and the performance indicators include at least one of battery resistance, battery voltage and/or current, battery state of charge, and estimated capacity. ### Claim 5 (depends on 3) The diagnostic system of claim 3, wherein the component is a motor and the performance indicators include at least one of a motor torque response time, a motor torque accuracy, an estimated motor coil resistance, an estimated motor coil inductance, a maximum torque achieved, and a maximum current achieved. ### Claim 6 (depends on 3) The diagnostic system of claim 3, wherein the component is an inverter and the performance indicators include at least one of a motor current response time, a motor current accuracy, a motor voltage response time, a motor voltage accuracy, and pulse width modulation accuracy. ### Claim 7 (depends on 3) The diagnostic system of claim 3, wherein the component is a drive unit and the performance indicators include at least one of bearing vibration, bearing noise, and drive unit efficiency. ### Claim 8 (depends on 3) The diagnostic system of claim 3, wherein the at least one model includes an energy model configured to generate an energy parameter E based on energy parameters indicative of energy applied to the component during the boosted mode. ### Claim 9 (depends on 8) The diagnostic system of claim 8, wherein the at least one model includes a wear model configured to generate a wear parameter indicated the wear of the component based on the health parameter H and the energy parameter E. ### Claim 10 (depends on 1) The diagnostic system of claim 1, wherein the wear estimation module is further configured to collect the wear data from a plurality of vehicles, estimate the wear of the component based on the wear data collected from the plurality of vehicles, and generate the prediction of the remaining lifetime of the component based on the wear data collected from the plurality of vehicles. ### Claim 11 (depends on 10) The diagnostic system of claim 10, wherein the wear data collected from the plurality of vehicles includes indication of failures of the component in the plurality of vehicles, and wherein the wear estimation module is configured to generate a probability that the component will fail in the vehicle based on the failures of the component in the plurality of vehicles. ### Claim 12 (depends on 1) The diagnostic system of claim 1, wherein the criteria include at least one of a maximum motor torque and a maximum engine torque available to the vehicle during the boosted mode and a frequency of the boosted mode and the control includes torque distribution to different axles of the vehicle during the boosted mode. ### Claim 13 A method of determining wear of a component a vehicle, method comprising: transitioning the vehicle from a normal operating to a boosted mode, wherein, in the boosted mode, at least one of a maximum motor torque, a maximum engine torque, and a maximum battery power available to the vehicle is increased relative to the normal operating mode; collecting wear data associated with the component of the vehicle while being operated in the boosted mode; estimating, based on the collected wear data, the wear of the component as caused by being operated in the boosted mode including applying a different weighting factor during the boosted mode than during the normal operating mode, wherein the weight factor increases during the boosted mode relative to the normal operating mode; generating a prediction of a remaining lifetime of the component based on the estimated wear of the component; and adjusting at least one of criteria for transitioning to the boosted mode and control during the boosted mode based on the prediction of the remaining lifetime of the component. ### Claim 14 (depends on 13) The method of claim 13, wherein estimating the wear of the component includes executing at least one component wear model that models component wear as a function of operating conditions during the boosted mode. ### Claim 15 (depends on 14) The method of claim 14, wherein the at least one model includes a health model configured to generate a health parameter H based on performance indicators of the component during the boosted mode. ### Claim 16 (depends on 15) The method of claim 15, wherein at least one of the component is a battery and the performance indicators include at least one of battery resistance, battery voltage and/or current, battery state of charge, and estimated capacity; the component is a motor and the performance indicators include at least one of a motor torque response time, a motor torque accuracy, an estimated motor coil resistance, an estimated motor coil inductance, a maximum torque achieved, and a maximum current achieved; the component is an inverter and the performance indicators include at least one of a motor current response time, a motor current accuracy, a motor voltage response time, a motor voltage accuracy, and pulse width modulation accuracy; and the component is a drive unit and the performance indicators include at least one of bearing vibration, bearing noise, and drive unit efficiency. ### Claim 17 (depends on 15) The method of claim 15, wherein the at least one model includes an energy model configured to generate an energy parameter E based on energy parameters indicative of energy applied to the component during the boosted mode. ### Claim 18 (depends on 17) The method of claim 17, wherein the at least one model includes a wear model configured to generate a wear parameter indicated the wear of the component based on the health parameter H and the energy parameter E.