Abstract: Methods and systems are provided for controlling an electrical system of a vehicle. Sensors are used to obtain first data for a first path of calculations and second data for a second path of calculations. The first path comprises a first plurality of calculations of generating a value of a parameter pertaining to the electrical system, and the second path comprises a second plurality of calculations of monitoring the electrical system with respect to the first path. A processor is coupled to the plurality of sensors, and is configured to determine whether a data frozen flag is active, perform the first plurality of calculations of the first path using the first data if the first data flag is inactive, and perform the second plurality of calculations of the second path if the first data flag is active.

Abstract: Methods and systems are provided for monitoring an electrical system of a vehicle. Data pertaining to the electrical system is obtained. Calculation modules are performed using the data to generate intermediate determinations. An aggregate calculation module is performed using each of the intermediate determinations to generate an aggregate determination pertaining to the electrical system. Redundant intermediate calculations are performed using the data to generate redundant intermediate determinations. Each of the redundant intermediate determinations is used for comparison with a respective intermediate determination.

Abstract: Methods and systems are provided for monitoring an automotive electrical system including an inverter having at least one switch. First and second voltage commands corresponding to respective first and second components of a commanded voltage vector on a synchronous frame of reference coordinate system are received. A plurality of duty cycles for operating the at least one switch are calculated based on the first and second voltage commands. First and second actual voltages are calculated based on the plurality of duty cycles. The first and second actual voltages correspond to respective first and second components of an actual voltage vector on the synchronous frame of reference coordinate system. An indication of a fault is generated based on the difference between the first components of the commanded voltage vector and the actual voltage vector and the difference between the second components of the commanded voltage vector and the actual voltage vector.

Abstract: Methods and systems are provided for controlling an electrical system of a vehicle. Sensors are used to obtain first data for a first path of calculations and second data for a second path of calculations. The first path comprises a first plurality of calculations of generating a value of a parameter pertaining to the electrical system, and the second path comprises a second plurality of calculations of monitoring the electrical system with respect to the first path. A processor is coupled to the plurality of sensors, and is configured to determine whether a data frozen flag is active, perform the first plurality of calculations of the first path using the first data if the first data flag is inactive, and perform the second plurality of calculations of the second path if the first data flag is active.

Abstract: Methods and systems are provided for monitoring an electrical system of a vehicle. Data pertaining to the electrical system is obtained. Calculation modules are performed using the data to generate intermediate determinations. An aggregate calculation module is performed using each of the intermediate determinations to generate an aggregate determination pertaining to the electrical system. Redundant intermediate calculations are performed using the data to generate redundant intermediate determinations. Each of the redundant intermediate determinations is used for comparison with a respective intermediate determination.

Abstract: Methods and systems are provided for monitoring an automotive electrical system including an inverter having at least one switch. First and second voltage commands corresponding to respective first and second components of a commanded voltage vector on a synchronous frame of reference coordinate system are received. A plurality of duty cycles for operating the at least one switch are calculated based on the first and second voltage commands. First and second actual voltages are calculated based on the plurality of duty cycles. The first and second actual voltages correspond to respective first and second components of an actual voltage vector on the synchronous frame of reference coordinate system. An indication of a fault is generated based on the difference between the first components of the commanded voltage vector and the actual voltage vector and the difference between the second components of the commanded voltage vector and the actual voltage vector.

Abstract: A system for validating velocities of components in a vehicle uses sensor measurements and mathematical relationships between the vehicle components to validate the velocities. A controller or controllers receive speed or velocity inputs and mathematically combine the velocities of more than one of the vehicle components. The velocities of at least one of the vehicle components is validated when the mathematical combination meets at least one predetermined criterion. The validated velocity or velocities are then communicated to at least one of the vehicle components.

Abstract: A system for validating velocities of components in a vehicle uses sensor measurements and mathematical relationships between the vehicle components to validate the velocities. A controller or controllers receive speed or velocity inputs and mathematically combine the velocities of more than one of the vehicle components. The velocities of at least one of the vehicle components is validated when the mathematical combination meets at least one predetermined criterion. The validated velocity or velocities are then communicated to at least one of the vehicle components.

Abstract: A method for validating engine and motor velocities in a vehicle having an engine and two motors is provided. The method validates the velocities without using two speed sensors for each device. The velocities of the engine and the two motors are first determined, and then mathematically combined using known velocity relationships based on the vehicle architecture. The mathematical combination of the velocities is then compared to a first pre-determined speed range, and if the mathematical combination is within the predetermined range, the velocities of the engine and the two motors are validated. If the validation of the engine and the two motors fails, additional equations can be used utilizing additional inputs, including the vehicle speed as measured at the vehicle wheels. In this way, the velocities of one or more of the torque generating devices in the vehicle may be validated.

Abstract: The present invention can diagnose a potential discrepancy in electrical operating characteristics of a three phase electric motor by generating two independent torque estimates using a plurality of current sensors and a shaft position sensor. The invention provides a strategy to generate two independent torque estimates of a three phase electric motor comprising first and second systems to determine currents in two motor phases, first and second systems to generate a first and second estimate of motor shaft position, and first and second systems to generate first and second estimates of motor torque using the first and second systems to determine current in each motor phase and the first and second values of motor shaft position. The present invention detects also an electrical operating characteristic discrepancy in an electric motor-propelled vehicle's electrical components and subsystems, including single subsystem discrepancies between the two independent torque estimates.

Abstract: A system and method for diagnosing a potential electrical operating discrepancy in a polyphase electric motor by generating two independent torque estimates using a plurality of current sensors and, optionally, a shaft position sensor. Differences between the independent torque estimates are used to indicate potential discrepancies in electrical operating characteristics of the motor.

Abstract: A system and method for accurate control of engine torque for a parallel/series hybrid electric vehicle (PSHEV) is disclosed. An accurate estimate of engine torque is determined from the generator motor torque of a PSHEV. The estimated engine torque can then be used to control engine torque in a closed loop torque control strategy. The invention comprises at least one controller to receive, process and output torque signals; a first control strategy to determine a modified engine torque signal from at least a desired engine torque signal; and a second control strategy to determine variables for air, fuel and spark from said modified engine torque signal. The first control strategy can include a proportional integral (PI) controller. The estimated engine torque signal can be a function of an estimated generator motor torque signal, a generator motor speed signal and an engine torque loss signal.

Abstract: This invention is a method and system to disconnect drive wheels from the powertrain of any electric powered vehicle. A vehicle controller monitors input from, for example, an inertia switch and electric motor generator conditions and can disconnect the output shaft from the drive wheels in predetermined vehicle conditions such as during a rear-end collision, or abnormal electric motor conditions such as over-torque, over-temperature, or over-current. The invention can be configured to monitor and respond to driver demand for four-wheel drive, two-wheel drive, and neutral tow. The disconnect device can comprise a disconnect actuator and joint attached to an axle disconnect. The axle disconnect can be electric or vacuum powered and positioned as a center disconnect or a wheel-end disconnect. The invention can be configured for conventional or limited slip axles.

Abstract: A system and method for diagnosing a potential electrical operating discrepancy in a polyphase electric motor by generating two independent torque estimates using a plurality of current sensors and, optionally, a shaft position sensor. Differences between the independent torque estimates are used to indicate potential discrepancies in electrical operating characteristics of the motor.

Abstract: The present invention can diagnose a potential discrepancy in electrical operating characteristics of an electric motor by generating two independent torque estimates using a plurality of current sensors and optionally a shaft position sensor. The invention provides a strategy to generate two independent torque estimates of a three phase electric motor comprising first and second systems to determine current in each motor phase, first and second systems to generate a first and second estimate of motor shaft position, and first and second systems to generate first and second estimates of motor torque using the first and second systems to determine current in each motor phase and the first and second estimates of motor shaft position. The present invention detects also an electrical operating characteristic discrepancy in an electric motor-propelled vehicle's electrical components and subsystems, including single subsystem discrepancies between the two independent torque estimates.

Abstract: In an electric or hybrid electric vehicle, a voltage monitor (102) is directly coupled to a traction motor (38) and/or generator motor (30) to detect a permanent magnet induced voltage within the motor at a predetermined speed and no load condition. A controller (100) compares the detected permanent magnet induced voltage with an expected reference voltage that represents an expected permanent magnet induced voltage at full magnetization and the predetermined speed. The comparison includes identifying points of synchronization and using those points to determine a difference in the detected permanent magnet induced voltage that is caused by a faulty component.

Abstract: In an electric or hybrid electric vehicle, a voltage monitor (102) is directly coupled to a traction motor (38) and/or generator motor (30) to detect a permanent magnet induced voltage within the motor at a predetermined speed and no load condition (300). A controller (100) compares the detected permanent magnet induced voltage with an expected reference voltage that represents an expected permanent magnet induced voltage at full magnetization and the predetermined speed (302). The controller produces an indication of magnetization based on the reference voltage, the detected permanent magnet induced voltage, and the predetermined speed. If the indication of magnetism reaches a predetermined threshold, the motor is made inoperable and/or a current to the motor is limited to prevent damage to components (306, 308, 310, 312, 314). Preferably, a user of the vehicle is made aware of these actions by an audible and/or visual indicator (308, 314).

Abstract: The present invention can diagnose a potential fault in an electric motor by generating two independent torque estimates using a plurality of current sensors and optionally a shaft position sensor. The invention provides a strategy to generate two independent torque estimates of a three phase electric motor comprising first and second systems to determine current in each motor phase, first and second systems to generate a first and second estimate of motor shaft position, and first and second systems to generate first and second estimates of motor torque using the first and second systems to determine current in each motor phase and the first and second estimates of motor shaft position. The present invention detects a fault in an electric motor propelled vehicle's electrical components and sub-systems, including single subsystem failures system based on discrepancies between to the two independent torque estimates.

Abstract: This invention is a method and system to disconnect drive wheels from the powertrain of any electric powered vehicle. A vehicle controller monitors input from, for example, an inertia switch and electric motor generator conditions and can disconnect the output shaft from the drive wheels in predetermined vehicle conditions such as during a rear-end collision, or abnormal electric motor conditions such as over-torque, over-temperature, or over-current. The invention can be configured to monitor and respond to driver demand for four-wheel drive, two-wheel drive, and neutral tow. The disconnect device can comprise a disconnect actuator and joint attached to an axle disconnect. The axle disconnect can be electric or vacuum powered and positioned as a center disconnect or a wheel-end disconnect. The invention can be configured for conventional or limited slip axles.

Abstract: In an electric or hybrid electric vehicle, a voltage monitor (102) is directly coupled to a traction motor (38) and/or generator motor (30) to detect a permanent magnet induced voltage within the motor at a predetermined speed and no load condition (300). A controller (100) compares the detected permanent magnet induced voltage with an expected reference voltage that represents an expected permanent magnet induced voltage at full magnetization and the predetermined speed (302). The controller produces an indication of magnetization based on the reference voltage, the detected permanent magnet induced voltage, and the predetermined speed. If the indication of magnetism reaches a predetermined threshold, the motor is made inoperable and/or a current to the motor is limited to prevent damage to components (306, 308, 310, 312, 314). Preferably, a user of the vehicle is made aware of these actions by an audible and/or visual indicator (308, 314).