Abstract: A method of controlling an interior permanent magnet (IPM) motor includes receiving a motor torque command, and selecting a nominal d-axis current and a nominal q-axis current stored in a first lookup table. The nominal d-axis current and the nominal q-axis current correspond with a predetermined efficiency of the IPM motor at a nominal temperature and are based on at least the motor torque command and magnetic flux at a nominal temperature of the IPM motor. A d-axis adjustment current and a q-axis adjustment current are then selected from a stored second lookup table. The adjustment currents correspond with the predetermined efficiency of the IPM motor and are based at least on the magnetic flux and an operating temperature of the IPM motor. A corrected d-axis current and a corrected q-axis current are commanded. The corrected currents are the sum of the respective nominal current and adjustment current.

Abstract: An electric motor control system of a vehicle includes a temperature module configured to, based on a motor torque request, (i) determine a plurality of stator current values based on a plurality of temperatures and (ii) generate a maximum stator current based on a lowest value of the plurality of stator current values. A torque module configured to, based on the maximum stator current, the motor torque request, and a maximum allowable flux, generate a maximum torque output. A current command module configured to, based on a speed of a rotor of the electric motor and the maximum torque output, generate a d-axis current adjustment and a q-axis current adjustment. A switching control module configured to, based on the d- and q-axis current adjustments, control switching of an inverter module and apply power to stator windings of the electric motor from an energy storage device.

Abstract: An electric motor control system of a vehicle includes a temperature module configured to, based on a motor torque request, (i) determine a plurality of stator current values based on a plurality of temperatures and (ii) generate a maximum stator current based on a lowest value of the plurality of stator current values. A torque module configured to, based on the maximum stator current, the motor torque request, and a maximum allowable flux, generate a maximum torque output. A current command module configured to, based on a speed of a rotor of the electric motor and the maximum torque output, generate a d-axis current adjustment and a q-axis current adjustment. A switching control module configured to, based on the B- and q-axis current adjustments, control switching of an inverter module and apply power to stator windings of the electric motor from an energy storage device.

Abstract: A control system for controlling operation of an asymmetric motor to operate as a symmetric motor is provided and includes first and second summers, a proportional flux error-to-voltage converter, a complex integration module, and a control module. The first summer determines a flux error for d and q axes of the asymmetric motor based on a commanded flux value and a feedback flux value. The proportional flux error-to-voltage converter converts the flux error to a proportional voltage term. The complex integration module, based on a time constant, a synchronous angular velocity, and a sampling period, calculates an integral voltage term. The second summer sums the proportional voltage term, the integral voltage term, and a damping resistance voltage to generate a voltage command signal. The damping resistance voltage is based on first and second damping resistances. The control module controls operation of the asymmetric motor based on the voltage command signal.

Abstract: A method and system for detecting a fault in a permanent magnet synchronous motor (PMSM), operably connected to a controller. The method includes receiving at a controller a stator voltages and currents for the PMSM, computing a negative sequence current and a negative sequence voltage for the PMSM; and determining if conditions are satisfied for monitoring for a fault of the PMSM. The method also includes ascertaining a change in the negative sequence current and a change in the negative sequence voltage for a selected time duration, calculating a ratio of the change in the negative sequence current and the negative sequence voltage corresponding to a negative sequence admittance for the PMSM, determining if the negative sequence admittance differs from a nominal value in excess of a threshold; and identifying the stator winding as faulted if the ratio exceeds the threshold.

Abstract: A method and system for detecting a fault in a permanent magnet synchronous motor (PMSM), operably connected to a controller. The method includes receiving at a controller a stator voltages and currents for the PMSM, computing a negative sequence current and a negative sequence voltage for the PMSM; and determining if conditions are satisfied for monitoring for a fault of the PMSM. The method also includes ascertaining a change in the negative sequence current and a change in the negative sequence voltage for a selected time duration, calculating a ratio of the change in the negative sequence current and the negative sequence voltage corresponding to a negative sequence admittance for the PMSM, determining if the negative sequence admittance differs from a nominal value in excess of a threshold; and identifying the stator winding as faulted if the ratio exceeds the threshold.

Abstract: A powertrain system including an electric machine rotatably coupled to a crankshaft of an internal combustion engine via a belt is described, wherein the electric machine is disposed to generate torque. A method for controlling the electric machine includes monitoring rotational position of the electric machine, and periodically executing a speed observer to determine a rotational speed of the electric machine based upon the monitored rotational position of the electric machine. An acceleration observer is periodically executed to determine an acceleration rate, wherein the acceleration rate is determined based upon a time-based change in the rotational speed of the electric machine. A virtual inertia term is determined based upon the acceleration rate, and a torque compensation term is determined based upon the virtual inertia term and the acceleration rate. The electric machine is controlled to generate torque based upon the torque compensation term.

Abstract: An apparatus and method for determining occurrence of a fault at an insulated-gate bipolar transistor (IGBT) module is disclosed. The IGBT module and apparatus can be part of an electric vehicle. A sensor obtains a measurement of a thermal parameter of the IGBT module. A processor receives the measured thermal parameter from the sensor, and runs a model of the IGBT module to determine a thermal parameter of the IGBT module under normal operation conditions. The processor provides an alert signal to indicate the occurrence of the fault when a difference between the estimated thermal parameter and the measured thermal parameter is greater than or equal to a selected threshold.

Abstract: An electric motor control system of a vehicle includes a current command module configured to, based on a motor torque request for an electric motor of the vehicle, generate a first d-axis current command for the electric motor and a first q-axis current command for the electric motor. An adjustment module is configured to, based on a speed of a rotor of the electric motor and the motor torque request, selectively determine at least one of a d-axis current adjustment and a q-axis current adjustment based on a temperature of the rotor of the electric motor. An adjusting module is configured to produce a second d-axis current command for the electric motor by adjusting the first d-axis current command based on the d-axis current adjustment and to produce a second q-axis current command for the electric motor by adjusting the first q-axis current command based on the q-axis current adjustment.

Abstract: Systems and method for operating motors are provided. In an exemplary embodiment, a method for operating a motor includes receiving a first output corresponding to a motor angular position. The method further includes synthesizing a synthesized second output from the first output and from an estimated motor angular velocity. The method also includes calculating the motor angular position from the first output and the synthesized second output. The method includes estimating the motor angular velocity from the motor angular position. Further, the method includes operating the motor to produce torque based on the motor angular position and the motor angular velocity.

Abstract: In various embodiments, methods, systems, and vehicles are provided for masking a tonal noise of a motor. In certain embodiments, a vehicle includes a drive system and an active masking acoustic signal generator (AMAG). The drive system includes a motor generating a tonal noise. The AMAG is configured to at least facilitate masking the tonal noise, by introducing a complementary harmonic tone, injecting dithering into the motor, or both.

Abstract: A device for monitoring a resolver disposed on a rotatable member is described herein, and includes a controller including a microprocessor circuit and an interface circuit connected to the resolver, wherein the microprocessor circuit includes a dual-core central processing unit (CPU), a pulse generator, a sigma-delta analog-to-digital converter (SDADC), a global memory device, an internal communication bus and a direct memory access device (DMA). The microprocessor circuit is disposed to control the pulse generator to generate an excitation pulse transferable to the excitation winding of the resolver, and control the SDADC to capture data from the secondary windings of the resolver and store the captured data in the memory buffer. A control routine is executed to detect an envelope for the captured data, and a rotor position for the resolver is determined based upon the detected envelope.

Abstract: A motor drive system for controlling operation of an electric machine is described. An inverter includes paired power transistors that are electrically connected to the electric machine, wherein the inverter is electrically connected to a DC power source via a high-voltage electrical power bus. A motor controller includes a first controller and an acoustic signal generator, wherein the first controller is disposed to control the paired power transistors of the inverter. The first controller determines an initial output voltage based upon a torque command and the acoustic signal generator is disposed to generate a sound injection voltage. The motor controller combines the initial output voltage and the sound injection voltage. The motor controller generates PWM commands to control the paired power transistors of the inverter, wherein the PWM commands are determined based upon the initial output voltage and the sound injection voltage.

Abstract: Systems and method for operating motors are provided. In an exemplary embodiment, a method for operating a motor includes receiving a first output corresponding to a motor angular position. The method further includes synthesizing a synthesized second output from the first output and from an estimated motor angular velocity. The method also includes calculating the motor angular position from the first output and the synthesized second output. The method includes estimating the motor angular velocity from the motor angular position. Further, the method includes operating the motor to produce torque based on the motor angular position and the motor angular velocity.

Abstract: A system includes a rotary device, a vector-based position sensor outputting raw sine and cosine signals indicative of an angular position of the rotary device, and a controller. The controller executes a method by receiving the raw sine and cosine signals from the sensor, generating corrected sine and cosine signals by applying an amplitude error input signal to a first integrator block using a first predetermined trigonometric relationship, and executing a control action for the rotary device via output signals using the corrected signals. The first predetermined trigonometric relationship is SC2?CC2, with SC and CC being the respective corrected sine and cosine signals. The controller may use a second predetermined trigonometric relationship, SC·CC, to apply an orthogonality error input signal to a second integrator block.

Abstract: A motor drive system for controlling operation of an electric machine is described. An inverter includes paired power transistors that are electrically connected to the electric machine, wherein the inverter is electrically connected to a DC power source via a high-voltage electrical power bus. A motor controller includes a first controller and an acoustic signal generator, wherein the first controller is disposed to control the paired power transistors of the inverter. The first controller determines an initial output voltage based upon a torque command and the acoustic signal generator is disposed to generate a sound injection voltage. The motor controller combines the initial output voltage and the sound injection voltage. The motor controller generates PWM commands to control the paired power transistors of the inverter, wherein the PWM commands are determined based upon the initial output voltage and the sound injection voltage.

Abstract: An electric motor control system of a vehicle includes a current command module configured to, based on a motor torque request for an electric motor of the vehicle, generate a first d-axis current command for the electric motor and a first q-axis current command for the electric motor. An adjustment module is configured to, based on a speed of a rotor of the electric motor and the motor torque request, selectively determine at least one of a d-axis current adjustment and a q-axis current adjustment based on a temperature of the rotor of the electric motor. An adjusting module is configured to produce a second d-axis current command for the electric motor by adjusting the first d-axis current command based on the d-axis current adjustment and to produce a second q-axis current command for the electric motor by adjusting the first q-axis current command based on the q-axis current adjustment.

Abstract: An electric machine assembly includes an electric machine having a stator configured to have a stator current and a controller configured to receive a torque command (T). The controller stores a modulation flag (Fm) and a six step active flag (FS), each having a respective status. The controller has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method of controlling a six step pulse width modulation operation in the assembly. The controller is programmed to determine the respective status of a six step active flag (FS) based at least partially on the torque command (T) and the respective status of the modulation flag (Fm). The controller is configured to control at least one operating parameter of the electric machine based at least partially on the respective status of the six step active flag (FS).

Abstract: A system includes a rotary device, a vector-based position sensor outputting raw sine and cosine signals indicative of an angular position of the rotary device, and a controller. The controller executes a method by receiving the raw sine and cosine signals from the sensor, generating corrected sine and cosine signals by applying an amplitude error input signal to a first integrator block using a first predetermined trigonometric relationship, and executing a control action for the rotary device via output signals using the corrected signals. The first predetermined trigonometric relationship is SC2-CC2, with SC and CC being the respective corrected sine and cosine signals. The controller may use a second predetermined trigonometric relationship, SC·CC, to apply an orthogonality error input signal to a second integrator block.

Abstract: A driveline system includes a drive axle coupled to a load, an electric machine, and a control system. The electric machine is responsive to a commanded torque, has a rotor shaft coupled to the axle, and produces an output torque that rotates the axle and load to produce driveline oscillation at a high resonant frequency. The control system generates the commanded torque using a nested control loop architecture in which an outer control loop operates at a sampling rate that is below a critical rate necessary for controlling the resonant frequency, and an inner control loop operates at a sampling rate that is above the critical rate. The inner loop determines a modified torque command and acceleration value in response to a commanded torque from the outer loop. The electric machine is thereafter controlled via the commanded torque.