Abstract: Methods and systems are provided for adapting pulse width modulation with randomized zero-sequence components for control of an electrified powertrain of a vehicle. In one example, a method may include determining a zero-sequence voltage of an electric machine of the vehicle based on a random distribution, and adjusting a voltage reference signal of the electric machine based on the determined zero-sequence voltage to decrease ambient acoustic noise in the vehicle. In this way, spectral energy dispersion of pulse width modulated control of the electric machine may be increased without affecting torque production of the electric machine.

Abstract: Methods and systems are provided for adaptive pulse width modulated control of an electrified powertrain of a vehicle. In one example, a method may include perturbing a switching frequency for pulse width modulated control of the electrified powertrain, and, responsive to sound measured in a vehicle cabin indicating a noise improvement after the perturbation, controlling the electrified powertrain with the perturbed switching frequency. In this way, acoustic emissions from an electrified powertrain may be reduced.

Abstract: Methods and systems are provided for adapting pulse width modulation with randomized zero-sequence components for control of an electrified powertrain of a vehicle. In one example, a method may include determining a zero-sequence voltage of an electric machine of the vehicle based on a random distribution, and adjusting a voltage reference signal of the electric machine based on the determined zero-sequence voltage to decrease ambient acoustic noise in the vehicle. In this way, spectral energy dispersion of pulse width modulated control of the electric machine may be increased without affecting torque production of the electric machine.

Abstract: Methods and systems are provided for adaptive pulse width modulated control of an electrified powertrain of a vehicle. In one example, a method may include perturbing a switching frequency for pulse width modulated control of the electrified powertrain, and, responsive to sound measured in a vehicle cabin indicating a noise improvement after the perturbation, controlling the electrified powertrain with the perturbed switching frequency. In this way, acoustic emissions from an electrified powertrain may be reduced.

Abstract: A method of separating a blank from a stack of blanks is provided and includes grasping a first blank and moving the first blank away from a plurality of blanks. At least one additional blank from the plurality of blanks is adhered to the first blank to form a sub-stack of blanks and at least one impulse electrically generated force (EGF) is applied to separate the at least one additional blank from the first blank. The first blank may be grasped by a device with a force F1, and the at least one impulse EGF may be less than the force F1. Also, the at least one impulse EGF may be applied to separate the at least one additional blank from the first blank by passing a pulse of current through an EGF generator positioned adjacent the first blank and inducing an EGF within the plurality of blanks.

Abstract: This disclosure relates to an electrified vehicle and a method for providing driver feedback by producing a torque ripple. An exemplary electrified vehicle includes, among other things, an electric machine configured to generate a torque output, and a controller configured to selectively adjust the torque output to produce a torque ripple in response to a triggering event.

Abstract: A method of separating a blank from a stack of blanks is provided and includes grasping a first blank and moving the first blank away from a plurality of blanks. At least one additional blank from the plurality of blanks is adhered to the first blank to form a sub-stack of blanks and at least one impulse electrically generated force (EGF) is applied to separate the at least one additional blank from the first blank. The first blank may be grasped by a device with a force F1, and the at least one impulse EGF may be less than the force F1. Also, the at least one impulse EGF may be applied to separate the at least one additional blank from the first blank by passing a pulse of current through an EGF generator positioned adjacent the first blank and inducing an EGF within the plurality of blanks.

Abstract: This disclosure relates to an electrified vehicle and a method for providing driver feedback by producing a torque ripple. An exemplary electrified vehicle includes, among other things, an electric machine configured to generate a torque output, and a controller configured to selectively adjust the torque output to produce a torque ripple in response to a triggering event.

Abstract: A rotor for an electric machine assembly including a rotor mount region and a plurality of magnet pockets is provided. The rotor mount region may extend radially about a shaft through-hole. Each of the plurality of magnet pockets may be defined within the rotor mount region. Each magnet pocket may include a central pocket region between an outer pocket region and an inner pocket region. The central pocket region may be sized to receive a magnet having a wedge shape. The central pocket region and the magnet may each have a first side offset at an angle relative to a second side. The outer pocket region may define an outcropped portion extending into the central pocket region. A length of the magnet may be greater than a length between an edge of the magnet adjacent the inner pocket region and an edge of the outcropped portion adjacent the central pocket region.

Abstract: A grain boundary diffusion method for a rare-earth (RE) magnet is provided. The method includes coating particles of the RE magnet with a coating material. Each RE magnet particle includes a plurality of grains. The coated particles are then simultaneously heat treated and compacted. The heat treated, compacted, and coated particles are then formed into a rare earth magnet. In a form of the method, the heat treated, compacted, and coated particles are hot deformed prior to being formed into a rare earth magnet. Another form of the method achieves the grain boundary diffusion without first sintering the rare earth magnet.

Abstract: A method for estimating torque control error at an electric machine considers the effects of current sensor error characteristics. Systems and methods can be practiced to determine the maximum sensor error that can be tolerated without causing unacceptable torque error. An example method uses sensor characteristics and machine characteristics to determine current sensing error, current control error, and torque control error. Determining the lowest sensor accuracy required for a desired torque control accuracy can facilitate the use of lower cost sensors in current-feedback controlled electric drive systems without compromising performance. Other applications can include vehicle diagnostics and torque error compensation.

Abstract: An energy conversion system transfers energy between an energy source, or storage unit, and an electric device via a first port and a second port and at least one of receives and provides energy via a third port.

Abstract: Systems, apparatus, and methods detect a current sensor error in an FOC electric machine system. A voltage command is monitored to detect the presence of an ac component that indicates that an error has occurred at a current sensor. For example, a sensor fault detection module can be configured to determine the deviation between an actual voltage command and an ideal voltage command to provide a complex deviation vector. By transforming the deviation vector to a reference frame rotating at the fundamental frequency of the command voltage, a dc component of the positive and negative sequences can be filtered, and their amplitudes determined. Error detection can be based on the total amplitude of the fundamental component, determined by positive and negative component amplitudes. Sensor error detection enables an FOC system to operate with two current sensors, rather than three, and provides a dedicated fault diagnostic for a current sensor.

Abstract: An energy conversion system transfers energy between an energy source, or storage unit, and an electric device via a first port and a second port and at least one of receives and provides energy via a third port.

Abstract: Methods of providing a control band for a hysteresis controller are presented. A method can determine a control band analytically to avoid the time and costs associated with manual calibration of a hysteresis controller. By way of example, a method can include modeling a machine output, such as stator flux or machine torque, modeling the variation rate for the machine output, and providing a control band based on the variation rate modeling.

Abstract: An energy conversion system transfers energy between an energy source, or storage unit, and an electric device via a first port and a second port and at least one of receives and provides energy via a third port.

Abstract: Systems, apparatus, and methods detect a current sensor error in an FOC electric machine system. A voltage command is monitored to detect the presence of an ac component can indicate that an error has occurred at a current sensor. By way of example, a sensor fault detection module can be configured to determine the deviation between an actual voltage command and an ideal voltage command to provide a complex deviation vector. By transforming the deviation vector to a reference frame rotating at the fundamental frequency of the command voltage, a dc component of the positive and negative sequences can be filtered, and their amplitudes determined. Error detection can be based on the total amplitude of the fundamental component, determined by positive and negative component amplitudes. The invention enables an FOC system to operate with two current sensors, rather than three, and provides a dedicated fault diagnostic for a current sensor.

Abstract: A method for estimating torque control error at an electric machine considers the effects of current sensor error characteristics. Systems and methods can be practiced to determine the maximum sensor error that can be tolerated without causing unacceptable torque error. An example method uses sensor characteristics and machine characteristics to determine current sensing error, current control error, and torque control error. Determining the lowest sensor accuracy required for a desired torque control accuracy can facilitate the use of lower cost sensors in current-feedback controlled electric drive systems without compromising performance. Other applications can include vehicle diagnostics and torque error compensation.

Abstract: Methods of providing a control band for a hysteresis controller are presented. A method can determine a control band analytically to avoid the time and costs associated with manual calibration of a hysteresis controller. By way of example, a method can include modeling a machine output, such as stator flux or machine torque, modeling the variation rate for the machine output, and providing a control band based on the variation rate modeling.

Abstract: A method for charging an electric storage battery in a plug-in electric vehicle through a power supply circuit includes coupling a charger to the circuit, providing the charger with a signal representing a current capacity of the circuit, using the signal to determine a maximum charge rate corresponds to the current capacity of the circuit represented by the signal, and charging the battery through the circuit and charger at the maximum charge rate.