Incorporating a Deep Neural Network into Moving Horizon Estimation for Embedded Thermal Torque Derating of an Electric Machine

Abstract: This study introduces a novel state estimation framework that incorporates Deep Neural Networks (DNNs) into Moving Horizon Estimation (MHE), shifting from traditional physics-based models to rapidly developed data-driven techniques. A DNN model with Long Short-Term Memory (LSTM) nodes is trained on synthetic data generated by a high-fidelity thermal model of a Permanent Magnet Synchronous Machine (PMSM), which undergoes thermal derating as part of the torque control strategy in a battery electric vehicle. The MHE is constructed by integrating the trained DNN with a simplified driving dynamics model in a discrete-time formulation, incorporating the LSTM hidden and cell states in the state vector to retain system dynamics. The resulting optimal control problem (OCP) is formulated as a nonlinear program (NLP) and implemented using the acados framework. Model-in-the-loop (MiL) simulations demonstrate accurate temperature estimation, even under noisy sensor conditions or failures. Achieving threefold real-time capability on embedded hardware confirms the feasibility of the approach for practical deployment. The primary focus of this study is to assess the feasibility of the MHE framework using a DNN-based plant model instead of focusing on quantitative comparisons of vehicle performance. Overall, this research highlights the potential of DNN-based MHE for real-time, safety-critical applications by combining the strengths of model-based and data-driven methods.