Abstract: An engine starter system includes a starter including a multi-phase brushless electric motor and an electronic commutator assembly. A controller includes an instruction set that is executable in response to a command to execute an engine starting event. Operation includes determining a desired starting profile, controlling the starter to engage a rotatable member of the engine, and monitoring the rotational speed of the electric motor via a rotor position sensing circuit. The starter inverter is dynamically controlled to control the electric motor to spin the rotatable member of the internal combustion engine responsive to the desired starting profile, including dynamically controlling the starter inverter to control the electric motor to control the spin of the engine responsive to the desired starting profile to prevent occurrence of an engine speed flare event during the engine starting event.

Abstract: An electric starter system includes a brushless alternating current (AC) starter motor selectively coupled to an engine and having a rotor with a rotor position. A position sensor generates measured position signals indicative of rotor position. A controller is in communication with the sensor. The controller has sensorless logic, e.g., a BEMF, inductance, or high-frequency signal injection method, for generating an estimated rotor position. The controller executes a method in which, below a threshold speed of the starter motor, the controller calibrates the sensorless logic using the measured position signals and controls a torque operation of the starter motor using the measured position signals. Above the threshold speed, the torque operation is controlled solely using the estimated rotor position. A powertrain includes the engine, a transmission, a drive shaft, and a load, along with the electric starter system.

Abstract: An electric starter system is usable with an engine and a power inverter module (PIM), e.g., of a powertrain. The starter system includes a polyphase/AC brushless starter motor connected to the PIM via an AC voltage bus and selectively connected to the engine during a requested engine start event. A sensor on the DC voltage bus outputs a signal indicative of a voltage level of the DC voltage bus. The controller executes a method using voltage stabilization logic having a proportional-integral (PI) torque control loop. Logic execution in response to the requested engine starting event causes the controller to control the starter motor, when the bus voltage exceeds a calibrated minimum voltage, using a starting torque determined via the control loop. The commanded starting torque limits inrush current to the starter motor such that the DC voltage bus remains above the minimum voltage.

Abstract: A starter assembly includes a multi-phase brushless electric motor including a stator, a rotor disposed on a rotatable shaft, and a motor endcap disposed at a first end of the stator. An electronic commutator assembly includes a sensing circuit, a control electronics subassembly, a power electronics subassembly and a heat sink. The sensing circuit is disposed adjacent to the second end of the rotatable shaft. The control electronics subassembly, the power electronics subassembly and the heat sink are disposed on disk-shaped devices arranged in a stacked configuration orthogonal to the axis defined by the rotatable shaft. The control electronics subassembly is disposed adjacent to the sensing circuit, and the power electronics subassembly is disposed adjacent to the control electronics subassembly. The control electronics subassembly is interposed between the power electronics subassembly and the sensing circuit. The heat sink is disposed adjacent to the power electronics subassembly.

Abstract: A starter system includes a brushless electric starter motor and a battery power pack, the motor operatively connectable to an internal combustion engine of a powertrain. A power inverter converts direct current provided from the battery power pack to multi-phase alternating current to drive the motor. A pinion gear with one-way clutch is rotatably driven by the motor and movable between a disengaged position and an engaged position in which the pinion gear is meshingly engaged with a ring gear operatively connected to a crankshaft of the engine. A solenoid is operatively connected to the pinion gear. An electronic control system controls the motor to crank the engine using power provided from the battery power pack, and to separately command the solenoid to a disabled or an enabled state. A method of controlling the starter system controls the motor to crank the engine in a restart following an autostop.

Abstract: A brushless electric motor includes a motor casing having a first bearing, a motor end-cap including a second bearing, a multi-phase stator assembly, and a rotor assembly having a rotor shaft. The shaft has a first end, a second end, and a knurled section therebetween. The shaft also has a first bearing surface proximate the first end and supported by the first bearing, a second bearing surface proximate the second end and supported by the second bearing, and a rotor position and speed sensor target. The shaft additionally has a sun gear integrated with the shaft proximate the first bearing surface for engaging a partial planetary gear set. The rotor assembly also includes a rotor lamination fixed to the shaft at the knurled section and having opposing first and second sides, and first and second end plates arranged on the respective first and second sides of the rotor lamination.

Abstract: A starter includes a three-phase switched reluctance electric motor including a rotor and a stator, a pinion gear, a power inverter that is connected to the stator, and a rotational position sensor. The rotor includes a quantity of rotor poles that is between 6 and 16, and the stator includes a quantity of stator poles that is between 8 and 24. An outer diameter of the electric motor is less than 85 mm. An active length of the motor is less than 50 mm. An airgap distance between the rotor and the stator is between 0.1 mm and 0.5 mm. A ratio between a rotor pole arc and a stator pole arc is at least 1.0:1. A ratio between a stator diameter and a rotor diameter is at least 2.0:1, and a ratio between a stator pole height and a rotor pole height is at least 2.5:1.

Abstract: A starter system for a powertrain comprises a brushless electric starter motor operatively connectable to an internal combustion engine. The starter system includes both an ultracapacitor power pack and a battery power pack. A nominal voltage of the ultracapacitor power pack is greater than that of the battery power pack. A DC-DC converter operatively connects the battery power pack and the ultracapacitor power pack and converts direct current at a first voltage level of the battery power pack to direct current at a greater second voltage level of the ultracapacitor power pack. An electronic control system is operable to control the brushless electric starter motor to start the engine using power provided from the ultracapacitor power pack, and to control the DC-DC converter to recharge the ultracapacitor power pack using power provided from the battery power pack through the DC-DC converter. A method of controlling the starter system is included.

Abstract: A starter assembly includes a partial planetary gear set connected to a pinion gear slidable along a first axis. The starter also includes a motor casing housing a brushless electric motor and having a first bearing. The motor includes multi-phase stator and rotor assemblies arranged inside the casing concentrically relative to the first axis. The rotor assembly has a rotor with a shaft supported by the first bearing and connected to a sun gear engaging the gear set, and a rotor position and speed sensor target. The starter additionally includes a motor end-cap for mating with and enclosing the motor casing and having a second bearing supporting the shaft. The starter also includes an electronics cover with a power connector for mating with the end-cap and housing an electronic commutator assembly. The commutator assembly includes power electronics, and control processor electronics arranged between the end-cap and the power electronics.

Abstract: A starter system for a powertrain comprises a brushless electric starter motor operatively connectable to an internal combustion engine. The starter system includes both an ultracapacitor power pack and a battery power pack. A nominal voltage of the ultracapacitor power pack is greater than that of the battery power pack. A DC-DC converter operatively connects the battery power pack and the ultracapacitor power pack and converts direct current at a first voltage level of the battery power pack to direct current at a greater second voltage level of the ultracapacitor power pack. An electronic control system is operable to control the brushless electric starter motor to start the engine using power provided from the ultracapacitor power pack, and to control the DC-DC converter to recharge the ultracapacitor power pack using power provided from the battery power pack through the DC-DC converter. A method of controlling the starter system is included.

Abstract: An electric powertrain includes an electric machine, an inverter connected to the electric machine, and an energy storage system for providing an electric current. The energy storage system includes a first energy storage device operable at a first device voltage, and a second energy storage device operable at a second device voltage. A plurality of low-loss switching devices interconnect the first energy storage device and the second energy storage device. The switching devices are selectively controllable between a first operating mode for providing the electric current at a first system voltage, and a second operating mode for providing the electric current at a second system voltage. The first system voltage is different from the second system voltage.

Abstract: An electric starter system for a powertrain or other system having an engine includes a solenoid device coupled to a pinion gear, a brushless starter motor, and a controller. The starter motor has actual machine speed, and is connectable to the flywheel via the pinion gear during a change-of-mind event when a commanded engine auto-stop sequence is interrupted before completion. When engine speed exceeds a threshold speed and is less than a calibrated starting speed, the controller executes a method in which closed-loop speed control of the starter motor is enabled using the engine speed as a reference value until an effective machine speed is within a permissible speed delta of engine speed. The controller causes the solenoid device to translate the pinion gear into engagement with the flywheel and starter motor, disables closed-loop speed control, and commands the starter motor to start the engine.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: A starter for an internal combustion engine includes a multi-phase brushless electric motor, a controller and an inverter. A method for controlling the starter includes determining initial current commands for operating the electric motor in response to an activation command. Electrical current supplied to the electric motor and a rotational position of an output member of the electric motor are monitored. The electrical current is monitored directly without an intervening current prediction step. Interim voltage commands are determined based upon the initial current commands and the monitored currents, and final voltage commands are determined by subjecting the interim voltage commands to voltage limits. A rotational position compensation term is determined based upon the rotational position and rotational speed of the electric motor, and operation of the inverter is controlled to control the electric motor based upon the final voltage commands and the rotational position compensation term.

Abstract: An electric motor includes a rotor having a stack of laminations positioned axially relative to one another. The stack of laminations includes a first rotor lamination that is divided into a first portion and a second portion. The first rotor lamination is configured to have an asymmetric mass distribution such that the first portion has a first mass and the second portion has a second mass, with the first mass being different from the second mass. The electric motor is configured to selectively generate an unbalanced force during operation (i.e., when the rotor is spinning). The electric motor may include a stator configured to have an asymmetric magnetic field distribution. The electric motor may be employed in a haptic assembly and eliminates the need for a separate eccentric mass to generate a haptic signal.

Abstract: An electric powertrain includes an electric machine, an inverter connected to the electric machine, and an energy storage system for providing an electric current. The energy storage system includes a first energy storage device operable at a first device voltage, and a second energy storage device operable at a second device voltage. A plurality of low-loss switching devices interconnect the first energy storage device and the second energy storage device. The switching devices are selectively controllable between a first operating mode for providing the electric current at a first system voltage, and a second operating mode for providing the electric current at a second system voltage. The first system voltage is different from the second system voltage.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: A vehicle propulsion system includes an engine and a first electric machine each configured to selectively provide torque to propel the vehicle. The propulsion system also includes a second electric machine coupled to the engine and configured to start the engine from an inactive state. A high-voltage battery powers both of the first electric machine and the second electric machine over a high-voltage bus. The vehicle further includes a controller programmed to issue a command to start the engine using the second electric machine in response to a threshold acceleration demand following a period of reduced acceleration demand.

Abstract: A starter for an internal combustion engine includes a multi-phase brushless electric motor, a controller and an inverter. A method for controlling the starter includes determining initial current commands for operating the electric motor in response to an activation command. Electrical current supplied to the electric motor and a rotational position of an output member of the electric motor are monitored. The electrical current is monitored directly without an intervening current prediction step. Interim voltage commands are determined based upon the initial current commands and the monitored currents, and final voltage commands are determined by subjecting the interim voltage commands to voltage limits. A rotational position compensation term is determined based upon the rotational position and rotational speed of the electric motor, and operation of the inverter is controlled to control the electric motor based upon the final voltage commands and the rotational position compensation term.

Abstract: An electric machine is provided that has a rotor assembly having a rotor core configured to support permanent magnets spaced around the rotor core to define a number of rotor poles. The rotor core has multiple rotor slots arranged as multiple barrier layers at each of the rotor poles. The multiple barrier layers are positioned adjacent one another between an inner periphery of the rotor core and an outer periphery of the rotor core and include a first barrier layer nearest the inner periphery. Permanent magnets are disposed in at least the first barrier layer. A stator assembly surrounds the rotor assembly. The electric machine is configured to function as a motor in a motoring mode and as a generator in a generating mode. The electric machine is configured with predetermined operating parameters selected for optimizing operation in the motoring mode and/or the generating mode.