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: 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 machine assembly includes an electric machine, an inverter configured to provide pulse-width modulation characterized by a switching frequency and a controller. The controller has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method of controlling the switching frequency to minimize a beat frequency phenomenon. Execution of the instructions by the processor causes the controller to obtain a first function (G1) and a second function (G2) based at least partially on the original pulse ratio (PR0). The original pulse ratio (PR0) is a ratio of the switching frequency and a predefined fundamental frequency. If each of a plurality of conditions are met, a new pulse ratio (PRN) is determined based at least partially on the original pulse ratio (PR0), the first function (G1) and the second function (G2).

Abstract: An inverter electrically connected to an electric machine is described. A method for controlling switching in the inverter includes determining a torque output of the electric machine and determining a temperature related to an inverter cooling circuit. A preferred inverter switch control mode for controlling the inverter is selected based upon the torque output of the electric machine and the temperature related to the inverter cooling circuit.

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.

Abstract: A system and method for detecting an erratic state of a monitored sensor includes generating a variation value for a monitored signal generated by a monitored sensor and a variation value for an estimated signal estimated based on a predictive signal generated by predictive sensor, where the predictive signal is predictive of the monitored signal. The monitored signal can rapidly fluctuate based on system operating conditions. A dynamic threshold value is generated based on the estimated variation value, and the monitored signal is compared with the dynamic threshold value to determine if the monitored signal is in an erratic state. The detection method is sufficiently sensitive to distinguish between rapid fluctuation of the monitored sensor and an erratic state.

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: A method for detecting a sensor that is stuck in range includes computing a variation value for each of a first signal and a second signal generated by a respective first and second sensor, wherein the first and second signals are correlated signals. The variation value for each of the first and second signals is computed for the same diagnostic period, such that when one of the first and second sensors is generating a signal which is stuck in range during the diagnostic period, the signal stuck in range will be characterized by a variation value which is much less than the variation value of the correlated signal. The magnitude of difference between the variation values of the first and second signals can be compared to a predetermined fault threshold to diagnose a sensor stuck in range.

Abstract: A multi-phase electric machine electrically connected to an inverter is described. A method for controlling the electric machine includes determining an initial current command responsive to a torque command for the electric machine and determining an expected torque ripple associated with operation of the electric machine. A mitigation current command is determined based upon the torque command and the expected torque ripple, and the electric machine is dynamically controlled responsive to the initial current command and the mitigation current command.

Abstract: An inverter electrically connected to an electric machine is described. A method for controlling switching in the inverter includes determining a torque output of the electric machine and determining a temperature related to an inverter cooling circuit. A preferred inverter switch control mode for controlling the inverter is selected based upon the torque output of the electric machine and the temperature related to the inverter cooling circuit.

Abstract: A method of distributing processor loading in a real-time operating system between a high frequency processing task and a lower frequency processing task, the method including: making a processing request to the high frequency processing task from the lower frequency processing task, the processing request including a plurality of discrete processing commands; queuing the plurality of discrete processing commands; and executing a subset of the queued processing commands with the execution of each of a plurality of high frequency processing tasks such that the execution of the plurality of discrete processing commands is distributed across the plurality of high frequency processing tasks.

Abstract: A system and method for detecting an erratic state of a monitored sensor includes generating a variation value for a monitored signal generated by a monitored sensor and a variation value for an estimated signal estimated based on a predictive signal generated by predictive sensor, where the predictive signal is predictive of the monitored signal. The monitored signal can rapidly fluctuate based on system operating conditions. A dynamic threshold value is generated based on the estimated variation value, and the monitored signal is compared with the dynamic threshold value to determine if the monitored signal is in an erratic state. The detection method is sufficiently sensitive to distinguish between rapid fluctuation of the monitored sensor and an erratic state.

Abstract: A method for detecting a sensor that is stuck in range includes computing a variation value for each of a first signal and a second signal generated by a respective first and second sensor, wherein the first and second signals are correlated signals. The variation value for each of the first and second signals is computed for the same diagnostic period, such that when one of the first and second sensors is generating a signal which is stuck in range during the diagnostic period, the signal stuck in range will be characterized by a variation value which is much less than the variation value of the correlated signal. The magnitude of difference between the variation values of the first and second signals can be compared to a predetermined fault threshold to diagnose a sensor stuck in range.

Abstract: Methods and systems are provided for controlling the charging of onboard energy storage systems of a plurality of plug-in vehicles using a remote command center. A system for directing the charging of a plurality of remotely located plug-in vehicles is provided. The system includes a communication system configured to transmit charging authorizations to charge each of the plurality of plug-in vehicles and to receive data related to power consumption from each of the plurality of plug-in vehicles. The system also includes a controller communicatively coupled to the communication system and configured to receive the data related to power consumption and to direct the charge authorizations based thereon. A database is also included in the system and is communicatively coupled to the controller, with the database configured to store the data related to power consumption.

Abstract: A method of distributing processor loading in a real-time operating system between a high frequency processing task and a lower frequency processing task, the method including: making a processing request to the high frequency processing task from the lower frequency processing task, the processing request including a plurality of discrete processing commands; queuing the plurality of discrete processing commands; and executing a subset of the queued processing commands with the execution of each of a plurality of high frequency processing tasks such that the execution of the plurality of discrete processing commands is distributed across the plurality of high frequency processing tasks.

Abstract: A method to control a powertrain having an electric motor includes monitoring a torque command to the motor, predicting a motor torque for the motor based upon the torque command, monitoring an actual motor torque of the motor, comparing the actual motor torque to the predicted torque, and indicating a motor fault when the actual motor torque and the predicted torque differ by more than a calibratable threshold.

Abstract: A method for operating an electric motor is provided. The method includes receiving a torque request; determining long term torque capabilities and short term torque capabilities of the electric motor; generating a torque command based on the torque request and at least one of the long term torque capabilities or the short term torque capabilities; and controlling the electric motor in accordance with the torque command.

Abstract: Embodiments of the present invention relate to methods, systems, a machine-readable medium operable in a controller, and apparatus for controlling a multi-phase inverter that drives a multi-phase electric machine. When a sensor fault is detected, a phase current angle is computed based on the feedback stator currents, and used to estimate an angular velocity and an angular position of a rotor of the multi-phase electric machine. When the estimated angular velocity of the multi-phase electric machine is less than a transition angular velocity threshold, an open-circuit response can be applied at the multi-phase inverter by controlling all switches in the multi-phase inverter drive to be open. By contrast, when the estimated angular velocity is greater than the transition angular velocity threshold, a short-circuit response can be applied at the multi-phase inverter by controlling selected switches in the multi-phase inverter drive to connect all phases of the multi-phase inverter to a single bus (e.g.

Abstract: A hybrid powertrain system includes an engine, an electric machine, a power electronics device including a plurality of electric circuit layers, and a cooling system. A method for managing thermal energy in the power electronics device includes monitoring a plurality of temperature sensors in the power electronics device, monitoring electric power into and out of the power electronics device, predicting temperatures for the plurality of electric circuit layers, and controlling the hybrid powertrain system based upon the predicted temperatures for the plurality of electric circuit layers.

Abstract: Systems and methods are provided for monitoring current in an electric motor. An electrical system includes a (DC) interface, an electric motor, an inverter module coupled between the DC interface and the electric motor, a first current sensor between a first phase leg of the inverter module and a first phase of the electric motor to measure a first current flowing through the first phase of the electric motor, a second current sensor between the first phase leg and the DC interface to measure a second current flowing through the first phase leg, and a control module coupled to the first current sensor and the second current sensor. The control module is configured to initiate remedial action based at least in part on a difference between the first current measured by the first current sensor and the second current measured by the second current sensor.