Abstract: A method controls an electrified powertrain having an electric traction motor and a traction power inverter module (TPIM). A controller determines a current component capability and use case of the electrified powertrain. In response to the current component capability being less than a capability threshold and the use case matching a predetermined approved use case, the controller determines whether a predetermined margin exists in the component capability for operating the electrified powertrain in a maximum performance mode (MPM) for a full duration of a boosted driving maneuver. When the predetermined margin exists, the controller temporarily applies an extended inverter limit (EIL) of the TPIM to enable the MPM. The EIL allows operation of the traction motor to occur above default torque and speed operating limits for the full duration of the boosted driving maneuver. MPM/EIL availability is communicated to the operator.

Abstract: Presented are high-voltage electrical systems, control logic, and electric-drive vehicles with optimized motor torque output. A method of operating an electric-drive vehicle includes a controller identifying the vehicle's operating mode and determining calibration settings corresponding to this operating mode. These calibration settings include low and high coolant temperature (CoolTemp) thresholds, and motor-calibrated torque limits as a function of CoolTemp. The controller determines if the present CoolTemp of the power inverter's coolant is greater than the low CoolTemp threshold and less than the high CoolTemp threshold. If so, the controller sets a motor torque limit of the vehicle's electric motor to a torque limit value selected from a fixed torque limit region within the torque limits data between the low and high CoolTemp thresholds.

Abstract: Control of an AC motor includes rotation over an operating speed range with the output from an inverter by operating the inverter at switching frequencies that vary in proportion to rotor speed. The operating speed range is parsed into a plurality of speed regions and the switching frequencies within each operating speed region may correspond to a respective pulse ratio that is different from the respective pulse ratio corresponding to an adjacent speed region.

Abstract: A novel power inverter system for transferring electric power between a DC power source and a multi-phase electric machine is described, and includes a power inverter, a Z-source inverter, a first switch, and a second switch. The first switch is arranged between positive and negative conductors of a high-voltage bus that is electrically coupled to the DC power source, and the second switch is arranged in-line on the positive conductor of the high-voltage bus.

Abstract: Presented are high-voltage electrical systems with optimized pulse width modulation (PWM) control, methods for making/using such systems, and vehicles with enhanced electric drive capabilities via PWM type and frequency control. A method of operating an electrical system includes an electronic controller determining a PWM region layout with multiple PWM regions arranged in a torque-speed curve calibrated to an electric motor and power inverter. The controller selects one of the PWM regions based on a speed and torque of the motor, and selects a PWM type based on this selected PWM region. The controller selects a PWM switching frequency style based on the selected PWM region, and selects a PWM switching frequency based on the selected PWM region, switching frequency style, and PWM type. The controller commands a power inverter to regulate transfer of electrical power between a rechargeable battery and the motor based on the PWM type and switching frequency.

Abstract: An apparatus and a method for controlling operation of a vehicle includes a controller having a processor and a tangible, non-transitory memory. The vehicle includes a park assembly with a park actuator motor having an actuator shaft. The vehicle has a park mode and an out-of-park mode. The controller is configured to determine if the park actuator motor has reached an out-of-park position when a shift command to the out-of-park mode is received. The controller is configured to obtain and store at least one dynamic parameter associated with the park actuator motor prior to the detent member reaching the out-of-park position. The method includes determining a load factor based on the dynamic parameter over time when at least one of a predefined time threshold and a predefined motor position threshold is reached. Operation of the vehicle is controlled based at least partially on the load factor.

Abstract: A DC-DC power converter including switched inductance circuits arranged in parallel is described. Operation includes determining a commanded current and activation commands for the switched inductance circuits based upon the commanded current. This includes executing the activation commands and monitoring current in the switched inductance circuits. An average measured current is determined for each of the switched inductance circuits, and a modified activation command is determined for each of the switched inductance circuits based upon the average measured current. A time portion of the modified activation command that exceeds an end time point of a subsequent time period is determined, and the modified activation commands for the switched inductance circuits are executed, including forward-shifting that time portion of the modified activation command for each of the switched inductance circuits that exceeds the end time point.

Abstract: A DC-DC power converter including switched inductance circuits arranged in parallel is described. Operation includes determining a commanded current and activation commands for the switched inductance circuits based upon the commanded current. This includes executing the activation commands and monitoring current in the switched inductance circuits. An average measured current is determined for each of the switched inductance circuits, and a modified activation command is determined for each of the switched inductance circuits based upon the average measured current. A time portion of the modified activation command that exceeds an end time point of a subsequent time period is determined, and the modified activation commands for the switched inductance circuits are executed, including forward-shifting that time portion of the modified activation command for each of the switched inductance circuits that exceeds the end time point.

Abstract: A cascaded inverter system is described and includes an electric machine that is electrically connected in series between first and second inverters. A controller is in communication with the first and second inverters, and includes an executable instruction set. A first dead-time compensation term and a first voltage compensation term are determined based upon an initial phase current and a switching frequency for the first inverter, and a final first duty cycle is determined based thereon. Simultaneously, a second dead-time compensation term and a second voltage compensation term are determined based upon the inverted initial phase current and a switching frequency for the second inverter, and a final second duty cycle is determined based thereon. Operation of the first and second inverters are dynamically controlled based upon the final first duty cycle and the final second duty cycle, respectively.

Abstract: A DC-DC power converter is described, and includes switched inductance circuits arranged in parallel, current sensors disposed to monitor one of the switched inductance circuits, and a controller. The DC-DC power converter supplies electric power originating from a DC power source to a high-voltage bus. Control and operation includes determining a desired control mode for operating the DC-DC power converter, wherein the desired control mode includes one of a voltage control mode and a current control mode. A desired voltage and a desired differential current for operating the DC-DC power converter are determined based upon the desired control mode. A desired current for operating the DC-DC power converter is determined based upon the desired differential current. Operation of the DC-DC power converter is controlled in the desired control mode based upon the desired voltage and the desired current.

Abstract: A cascaded inverter system is described and includes an electric machine that is electrically connected in series between first and second inverters. A controller is in communication with the first and second inverters, and includes an executable instruction set. A first dead-time compensation term and a first voltage compensation term are determined based upon an initial phase current and a switching frequency for the first inverter, and a final first duty cycle is determined based thereon. Simultaneously, a second dead-time compensation term and a second voltage compensation term are determined based upon the inverted initial phase current and a switching frequency for the second inverter, and a final second duty cycle is determined based thereon. Operation of the first and second inverters are dynamically controlled based upon the final first duty cycle and the final second duty cycle, respectively.

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: Methods may involve determining a minimum voltage for a voltage command. A maximum voltage for the voltage command may be determined. A first representation of a first performance curve corresponding to the minimum voltage may be determined. A second representation of a second performance curve corresponding to the maximum voltage may be determined. An operating point to be achieved through the voltage command may be obtained. An evaluation may be made of whether the operating point lies between the first and second representations. When the operating point lies between the first and second representations, an interpolation may be conducted between the first and second representations to determine a magnitude of the voltage command.

Abstract: An electric power system for supplying power to a permanent magnet electric machine includes a high-voltage DC power source that is disposed to supply electric power to a front-end converter connected via a high-voltage DC bus to an electric inverter that is connected to the electric machine. A method for operating a control system includes monitoring the electric machine. Upon detecting a fault associated with the electric machine, a controller commands operation of the front-end converter to generate a voltage level on the high-voltage DC bus that is a maximum setpoint voltage level and monitors back-emf voltage level from the electric machine. The inverter is controlled to a three-phase open state when the back-emf voltage level is less than the maximum setpoint voltage level. The inverter is controlled to a three-phase short state when the back-emf voltage level is greater than the maximum setpoint voltage level.

Abstract: An electric power system includes a polyphase electric machine, battery pack, power inverter module, analog input sensor, and diagnostic controller executing a method. The sensor measures an electrical parameter that differs from a true value of the parameter by an initial offset value. The controller collects sample sets of the parameter, compares the initial offset of each sample to an outlier threshold in a first diagnostic loop, and transmits a bit flag indicative of an outlier sample to a slower second diagnostic loop when the initial offset of a sample exceeds the outlier threshold. The second control loop calculates a rolling average of the initial offsets of the sample sets, discards the set containing the outlier sample in response to the bit flag, and executes a control action when the average exceeds a threshold that is lower than the outlier threshold.

Abstract: A method of exchanging data in a real-time operating system, between a primary core and a secondary core in a multi-core processor, includes executing a primary path via the primary core and executing a secondary path via the secondary core. The primary path is configured to be a relatively faster processing task and the secondary path is configured to be a relatively slower processing task. The method includes devising a freeze in process flag to have a respective flag status set and cleared by the primary path. The method includes devising a data frozen flag to have a respective flag status set and cleared by both the primary and the secondary paths. A component that is operatively connected to the multi-core processor may be controlled based at least partially on a difference between primary and secondary sets of calculations executed by the primary and secondary cores, respectively.

Abstract: An electric power system includes a polyphase electric machine, battery pack, power inverter module, analog input sensor, and diagnostic controller executing a method. The sensor measures an electrical parameter that differs from a true value of the parameter by an initial offset value. The controller collects sample sets of the parameter, compares the initial offset of each sample to an outlier threshold in a first diagnostic loop, and transmits a bit flag indicative of an outlier sample to a slower second diagnostic loop when the initial offset of a sample exceeds the outlier threshold. The second control loop calculates a rolling average of the initial offsets of the sample sets, discards the set containing the outlier sample in response to the bit flag, and executes a control action when the average exceeds a threshold that is lower than the outlier threshold.

Abstract: Methods may involve determining a minimum voltage for a voltage command. A maximum voltage for the voltage command may be determined. A first representation of a first performance curve corresponding to the minimum voltage may be determined. A second representation of a second performance curve corresponding to the maximum voltage may be determined. An operating point to be achieved through the voltage command may be obtained. An evaluation may be made of whether the operating point lies between the first and second representations. When the operating point lies between the first and second representations, an interpolation may be conducted between the first and second representations to determine a magnitude of the voltage command.

Abstract: A method of exchanging data in a real-time operating system, between a primary core and a secondary core in a multi-core processor, includes executing a primary path via the primary core and executing a secondary path via the secondary core. The primary path is configured to be a relatively faster processing task and the secondary path is configured to be a relatively slower processing task. The method includes devising a freeze in process flag to have a respective flag status set and cleared by the primary path. The method includes devising a data frozen flag to have a respective flag status set and cleared by both the primary and the secondary paths. A component that is operatively connected to the multi-core processor may be controlled based at least partially on a difference between primary and secondary sets of calculations executed by the primary and secondary cores, respectively.

Abstract: An electric power system including a front-end converter that is supplied electric power from a high-voltage DC power source, and an associated motor control system is described. A control method includes monitoring the electric machine and determining a reference current based upon the electric power supplied from the high-voltage DC power source. A motor current is determined based upon the monitoring of the electric machine, and a feed-forward current is determined based upon the motor current and the monitoring of the electric machine. A first duty cycle is determined based upon the reference current, the motor current and the feed-forward current, and a feed-forward duty cycle is determined based upon the monitoring of the electric machine. A second duty cycle is determined based upon the feed-forward duty cycle and the first duty cycle, and the front-end converter is controlled based upon the second duty cycle.