Abstract: Position and speed correction are applied to observed values from a position sensor in order to operate an electric motor. Observed position values and observed speed values are obtained from the position sensor for time points during a sampling window, ideal position values and ideal speed values are determined for each of the time points, and position and speed error values are determined based on the observed and ideal values. Stored position information is updated using the position error values and the speed error values. The electric motor is operated using corrected position values and corrected speed values that are determined from the observed position values, the observed speed values, and the stored position information.

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: A torque system includes a DC power device, a polyphase electric machine, a contactor pair, a power inverter module (PIM), and a controller. The PIM connects to the power device via the contactor pair and directly connects to the electric machine. The controller executes a method to control a fault response under a fault condition resulting in opening of the contactor pair and a polyphase short condition. The controller calculates a back EMF of the electric machine and transmits switching control signals to semiconductor switches of the PIM to transition from the polyphase short condition to a polyphase open condition only when the calculated back EMF is less than a calibrated value and a voltage rise on a DC side of the PIM is less than a calibrated voltage rise. A vehicle includes the DC power device, road wheels, electric machine, PIM, and controller.

Abstract: A torque system includes a DC power device, a polyphase electric machine, a contactor pair, a power inverter module (PIM), and a controller. The PIM connects to the power device via the contactor pair and directly connects to the electric machine. The controller executes a method to control a fault response under a fault condition resulting in opening of the contactor pair and a polyphase short condition. The controller calculates a back EMF of the electric machine and transmits switching control signals to semiconductor switches of the PIM to transition from the polyphase short condition to a polyphase open condition only when the calculated back EMF is less than a calibrated value and a voltage rise on a DC side of the PIM is less than a calibrated voltage rise. A vehicle includes the DC power device, road wheels, electric machine, PIM, and controller.

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 inverter electrically operatively connected to an electric machine and in communication with a controller is described. The inverter is electrically connected to a high-voltage DC power bus. A method for controlling the multi-phase inverter circuit includes monitoring, via the controller, a rotational speed of the electric machine during operation of the inverter in an over-modulation mode. The inverter is commanded to operate in a linear modulation mode when the rotational speed is within a speed range associated with objectionable audible noise generated by operating the electric machine in the over-modulation mode.

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 has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method of modifying the stator current for enhanced flux weakening. The controller is programmed to obtain a base stator current [IdLU, IqLU] from a look-up table based at least partially on the torque command (T). The controller is programmed to obtain a characteristic angle (?i, i=1, 2, 3) based at least partially on a value of the torque command (T) and the base stator current [IdLU, IqLU]. A stator current modifier [?Id, ?Iq] is obtained based at least partially on the characteristic angle (?i, i=1, 2, 3) and a flux weakening factor (?IS) such that: ?Id=(?IS*cosine (?i)) and ?Iq=(?IS*sine (?i)).

Abstract: A method for monitoring an electrically-powered torque machine configured to generate torque in a hybrid powertrain system includes monitoring signal outputs of a resolver configured to monitor rotational position of the torque machine. Upon detecting a fault warning state associated with the signal outputs of the resolver, a motor torque capacity of the torque machine is derated. Upon a clearing of the fault warning state, a torque ramp-up state to increase the motor torque capacity of the torque machine is executed. Notice of an incidence of a fault associated with the signal outputs of the resolver is provided only when the motor torque capacity fails to achieve a threshold motor torque capacity within a threshold recovery time period while executing the torque ramp-up state.

Abstract: A method for controlling an electrically-powered torque machine of a powertrain system includes determining a predicted torque command to control the torque machine. A flux command is determined responsive to the predicted torque command. The flux command is a flux level providing a fast torque reserve that is responsive to the predicted torque command. The fast torque reserve is a prescribed minimum rate of change in torque output from the torque machine responsive to the predicted torque command. An inverter controller controls flux of the torque machine responsive to the flux command.

Abstract: An inverter electrically operatively connects to a multi-phase electric machine, and a method for controlling the inverter includes executing a six-step mode to control the inverter and monitoring an electric voltage angle of the electric machine at a preset sampling frequency. When the electric voltage angle approaches a step transition associated with control of one of a plurality of switches of the inverter in the six-step mode, an intermediate duty command for the one of the switches is determined and a carrier signal is aligned based upon a present state of the one of the switches. The one of the switches is controlled employing the intermediate duty command and the aligned carrier.

Abstract: A voltage source inverter controller for controlling an inverter electrically connected to an electric machine includes a current command generator, a six-step flux controller and a current regulator. The six-step flux controller generates a flux modifier to regulate flux in a flux-weakening speed/load operating region of the electric machine when operating the electric machine in a six-step mode. The current command generator converts a desired torque to three-phase desired currents that are input to a dq0-dq transformer and combined with the flux modifier to determine a modified-flux direct-quadrature (dq) current request. The current regulator includes a proportional-integral feedback controller, anti-windup elements, a dq voltage limit element and a voltage magnitude limiter. The proportional-integral feedback controller and the anti-windup elements perform closed-loop current control on the modified-flux dq current request to determine commanded dq voltages.

Abstract: An inverter electrically operatively connects to a multi-phase electric machine, and a method for controlling the inverter includes executing a six-step mode to control the inverter and monitoring an electric voltage angle of the electric machine at a preset sampling frequency. When the electric voltage angle approaches a step transition associated with control of one of a plurality of switches of the inverter in the six-step mode, an intermediate duty command for the one of the switches is determined and a carrier signal is aligned based upon a present state of the one of the switches. The one of the switches is controlled employing the intermediate duty command and the aligned carrier.

Abstract: A voltage source inverter controller for controlling an inverter electrically connected to an electric machine includes a current command generator, a six-step flux controller and a current regulator. The six-step flux controller generates a flux modifier to regulate flux in a flux-weakening speed/load operating region of the electric machine when operating the electric machine in a six-step mode. The current command generator converts a desired torque to three-phase desired currents that are input to a dq0-dq transformer and combined with the flux modifier to determine a modified-flux direct-quadrature (dq) current request. The current regulator includes a proportional-integral feedback controller, anti-windup elements, a dq voltage limit element and a voltage magnitude limiter. The proportional-integral feedback controller and the anti-windup elements perform closed-loop current control on the modified-flux dq current request to determine commanded dq voltages.

Abstract: A powertrain system includes a torque machine rotatably coupled to an internal combustion engine via a pulley mechanism. The torque machine and the internal combustion engine are configured to transfer torque to a driveline and include a first sensor configured to monitor rotation of the engine and a second sensor configured to monitor rotation of the torque machine. The first sensor signally connects to a controller configured to control operation of the torque machine. A method for operating the powertrain system includes employing a signal output from the first sensor to monitor rotation of the torque machine to control operation thereof, said signal output from the first sensor adjusted for a pulley ratio of the pulley mechanism upon detecting a fault associated with the second sensor.

Abstract: Embodiments of the present disclosure relate to methods, systems and apparatus for adjusting current and/or torque commands used to control operation of an asynchronous machine based on rotor flux of the asynchronous machine.

Abstract: In accordance with exemplary embodiments, rotor temperature estimation is provided for estimating rotor temperatures of an electric motor in an electric vehicle. A method comprises estimating a rotor temperature in a controller for an electric motor of a vehicle using a fast-mode rotor temperature estimator for a time interval, and then deactivating the fast-mode rotor temperate estimator after the time interval and activating a normal-mode rotor temperature estimator in the controller for the electric motor of the vehicle. A system comprises an electric motor, a resistance rotor temperature estimator including a limit value limiting a temperature estimate increase for temperature estimates, and a controller for the electric motor, which uses the temperature estimate and is configured to temporarily increase the limit value of the resistance rotor temperature estimator providing a fast-mode rotor temperature estimate.

Abstract: A vehicle includes a motor having a rotor shaft, a transmission having a gear set directly or selectively connected to the motor, a resolver circuit, and a controller. The resolver circuit includes a resolver that measures an absolute position of the shaft, and a resolver-to-digital converter (RDC) which receives the absolute position and generates, via a tracking loop, a raw position signal. The controller includes recorded predetermined frequency characteristics of the RDC and method instructions which cause the controller to receive the raw position signal from the RDC and create a lookup table describing position wobble. The controller compensates for the position wobble at all rotational speeds of the rotor shaft by applying the predetermined frequency characteristics to the position wobble to derive a compensated position signal. The controller also uses the compensated position signal to control an operation of the electric motor.

Abstract: A method for controlling an electrically-powered torque machine of a powertrain system includes determining a predicted torque command to control the torque machine. A flux command is determined responsive to the predicted torque command. The flux command is a flux level providing a fast torque reserve that is responsive to the predicted torque command. The fast torque reserve is a prescribed minimum rate of change in torque output from the torque machine responsive to the predicted torque command. An inverter controller controls flux of the torque machine responsive to the flux command.

Abstract: Methods, systems and apparatus are provided for generating voltage commands used to control operation of a permanent magnet machine. For example, a control system is provided that generates voltage command signals for controlling a permanent magnet machine during a transition from an initial operating condition to a final operating condition. The control system includes a processor configured to execute software instructions, and a memory configured to store software instructions accessible by the processor. The software instructions comprise a voltage command generator module. Based on an electrical angular frequency of the permanent magnet machine, and synchronous reference frame current signals, the voltage command generator module is configured to generate ramped voltage command signals that each change linearly in accordance with a slope during a transition period that is set to a rise time.

Abstract: A powertrain system includes a torque machine rotatably coupled to an internal combustion engine via a pulley mechanism. The torque machine and the internal combustion engine are configured to transfer torque to a driveline and include a first sensor configured to monitor rotation of the engine and a second sensor configured to monitor rotation of the torque machine. The first sensor signally connects to a controller configured to control operation of the torque machine. A method for operating the powertrain system includes employing a signal output from the first sensor to monitor rotation of the torque machine to control operation thereof, said signal output from the first sensor adjusted for a pulley ratio of the pulley mechanism upon detecting a fault associated with the second sensor.