Abstract: A hybrid electric vehicle (HEV) has an algorithm for executing a method for diagnosing a high-voltage (HV) fault condition aboard the HEV. The HEV includes a high-voltage (HV) battery, an auxiliary power module (APM), a power inverter module (PIM), and a three-phase motor/generator unit (MGU). A controller executes the method to thereby measure a DC output current from the HV battery, a DC inlet current into the APM, and a pair of AC phase currents in the MGU. The method further includes calculating a DC inlet current into the PIM using the AC phase currents, diagnosing the HV fault condition using the DC output currents and the DC inlet currents, and executing a control action in response to the diagnosed condition. The method can include shutting off the APM to determine whether the APM is the root cause of the HV fault condition.

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 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: Methods of controlling deposition of metal on field regions of a substrate in an electroplating process are provided. In one aspect, a dielectric layer is deposited under plasma on the field region of a patterned substrate, leaving a conductive surface exposed in the openings. Electroplating on the field region is reduced or eliminated, resulting in void-free features and minimal excess plating. In another aspect, a resistive layer, which may be a metal, is used in place of the dielectric. In a further aspect, the surface of the conductive field region is modified to change its chemical potential relative to the sidewalls and bottoms of the openings.

Abstract: A method for detecting speed faults in a hybrid powertrain having engine and electric machine speed inputs includes directly sensing the engine and machine speeds and performing comparisons of sensed engine speed with engine speed determined based upon the machine speeds.

Abstract: A method and an article of manufacture are provided to monitor a temperature sensing circuit and detect a fault therein. The method comprises monitoring sensor readings output from a plurality of temperature sensing circuits. An average sensor reading is determined, calculated from the sensor readings output from a subset of the temperature sensing circuits. Each of the sensor readings is compared to the average sensor reading. A fault is identified when one of the sensor readings deviates from the average sensor reading by an amount greater than a threshold, more particularly when one of the sensor readings deviates from the average sensor reading by an amount greater than the threshold at least a quantity of X times out of Y sensor readings.

Abstract: A method and apparatus are described for reducing particle contamination in a plasma processing chamber. In one embodiment, a pasting disk is provided which includes a disk-shaped base of high-resistivity material that has an electrically conductive pasting material layer applied to a top surface of the base so that the pasting material layer partially covers the top surface of the base. The pasting disk is sputter etched to deposit conductive pasting material over a wide area on the interior surfaces of a plasma processing chamber while minimizing deposition on dielectric components that are used to optimize the sputter etch process during substrate processing.

Abstract: A diagnostic system for a hybrid vehicle comprises a processor module and a motor control module. The processor module outputs a first seed value. The motor control module controls torque output by an electric motor of the hybrid vehicle and outputs a key value based on the first seed value. The processor module outputs a second seed value after receiving the key value, and the motor control module selectively diagnoses a fault in the processor module based on a comparison of the second seed value with the first seed value.

Abstract: A diagnostic system for a hybrid vehicle comprises a motor control module and a fault diagnostic module. The motor control module controls torque output of an electric motor having a predetermined number of phases. The fault diagnostic module determines a position of a rotor of the electric motor, aligns the rotor with a phase angle of one of the phases, selectively diagnoses a fault based on a current of at least one of the phases, and selectively disables the electric motor based on the diagnosis.

Abstract: A diagnostic system for a hybrid vehicle comprises a processor module and a motor control module. The processor module outputs a seed value. The motor control module controls torque output by an electric motor of the hybrid vehicle, receives the seed value, generates a final key value based on the seed value, and outputs the final key value to the processor module.

Abstract: A method for determining a voltage level across an electrical circuit of a powertrain includes measuring a plurality of voltage levels and utilizing a comparison test between at least two voltage levels of the plurality of voltage levels to determine the circuit voltage level.

Abstract: A method for detecting speed faults in a hybrid powertrain having engine and electric machine speed inputs includes directly sensing the engine and machine speeds and performing comparisons of sensed engine speed with engine speed determined based upon the machine speeds.

Abstract: Temperature of an electric power device of a hybrid transmission is managed based upon device temperatures and power flow, ambient temperature, and a cooling circuit flow rate.

Abstract: Temperature of an electric drive is regulated to prevent undesirable thermal effects. Temperature conditions of the electric drive system are monitored and torque of the electric drive system is limited based on the temperature conditions.

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 of depositing a bilayer of tungsten over tungsten nitride by a plasma sputtering process in which krypton is used as the sputter working gas during the tungsten deposition. Argon may be used as the sputtering working gas during the reactive sputtering deposition of tungsten nitride. The beneficial effect of reduction of tungsten resistivity is increased when the thickness of the tungsten layer is less than 50 nm and further increased when less than 35 nm. The method may be used in forming a gate stack including a polysilicon layer over a gate oxide layer over a silicon gate region of a MOS transistor in which the tungsten nitride acts as a barrier. A plasma sputter chamber in which the invention may be practiced includes gas sources of krypton, argon, and nitrogen.

Abstract: Apparatus and methods are provided for diagnosing faults in multiple, associated motor-resolver systems. One apparatus includes a swapping circuit coupling a first resolver to a first or second decoder, and a swapping circuit coupling a second resolver to the first or second decoder. One method includes applying a signal from a resolver to a first decoder to determine that the first decoder is malfunctioning if the first decoder continues to generate a fault signal, and applying a signal from a different resolver to a second decoder to determine that a motor associated with the first decoder is malfunctioning if the second decoder generates a fault signal. Another method includes transmitting a signal from a resolver to first and second decoders, transmitting a signal from a different resolver to the first and second decoders, and determining if the first decoder, second decoder, a first motor, or a second motor is malfunctioning.

Abstract: An apparatus, system, and method are provided for simulating outputs of a resolver. One apparatus includes an adjustable sine waveform generator for simulating first and second sine wave signals, and an adjustable cosine waveform generator for simulating first and cosine wave signals. The apparatus also includes an adjustable waveform generator and an adjustable gain circuit coupled to the sine waveform generator and cosine waveform generator. The system includes a device simulating a resolver coupled to a motor controller. The device includes an adjustable sine waveform generator and an adjustable cosine waveform generator coupled to an adjustable waveform generator and an adjustable gain circuit. One method includes transmitting a signal simulating at least one resolver fault condition to a motor controller to determine if the motor controller detects the fault condition(s).

Abstract: A power distribution system for a hybrid vehicle having an engine is disclosed. The power distribution system includes an electric motor/generator, a vehicle accessory drive system comprising a first accessory, and a power distribution apparatus. The power distribution apparatus includes a first power transfer member comprising a first shaft, the first shaft being configured to transfer power to the engine and from the engine. The power distribution apparatus further includes a second power transfer member comprising a second shaft, the second shaft being configured to transfer power to the motor/generator and from the motor/generator. The power distribution apparatus further includes a third power transfer member comprising a third shaft, the third shaft being configured to transfer power to the accessory drive system to drive the first accessory. The power distribution apparatus further includes a first clutch and a second clutch.

Abstract: A method and an article of manufacture are provided to monitor a temperature sensing circuit and detect a fault therein. The method comprises monitoring sensor readings output from a plurality of temperature sensing circuits. An average sensor reading is determined, calculated from the sensor readings output from a subset of the temperature sensing circuits. Each of the sensor readings is compared to the average sensor reading. A fault is identified when one of the sensor readings deviates from the average sensor reading by an amount greater than a threshold, more particularly when one of the sensor readings deviates from the average sensor reading by an amount greater than the threshold at least a quantity of X times out of Y sensor readings.