Abstract: In an electrified vehicle having a synchronous traction motor, an inverter is connected to stator windings by three power cables. If these cables are accidentally connected to the wrong windings, the resulting torque will not match the desired torque, and may even be in the wrong direction. To avoid this problem, a test is performed any time that the cables may have been unplugged and re-connected. The inverter is commanded to generate a rotating magnetic field while the rotor is held stationary, resulting in a positive and a negative response current. A relationship between a phase angle of the negative response current and the rotor position indicates which cables are connected to which windings. If the cables are incorrectly connected, the controller disables the motor and informs an operator which cables to swap to achieve correct connection.

Abstract: A vehicle power system includes an electric machine, an inverter electrically connected with the electric machine, and a controller. The controller, while injecting AC voltage output by the inverter into the electric machine as a DC voltage input to the inverter changes, drives a duty ratio of the inverter toward a constant value to obtain resolver offset information associated with the electric machine from a current response of the electric machine to the AC voltage.

Abstract: A vehicle power system includes an electric machine, an inverter electrically connected with the electric machine, and a controller. The controller, while injecting AC voltage output by the inverter into the electric machine as a DC voltage input to the inverter changes, drives a duty ratio of the inverter toward a constant value to obtain resolver offset information associated with the electric machine from a current response of the electric machine to the AC voltage.

Abstract: A vehicle includes a controller programmed to, responsive to injecting a high frequency voltage signal to an electric machine, determine an estimated negative sequence current phase associated with an electric machine current, and responsive to a rotor of the electric machine being at a predetermined rotor position, inject a pulse torque command to the electric machine and observe a speed change of the electric machine to determine a cable sequence.

Abstract: An electric machine assembly for a vehicle is provided. The electric machine is in operational communication with a traction battery and includes a stator core defining a cavity and a rotor disposed within the cavity having an inner region defined by sets of triangle-shaped holes tessellated about respective central regions to form a truss structure such that the holes of the truss structure, during operational rotation, do not influence magnetic flux paths generated by magnets of the rotor. The rotor may have a strain energy value less than or equal to 16,100 Joules. The truss structure may include pairs of symmetrical portions each including segments arranged with adjacent rotor portions to define the triangle-shaped holes.

Abstract: A vehicle includes an electric machine. The vehicle includes a controller configured to repeatedly adjust power outputs for the two inverters so that they differ to drive the difference toward zero and such that power provided to the electric machine satisfies demand until the difference falls below a second predetermined threshold. The controller may be configured to adjust responsive to a temperature difference between two inverters associated with the electric machine exceeding a predetermined threshold.

Abstract: An electric drive system has a motor including a rotor, an inverter, and a controller. The controller perturbs a position of the rotor via a pulse width modulation (PWM) command to the inverter such that the motor receives an Id current that changes during the perturbing and an Iq current, and responsive to the Iq current settling at zero during the perturbing, alters the PWM command to cause the rotor to rotate.

Abstract: Systems and methods for operating an inverter that is electrically coupled to a battery and an electric machine that provides propulsive force to vehicle are described. The systems and methods may selectively adjust a duty cycle of an inverter transistor responsive to battery voltage and a dead time between when a first transistor is deactivated and when a second transistor is activated.

Abstract: An electric motor/generator includes a stator-core enclosing a rotor-core, which are each formed from stacked annular laminates. The stator-core laminates are configured to reduce vibration, and each have teeth extending radially inward from a root of an annular stator yoke/back-iron, to a flux-cap. Each tooth is formed to have opposite, lateral-edges spaced a distance-apart that changes between the root to the flux-cap, to establish a variable tooth-stiffness and a predetermined mechanical-resonance of the tooth. The opposite lateral-edges may each be configured with either a linear or a non-linear, curved edge-profile, and to have the variable tooth-stiffness and the lateral-edge distance-apart changing or decreasing between the root and the flux-cap. Each tooth may also have an edge-profile that is different from at least one adjacent tooth, and which is configured with a variable tooth-stiffness and a predetermined mechanical resonance that is different from the at least one adjacent tooth.

Abstract: A vehicle includes a controller programmed to, responsive to injecting a high frequency voltage signal to an electric machine, determine an estimated negative sequence current phase associated with an electric machine current, and responsive to a rotor of the electric machine being at a predetermined rotor position, inject a pulse torque command to the electric machine and observe a speed change of the electric machine to determine a cable sequence.

Abstract: A vehicle includes an electric machine operated by an inverter. The electric machine includes a gate driver configured to energize a switch of the inverter with a pulse width modulation (PWM) signal. The gate driver is configured to delay the PWM signal by a dependent amount that is a function of a magnitude of current of a lead of the electric machine. The delay is responsive to a polarity of the current being positive.

Abstract: A system for controlling an electric machine of a vehicle includes, among other things, a controller module configured to attenuate noise from the electric machine by altering a corrective voltage in response to feedback about the noise. The corrective voltage and a fundamental voltage command are supplied to the electric machine as a combined voltage command. The corrective voltage is on a harmonic adjacent to a harmonic of the noise. A method of controlling noise associated with an electric machine of a vehicle includes, among other things, altering a corrective voltage to attenuate noise in response to feedback about the noise. The corrective voltage and a fundamental voltage command are supplied to the electric machine as a combined voltage command. The corrective voltage is on a harmonic adjacent to a harmonic of the noise.

Abstract: An electric drive system for a vehicle includes an electric machine having first conductors arranged in slots of a stator to form phase windings and a second conductor arranged in the slots to form a secondary winding that produces a voltage indicative of a common mode voltage caused by voltages applied to the phase windings. The voltage can be used to supply power to electronic components and for diagnosis and control of the electric machine and an associated inverter.

Abstract: A vehicle includes a five-phase electric machine with open windings driven at each side by phase legs of an inverter. A controller monitors for open-circuit windings. In response to detecting an open-circuit winding above a predetermined speed threshold, the controller operates the inverter to drive the windings that are not open-circuited in a square configuration.

Abstract: An electric drive system for a vehicle includes an electric machine having first conductors arranged in slots of a stator to form phase windings and a second conductor arranged in the slots to form a secondary winding that produces a voltage indicative of a common mode voltage caused by voltages applied to the phase windings. The voltage can be used to supply power to electronic components and for diagnosis and control of the electric machine and an associated inverter.

Abstract: A vehicle includes an electric machine operated by an inverter. The electric machine includes a gate driver configured to energize a switch of the inverter with a pulse width modulation (PWM) signal. The gate driver is configured to delay the PWM signal by a dependent amount that is a function of a magnitude of current of a lead of the electric machine. The delay is responsive to a polarity of the current being positive.

Abstract: A vehicle powertrain includes an inverter coupled with an electric machine and a controller. The controller may be configured to dither a base frequency of a pulse width modulated (PWM) signal, by less than an amount that is based on a rotational speed of the machine and the base frequency, to operate the inverter such that energy at sidebands and harmonics of the base frequency are reduced by distributing the energy to reduce audible vibrations of the powertrain.

Abstract: A vehicle includes a five-phase electric machine with open windings driven at each side by phase legs of an inverter. A controller monitors for open-circuit windings. In response to detecting an open-circuit winding above a predetermined speed threshold, the controller operates the inverter to drive the windings that are not open-circuited in a square configuration.

Abstract: In an electrified vehicle having a synchronous traction motor, an inverter is connected to stator windings by three power cables. If these cables are accidentally connected to the wrong windings, the resulting torque will not match the desired torque, and may even be in the wrong direction. To avoid this problem, a test is performed any time that the cables may have been unplugged and re-connected. The inverter is commanded to generate a rotating magnetic field while the rotor is held stationary, resulting in a positive and a negative response current. A relationship between a phase angle of the negative response current and the rotor position indicates which cables are connected to which windings. If the cables are incorrectly connected, the controller disables the motor and informs an operator which cables to swap to achieve correct connection.

Abstract: Systems and methods for operating an inverter that is electrically coupled to a battery and an electric machine that provides propulsive force to vehicle are described. The systems and methods may selectively adjust a duty cycle of an inverter transistor responsive to battery voltage and a dead time between when a first transistor is deactivated and when a second transistor is activated.