Abstract: A method for evaluating a permanent magnet motor, which includes a rotor with a plurality of magnets mounted thereon, and a stator with a plurality of windings in proximity to the rotor and coupled to an inverter, includes spinning the motor such that a voltage is induced in the windings of the stator and the inverter; measuring the voltage on the inverter; calculating the voltage constant from the motor from the measured voltage; comparing the voltage constant to accepted voltage constants; and identifying the motor as not acceptable if the voltage constant is outside of a range of the accepted voltage constants.

Abstract: Methods and apparatus are provided for monitoring an achieved motor torque produced by an electric motor. The method includes determining the achieved motor torque based on a rotor position of the electric motor and a phase current of the electric motor when the motor speed is not greater than a first pre-determined threshold, determining the achieved motor torque based on a loss-compensated power supplied to the electric motor when the motor speed is greater than the first pre-determined threshold, comparing the achieved motor torque with the torque command, and indicating a fault when the achieved motor torque is not within a pre-determined margin of the torque command.

Abstract: A method for evaluating a permanent magnet motor, which includes a rotor with a plurality of magnets mounted thereon, and a stator with a plurality of windings in proximity to the rotor and coupled to an inverter, includes spinning the motor such that a voltage is induced in the windings of the stator and the inverter; measuring the voltage on the inverter; calculating the voltage constant from the motor from the measured voltage; comparing the voltage constant to accepted voltage constants; and identifying the motor as not acceptable if the voltage constant is outside of a range of the accepted voltage constants.

Abstract: Methods and systems are provided for aligning a resolver in an electric motor system. The method includes commanding a d-axis current command and a speed command, operating an electric motor without a load in response to the d-axis current command and the speed command, determining a rotor speed in response to the speed command, and determining an offset of the resolver based on the speed command and the rotor speed when the rotor speed has substantially stabilized.

Abstract: A method evaluates a motor assembly having a first permanent magnet motor in a transmission of an automotive drive system at an end of manufacturing line evaluation. The first motor includes a first rotor with a first plurality of magnets mounted thereon, and a first stator with a first plurality of windings in proximity to the first rotor and coupled to a first inverter. The method includes spinning the first motor with an input dynamometer machine to a predetermined speed such that the first rotor of the first motor induces a first voltage on the first inverter; measuring the first voltage on the first inverter; calculating a first voltage constant of the first motor from the first voltage; comparing the first voltage constant to accepted voltage constants; and identifying the motor as not acceptable if the first voltage constant is outside of a range of the accepted voltage constants.

Abstract: A method is provided for detecting an insufficient or missing phase current in a permanent magnet synchronous motor, and includes determining a composite vector position of a combined three-phase phase current with respect to a stationary portion of the motor, and assigning a sector to the position. The method includes comparing the phase current to a calibrated threshold current corresponding to the sector, and executing a response when the absolute value is less than the threshold. A vehicle includes an energy storage device (ESD), a motor/generator configured as a permanent magnet synchronous motor, a voltage inverter, and a bus for conducting DC current from the ESD to the inverter. A controller detects an insufficient phase current, determines a current vector position of the three-phase AC, assigns a sector to the position, and executes a response when an absolute value of the phase current is less than a calibrated threshold.

Abstract: A control apparatus for a powertrain system comprising an engine and two electrical machines operably coupled to a two-mode compound-split electro-mechanical transmission is provided. It includes a system controller and two motor control processors. The system controller communicates with the motor control processors via two high speed communications buses and directly-linked serial peripheral interface buses. The motor control processors control flow of electrical power between the electrical machines and an electrical energy storage device. A second control device is operable to control the engine, preferably to control torque output. The internal combustion engine preferably has a crank position sensor which is signally connected to a dedicated input to the second control device and to a dedicated input to the system controller of the first control device.

Abstract: A rotatable shaft is equipped with a measurement device that generates output signals corresponding to discrete angular positions of the shaft. Rotational angles of the shaft are measured for a complete rotational period. A true angular velocity of the shaft is determined. Angular velocity is calculated between contiguous pairs of the discrete angular positions. A velocity correction is determined, and a rotational angle error term is determined based upon the velocity correction.

Abstract: A hybrid powertrain system includes an engine, an electric machine, a power electronics device including a plurality of electric circuit layers, and a cooling system. A method for managing thermal energy in the power electronics device includes monitoring a plurality of temperature sensors in the power electronics device, monitoring electric power into and out of the power electronics device, predicting temperatures for the plurality of electric circuit layers, and controlling the hybrid powertrain system based upon the predicted temperatures for the plurality of electric circuit layers.

Abstract: Methods and apparatus are provided for monitoring an achieved motor torque produced by an electric motor. The method includes determining the achieved motor torque based on a rotor position of the electric motor and a phase current of the electric motor when the motor speed is not greater than a first pre-determined threshold, determining the achieved motor torque based on a loss-compensated power supplied to the electric motor when the motor speed is greater than the first pre-determined threshold, comparing the achieved motor torque with the torque command, and indicating a fault when the achieved motor torque is not within a pre-determined margin of the torque command.

Abstract: Methods and systems are provided for aligning a resolver in an electric motor system. The method includes commanding a d-axis current command and a speed command, operating an electric motor without a load in response to the d-axis current command and the speed command, determining a rotor speed in response to the speed command, and determining an offset of the resolver based on the speed command and the rotor speed when the rotor speed has substantially stabilized.

Abstract: A control system and method to determine position of a rotor relative to a stator for a synchronous multipole electrical machine is presented, including one for application on a fuel/electric hybrid powertrain for a vehicle. The machine includes a stator, a rotor, and a rotor position sensing mechanism. The control system controls the electrical machine, in conjunction with an electrical storage device and an inverter, using algorithms and calibrations which derive a rotor position based upon a sensorless position sensing technique, and determine an offset from a sensed rotor position. Electrical output from the inverter to the machine is controlled based the offset, which is stored non-volatile memory. A rotor position is derived based upon a sensorless position sensing technique during initial machine operation after startup of the machine, and includes operation in a torque-generative mode and in an electrical energy-generative mode.

Abstract: A control apparatus for a powertrain system comprising an engine and two electrical machines operably coupled to a two-mode compound-split electro-mechanical transmission is provided. It includes a system controller and two motor control processors. The system controller communicates with the motor control processors via two high speed communications buses and directly-linked serial peripheral interface buses. The motor control processors control flow of electrical power between the electrical machines and an electrical energy storage device. A second control device is operable to control the engine, preferably to control torque output. The internal combustion engine preferably has a crank position sensor which is signally connected to a dedicated input to the second control device and to a dedicated input to the system controller of the first control device.

Abstract: A control system for a motor including a rotor comprises a sensorless sensor module that includes a saliency-based estimator module that generates a first rotor position signal based on saliency and a back electromotive force (emf) estimator module that generates a second rotor position signal based on back emf. A selector selects the first rotor position signal for rotor speeds below a first rotor speed and the second rotor position signal for rotor speeds above the first rotor speed. A rotor position sensor senses a position of the rotor and generates a third rotor position signal. A fault detection module senses faults in the rotor position sensor and outputs the third rotor position signal when a fault is not detected and one of the first and second rotor position signals when the fault is detected. An indirect field oriented control (IFOC) system controls the motor based on a selected one of the first, second and third rotor position signals.

Abstract: An improved control for an automatic transmission closed-throttle downshift, wherein closed-throttle engine torque is used to raise the transmission input speed to the synchronous speed of the target speed ratio, and wherein the on-coming clutch is controlled in a manner to complete the shift with minimum driveline torque disturbance in spite of clutch control variability. The invention includes a primary on-coming clutch control for completing the downshift when the input speed reaches the synchronous speed, and a contingent on-coming clutch control that is initiated if shift completion is not achieved by the primary control, the contingent control being effective to re-establish input speed synchronization and thereupon engage the on-coming clutch to complete the shift.

Abstract: An improved control for an automatic transmission garage shift, wherein a dynamic model of the transmission is used to estimate the transmission input torque during the shift and to schedule the on-coming clutch pressure in accordance with the estimated input torque to achieve a desired input shaft trajectory. The transmission input torque is estimated based on two different methodologies —one suited to steady-state engine idle conditions, and the other suited to engine output torque transient conditions. A fuzzy summation of the input torques provided by the two methodologies is utilized in transitions between the two conditions. Shift quality variations due to variations in mechanical and/or hydraulic stiffness are minimized by a pause or hold interval inserted between the end of the fill period and the initiation of on-coming clutch pressure control, which results in a reasonably consistent degree of perceived transmission-to-transmission hydraulic and mechanical compliance.

Abstract: A closed-throttle downshift control adjusts engine torque to raise the input speed of a transmission to the synchronous speed of the target speed ratio, and adaptively adjusts clutch control parameters to coordinate the off-going clutch release and the on-coming clutch apply, and to complete the shift with minimum driveline torque disturbance. A primary on-coming clutch control fills the on-coming clutch and then raises the on-coming pressure when the input speed reaches the synchronous speed of the target speed ratio. If input synchronization cannot be maintained, a contingent control increases the on-coming clutch pressure to gradually re-establish the input speed synchronization and thereupon engage the on-coming clutch to complete the shift. The fill time or the maintenance pressure of the on-coming clutch is adaptively decreased for reduced driveline disturbance in subsequent shifts of the same type if the output shaft jerk during the primary control exceeds a threshold.

Abstract: An improved transmission shift pattern control that preserves the attributes of a selected base shift pattern while dynamically adjusting the high throttle shift thresholds based on a measure of vehicle loading. Heavy vehicle loading is detected by recognizing a pattern of high engine throttle and lower than expected vehicle acceleration, and the high power shifting thresholds are dynamically adjusted based on the detected loading to automatically provide aggressive shifting in a heavily loaded vehicle without producing excessive shift cycling in a normally or lightly loaded vehicle. A throttle timer is used to detect a condition of sustained high throttle operation, and under such condition, an acceleration timer determines the duration of lower than expected acceleration. If the determined duration exceeds a threshold, a shift pattern override is activated until the acceleration rises above an exit threshold.

Abstract: An improved diagnostic control method for a motor vehicle powertrain including an electronically controlled multi-range transmission and a multi-range transfer case, wherein a default determination of transfer case range enables reliable evaluation of transmission ratio, for powertrain configurations with or without a transfer case range indicator switch. An overall speed ratio is computed according to a ratio of the transmission input speed and the transfer case output speed, and the computed ratio is monitored to identify a period of stable operation at the conclusion of transmission shifting and in steady state operation during which the rate of change of the computed ratio is stable over a predefined interval. If the computed ratio is also deemed to be stable, it is compared with an expected overall ratio based on an assumed speed range (low or high) of the transfer case.