Onboard diagnostics of an active air dam assembly

1. A vehicle comprising:

a vehicle body; and

an active air dam assembly coupled to the vehicle body and configured to control an ambient airflow between the vehicle body and a road surface, the active air dam assembly including:

an adjustable flap;

a flap actuator configured to move the adjustable flap via the shaft anywhere between and inclusive of a stowed position having a first height relative to the road surface and a deployed position having a second height relative to the road surface, wherein the first height is greater than the second height;

a plurality of sensors, each of which is operable for measuring a separate performance parameter of the flap actuator; and

a controller configured to receive the measured performance parameters from the plurality of sensors, identify a fault mode of the active air dam assembly from among a plurality of different possible fault modes using the received performance parameters, and execute a control action corresponding to the identified fault mode.

2. The vehicle of claim 1 , wherein the flap actuator is a motor.

3. The vehicle of claim 2 , wherein the motor is a brushless direct current motor.

4. The vehicle of claim 1 , wherein the fault modes include a first fault mode indicative of a fault or malfunction of the adjustable flap, a second fault mode indicative of a fault or malfunction of the flap actuator, and a third fault mode indicative of a fault or malfunction of one of the plurality of sensors.

5. The vehicle of claim 4 , wherein the plurality of electrical sensors includes a current sensor operable for measuring a current draw of the flap actuator, a voltage sensor operable for measuring a back-electromotive force of the flap actuator, and a position sensor operable for measuring a relative position of the flap actuator, and wherein the third fault mode is indicative of a fault or malfunction of the position sensor.

6. The vehicle of claim 5 , wherein the control action corresponding to the identified fault mode includes registering or recording of a diagnostic code in memory of the controller to indicate the identified fault mode.

7. An active air dam assembly for controlling an ambient airflow between a vehicle body and a road surface, the active air dam assembly comprising:

an adjustable flap;

a shaft coupled to the adjustable flap and configured to shift the adjustable flap between a stowed position having a first height relative to the road surface and a deployed position having a second height relative to the road surface, wherein the first height is greater than the second height;

a flap actuator coupled to the shaft and configured to move the adjustable flap via the shaft anywhere between and inclusive of the stowed position and the deployed position;

a plurality of sensors, each of which is operable for measuring a separate performance parameter of the flap actuator; and

a controller configured to receive the measured performance parameters from the sensors, identify a fault mode of the active air dam assembly from among a plurality of different fault modes using the received performance parameters, and execute a control action corresponding to the identified fault mode.

8. The active air dam assembly of claim 7 , wherein the flap actuator is a motor.

9. The active air dam assembly of claim 8 , wherein the motor is a brushless direct current motor.

10. The assembly of claim 7 , wherein the fault modes include a first fault mode indicative of a fault or malfunction of the adjustable flap, a second fault indicative of a fault or malfunction of the flap actuator, and a third fault indicative of a fault or malfunction of one of the plurality of sensors.

11. The active air dam assembly of claim 10 , wherein the plurality of sensors includes a current sensor operable for measuring a current draw of the flap actuator, a voltage sensor operable for measuring a back-electromotive force of the flap actuator, and a position sensor operable for measuring a relative position of the flap actuator or the adjustable flap, and wherein the third fault mode is indicative of a fault mode of the position sensor.

12. The active air dam assembly of claim 11 , wherein the control action corresponding to the identified fault mode includes recording a diagnostic code indicative of the identified fault mode.

13. A method for diagnosing performance of an active air dam assembly in a vehicle having a vehicle body, wherein the active air dam assembly includes a flap having a position that is adjustable anywhere between and inclusive of a stowed position having a first height relative to the road surface and a deployed position having a second height relative to the road surface, wherein the first height is greater than the second height, and a flap actuator configured to move the flap between the stowed and deployed positions to control an ambient airflow between the vehicle body and a road surface, the method comprising:

measuring a set of performance parameters of the flap actuator using a plurality of sensors;

identifying a fault mode of the active air dam assembly from among a plurality of different possible fault modes using the measured performance parameters to thereby diagnose the performance of the active air dam assembly; and

executing a control action corresponding to the identified fault mode.

14. The method of claim 13 , wherein the flap actuator is a motor.

15. The method of claim 14 , wherein the motor is a brushless direct current motor.

16. The method of claim 13 , wherein identifying a fault mode includes identifying a first fault mode indicative of a fault or malfunction of the adjustable flap, a second fault mode indicative of a fault or malfunction of the flap actuator, and a third fault mode indicative of a fault or malfunction of one of the plurality of sensors.

17. The method of claim 16 , wherein measuring a set of performance parameters includes measuring a current draw of the flap actuator via a current sensor, measuring a back-electromotive force of the flap actuator via a voltage sensor, and measuring a relative position of the flap actuator via a position sensor.

18. The method of claim 17 , further comprising:

calculating a load or torque variation of the flap actuator using the measured current draw; and

comparing the calculated load or torque variation of the flap actuator to an expected load or torque variation of the flap.

19. The method of claim 17 , wherein measuring the back-EMF of the actuator includes discontinuing a pulse width modulation (PWM) signal to the flap actuator, detecting a voltage spike in the PWM signal after discontinuing the PWM signal, and then measuring the back-EMF via a voltage sensor only after detecting the voltage spike.

20. The method of claim 13 , wherein executing the control action includes recording a diagnostic code indicative of the identified fault mode.