Abstract: Systems and methods for motor regeneration are provided. One method for motor regeneration includes receiving a torque command and a maximum DC current from an electronic control unit, determining a drive unit loss, generating a DC current, and providing the DC current to a DC battery pack. Generating the DC current is based, at least in part, on the torque command, the maximum DC current, and the drive unit loss. The method advantageously generates the maximum amount of DC current that is acceptable by the battery pack while keeping the torque availability high and consistent. The generated DC current is also known as the maximum battery charge DC current.

Abstract: A vehicle management system includes a torque control generates torque shaping logic for managing torque output of a drive unit and limiting displacement between a drive unit of a vehicle and a wheel coupled to the drive unit. A measuring device monitors a transferred displacement between the drive unit and the wheel coupled to the drive unit when the drive unit is operating to measure a lash angle corresponding to the transferred displacement between the drive unit and the wheel. The measuring device can provide data (e.g., displacement data), indicating the lash angle information, to the vehicle management system. Based on the lash angle information, the torque output generates the torque shaping logic used to manage the torque output of the drive unit.

Abstract: A vehicle management system includes a torque control generates torque shaping logic for managing torque output of a drive unit and limiting displacement between a drive unit of a vehicle and a wheel coupled to the drive unit. A measuring device monitors a transferred displacement between the drive unit and the wheel coupled to the drive unit when the drive unit is operating to measure a lash angle corresponding to the transferred displacement between the drive unit and the wheel. The measuring device can provide data (e.g., displacement data), indicating the lash angle information, to the vehicle management system. Based on the lash angle information, the torque output generates the torque shaping logic used to manage the torque output of the drive unit.

Abstract: Condition detection and resolution is provided. A system includes one or more processors of a vehicle, coupled with memory. The one or more processors can detect a condition of a motor of the vehicle. The one or more processors can select an action that reduces an amount of torque of the motor for a time interval. The selection can be based on the condition and a mode of operation of the vehicle. The one or more processors can perform the action to clear the condition of the motor without adjustment of the mode of operation of the vehicle.

Abstract: Systems and methods for estimating input current are provided, particularly when input currents are applied to an electric motor of a motor system. An Electric Control Unit (ECU), according to one implementation, is configured to control the motor system. The ECU is configured to store computer logic having instructions that, when executed, cause one or more processing devices to obtain a duty cycle parameter at an output of the ECU. The duty cycle parameter, for example, relates to control actions enforced on one or more switches of a power electronics circuit of the motor system. Based on the duty cycle parameter, the instructions further cause the one or more processing devices to estimate an input current provided to the electric motor of the motor system. A more accurate input current estimation may thereby be used to better estimate torque.

Abstract: Systems and methods for controlling one or more inverters in response to detecting a desaturation (DESAT) fault are disclosed herein. A DESAT fault of an inverter coupled to a motor is detected. In response to detecting the DESAT fault, all driving switches of the inverter are instructed to open. The driving switch that failed and a type of failure are determined based on current of the motor during a predetermined time period after instructing all of the driving switches to open, and the remaining driving switches are controlled based on which switch failed and the type of failure.

Abstract: High voltage discharge is provided. A system can include an electric motor of an electric vehicle electrically connected to a capacitor. A switching component can be connected with and intermediary to the electric motor and the capacitor. A controller can cause the switching component to enter a first state to cause the electric motor to convert electrical power of the capacitor to mechanical power to propel the electric vehicle, or convert mechanical power from a drive system of the electric vehicle to electrical power to charge the capacitor. The controller can cause the switching component to enter, in response to detection by the controller of an indication to discharge the capacitor, a second state to isolate the electric motor from the capacitor.

Abstract: A torque security system for a vehicle is provided. The system receives a signal from a sensor coupled to a motor shaft of an electric motor and determines an acceleration of the electric motor, based on the signal from the sensor that indicates an amount of rotation of the motor shaft. The system determines an internal torque between the motor shaft and an input gear coupled to the motor shaft, based on the acceleration of the electric motor and an inertia of the electric motor and a gearbox. The powertrain of the vehicle comprises the gearbox and the electric motor, and the input gear couples the electric motor to the gearbox. The system determines whether the internal torque exceeds a threshold torque, and in response to determining that the internal torque exceeds the threshold torque, the system reduces power output to the electric motor. The system also diagnoses the health of the gearbox.

Abstract: Systems and methods are provided herein for controlling the speed on each wheel of a vehicle, possibly operating a vehicle in a speed control mode. In response to receiving input to engage speed control mode and receiving an accelerator pedal input, the system determines a target wheel speed based on the accelerator pedal input, monitors wheel speed of each of a plurality of wheels and determines, for each monitored wheel, a difference based on the monitored wheel speed and the target wheel speed. A torque is provided to each of the plurality of wheels based on the respective difference to achieve the target wheel speed.

Abstract: High voltage discharge is provided. A system can include an electric motor of an electric vehicle electrically connected to a capacitor. A switching component can be connected with and intermediary to the electric motor and the capacitor. A controller can cause the switching component to enter a first state to cause the electric motor to convert electrical power of the capacitor to mechanical power to propel the electric vehicle, or convert mechanical power from a drive system of the electric vehicle to electrical power to charge the capacitor. The controller can cause the switching component to enter, in response to detection by the controller of an indication to discharge the capacitor, a second state to isolate the electric motor from the capacitor.

Abstract: Systems and methods for controlling a dual active bridge converter are disclosed herein. An output voltage of a dual active bridge converter is sensed. Based at least in part on the output voltage, a target intra-bridge phase shift amount between two bridges of the dual active bridge converter is computed. A plurality of switch control signals, which are provided to respective switches of the dual active bridge converter, are caused to switch according to a time-based switching sequence based on the target intra-bridge phase shift amount to compensate for variations in the output voltage.

Abstract: Systems and methods for estimating input current are provided, particularly when input currents are applied to an electric motor of a motor system. An Electric Control Unit (ECU), according to one implementation, is configured to control the motor system. The ECU is configured to store computer logic having instructions that, when executed, cause one or more processing devices to obtain a duty cycle parameter at an output of the ECU. The duty cycle parameter, for example, relates to control actions enforced on one or more switches of a power electronics circuit of the motor system. Based on the duty cycle parameter, the instructions further cause the one or more processing devices to estimate an input current provided to the electric motor of the motor system. A more accurate input current estimation may thereby be used to better estimate torque.

Abstract: A system is configured to manage motor engagement in a vehicle by determining to engage a disengaged motor shaft with a drivetrain, and in response, activating a feedback controller based on a speed of the motor shaft and activating a feedforward controller. The system determines at least one metric for modifying an output of the feedforward controller. The at least one metric is based on the speed of the motor shaft and the desired speed, and may be applied as a gain to the output of the feedforward controller. The system generates a command based on the feedback controller, the feedforward controller, and the at least one metric, and causes the motor shaft and the drivetrain to be engaged based on the speed of the motor shaft and the desired speed. The system nulls output of the feedforward controller as the speed of the motor shaft approaches the desired speed.

Abstract: A system is configured to manage motor engagement in a vehicle by determining to engage a disengaged motor shaft with a drivetrain, and in response, activating a feedback controller based on a speed of the motor shaft and activating a feedforward controller. The system determines at least one metric for modifying an output of the feedforward controller. The at least one metric is based on the speed of the motor shaft and the desired speed, and may be applied as a gain to the output of the feedforward controller. The system generates a command based on the feedback controller, the feedforward controller, and the at least one metric, and causes the motor shaft and the drivetrain to be engaged based on the speed of the motor shaft and the desired speed. The system nulls output of the feedforward controller as the speed of the motor shaft approaches the desired speed.

Abstract: Testing connections to phase windings of an electric motor upon startup includes, prior to entering a RUN state in which motor power commands are accepted from a user to perform work, applying to each respective phase of the electric motor a respective test voltage signal, measuring in each respective phase a respective current induced by the respective test voltage signal, and preventing entry into the RUN state when at least one values representative of a respective current is below the respective predetermined threshold.

Abstract: Testing connections to phase windings of an electric motor upon startup includes, prior to entering a RUN state in which motor power commands are accepted from a user to perform work, applying to each respective phase of the electric motor a respective test voltage signal, measuring in each respective phase a respective current induced by the respective test voltage signal, and preventing entry into the RUN state when at least one values representative of a respective current is below the respective predetermined threshold.

Abstract: A system is configured to manage motor engagement in a vehicle by determining to engage a disengaged motor shaft with a drivetrain, and in response, activating a feedback controller based on a speed of the motor shaft and activating a feedforward controller. The system determines at least one metric for modifying an output of the feedforward controller. The at least one metric is based on the speed of the motor shaft and the desired speed, and may be applied as a gain to the output of the feedforward controller. The system generates a command based on the feedback controller, the feedforward controller, and the at least one metric, and causes the motor shaft and the drivetrain to be engaged based on the speed of the motor shaft and the desired speed. The system nulls output of the feedforward controller as the speed of the motor shaft approaches the desired speed.

Abstract: Systems and methods for controlling a dual active bridge converter are disclosed herein. An output voltage of a dual active bridge converter is sensed. Based at least in part on the output voltage, a target intra-bridge phase shift amount between two bridges of the dual active bridge converter is computed. A plurality of switch control signals, which are provided to respective switches of the dual active bridge converter, are caused to switch according to a time-based switching sequence based on the target intra-bridge phase shift amount to compensate for variations in the output voltage.

Abstract: Testing connections to phase windings of an electric motor upon startup includes, prior to entering a RUN state in which motor power commands are accepted from a user to perform work, applying to each respective phase of the electric motor a respective test voltage signal, measuring in each respective phase a respective current induced by the respective test voltage signal, and preventing entry into the RUN state when at least one values representative of a respective current is below the respective predetermined threshold.

Abstract: Various disclosed embodiments include illustrative controller modules, direct current (DC) fast charging devices, and methods. In an illustrative embodiment, a controller module for a DC-DC converter includes a controller and computer-readable media configured to store computer-executable instructions configured to cause the controller to: receive an input voltage, an output voltage, and a requested power value.