Abstract: An inverter circuit electrically connects between a high-voltage bus and a multi-phase electric machine, including a plurality of switch pairs. Each switch pair includes a first switch electrically connected in series with a second switch at a node. Each node electrically connects to a phase of the multi-phase electric machine with the first switch electrically connected between a positive side of the high-voltage bus and the node and the second switch electrically connected between a negative side of the high-voltage bus and the node. The first switch is configured as a normally-OFF switch. The second switch is configured as a normally-ON switch.

Abstract: A hybrid powertrain system has a high-voltage electric circuit including a high-voltage battery and a DC link coupled to first and second inverters electrically connected to first and second torque machines. A method for operating the hybrid powertrain system includes receiving a motor torque command for the second torque machine, determining a preferred DC link voltage for achieving the motor torque commanded from the second torque machine, selectively interrupting electric power flow between the high-voltage battery and the DC link to achieve the preferred DC link voltage.

Abstract: A method for monitoring electric isolation of a high voltage DC bus to detect ground isolation faults includes monitoring voltage differentials between a positive DC electric power bus and a negative DC electric power bus and a chassis ground. Electrical isolation between each of the positive and negative DC electric power buses and the chassis ground is monitored using a ratio of the voltage differentials.

Abstract: A vehicle includes a motor, an alternating current (AC) power bus, a power inverter module (PIM), and a controller. The PIM includes a semiconductor die assembly with semiconductor power switches arranged in electrical parallel for delivering AC power to the motor via the bus. The controller determines an operating mode of the vehicle, selects and activates a designated one of the switches during a threshold low-current state of the PIM, and selects and activates all of the switches during a high-current state of the PIM. A PIM assembly for the vehicle includes the die assembly and controller. A method for optimizing energy efficiency of the vehicle includes providing the die assembly noted above, automatically determining the operating mode, and selecting and activating one of the switches when the operating mode corresponds to the threshold low-current state, and all of the electrical switches during the threshold high-current state of the PIM.

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: A method for controlling a traction power inverter module (TPIM) in a vehicle includes determining a commanded output torque of the motor using a controller. The method further includes controlling the TPIM and motor using a discontinuous pulse width modulated (DPWM) signal when the commanded output torque is less than a calibrated torque threshold. A continuous pulse width modulated (CPWM) signal is used when the commanded output torque is greater than the threshold. The method may include determining a direction of a change in the commanded output torque, and controlling the TPIM, via the controller, using the DPWM signal only when the commanded output torque drops below a predetermined hysteresis level. A vehicle includes a traction motor producing a motor torque for propelling the vehicle, an ESS, a TPIM, and a controller configured as noted above.

Abstract: A vehicle includes an energy storage system (ESS) rechargeable using electrical power from an off-board AC power supply, a traction power inverter module (TPIM), one or two motors, and a controller. The TPIM has two inverters. The controller energizes designated semiconductor switches of the TPIM and designated induction coils of the motor to boost electrical power from the AC power supply for charging the ESS when the vehicle is not running. With two motors, a contactor allows induction coils of a first motor to be connected to the switches of the first inverter as an input filter, and an additional semiconductor switch is positioned between the ESS and an output side of the switches of the second inverter. A controller charges the ESS by energizing designated semiconductor switches of the TPIM and induction coils of the motor to charge the ESS without using an onboard battery charger module.

Abstract: A method of detecting a phase winding fault in a multi-phase electric machine is executable via a motor controller, and includes measuring feedback signals of the machine, including each phase current, and generating reference phase voltages for each phase. The method includes calculating a predetermined voltage value using the feedback signals and reference phase voltages, and comparing the voltage value to a corresponding threshold to determine the fault. A control action is executed when the voltage value exceeds the corresponding threshold. The voltage value is one or more of: a ratio of a normalized negative sequence voltage to a modulation index, an RMS voltage for each phase, and total harmonic distortion of each phase current. An apparatus detects the fault, and includes a motor controller and an algorithm as set forth above. The apparatus may include a voltage inverter for generating a multi-phase alternating current output for powering the machine.

Abstract: Systems and methods are provided for diagnosing stator windings in an electric motor operating under control of a current-regulating control loop. The current-regulating control loop is configured to provide a command voltage to the electric motor. The command voltage comprises a current-regulated voltage based on a difference between a commanded current and a measured current through the stator windings. The method comprises determining a negative sequence component of the command voltage, and identifying a fault condition when a characteristic of the negative sequence component is greater than a threshold value.

Abstract: A method for avoiding electrical resonance in a vehicle having a high-voltage (HV) direct current (DC) bus shared by a first and a second power electronic converter device, such as an air conditioning compressor module (ACCM) and a traction power inverter (TPIM), includes determining an impedance characteristic of the bus, defining resonance points for the bus, selecting lower and upper switching frequency boundaries for the TPIM, and preventing the TPIM from operating within a range defined by these boundaries. A vehicle includes the first and second power electronic converter device, e.g., the APPM and the TPIM, the shared HV DC, and a controller having the algorithm set forth above, wherein the controller is adapted for avoiding electrical resonance in the HV DC bus by executing the algorithm.

Abstract: A vehicle includes a high-voltage (HV) energy storage system (ESS), an HV power bus, a DC-DC power converter electrically connected to the HV power bus, an HV bus connector, a low voltage (LV) battery power bus, and a pair of LV bus connectors. The vehicle includes a vehicle module electrically connected to the HV and LV bus connectors, an LV power bus electrically connected to the DC-DC power converter and to the module, and a controller. The controller has an algorithm that controls the converter to power the module via one of the LV bus connectors during a transient LV condition. The converter and a method of controlling the same are also provided, with the method including determining the LV condition, powering the vehicle module via one of the LV bus connectors during the transient LV condition, and powering the module via the other LV connector otherwise.

Abstract: Embodiments include a power processing system and methods of its operation in a plug-in electric vehicle. The power processing system includes at least one AC electric motor, a bi-directional inverter system, and an electronic control system. The electronic control system provides a drive function by providing first control signals to the bi-directional inverter system which, in response, draws DC electrical power from a DC energy source, converts the DC power to AC power, and provides the AC power to windings of the at least one AC electric motor. The electronic control system also provides a charging function by providing second control signals to the bi-directional inverter system which, in response, draws AC power from the windings of the at least one AC electric motor, converts the AC power to DC power, and provides the DC power to the DC energy source in order to recharge the DC energy source.

Abstract: A method for controlling a traction power inverter module (TPIM) in a vehicle includes determining a commanded output torque of the motor using a controller. The method further includes controlling the TPIM and motor using a discontinuous pulse width modulated (DPWM) signal when the commanded output torque is less than a calibrated torque threshold. A continuous pulse width modulated (CPWM) signal is used when the commanded output torque is greater than the threshold. The method may include determining a direction of a change in the commanded output torque, and controlling the TPIM, via the controller, using the DPWM signal only when the commanded output torque drops below a predetermined hysteresis level. A vehicle includes a traction motor producing a motor torque for propelling the vehicle, an ESS, a TPIM, and a controller configured as noted above.

Abstract: Methods and systems are provided for detecting loss of isolation of a motor, connections, or phase cables while an AC motor is operating. The system includes a power supply that is substantially isolated from the ground or chassis having a power supply voltage, and a power inverter electrically coupled to the power supply. The power inverter is configured to provide AC current from the power supply in an AC phase at an AC terminal, with the phase having current at a fundamental frequency that controls the motor speed. An electric motor is electrically coupled to the AC terminal of the power inverter and has a chassis that is substantially electrically isolated from the AC terminal of the power inverter under normal operating conditions. A processor is configured to control the AC current provided by the power inverter. The processor is configured to receive a first voltage signal related to current flowing through a motor chassis.

Abstract: A vehicle includes an energy storage system (ESS) rechargeable using electrical power from an off-board AC power supply, a traction power inverter module (TPIM), one or two motors, and a controller. The TPIM has two inverters. The controller energizes designated semiconductor switches of the TPIM and designated induction coils of the motor to boost electrical power from the AC power supply for charging the ESS when the vehicle is not running. With two motors, a contactor allows induction coils of a first motor to be connected to the switches of the first inverter as an input filter, and an additional semiconductor switch is positioned between the ESS and an output side of the switches of the second inverter. A controller charges the ESS by energizing designated semiconductor switches of the TPIM and induction coils of the motor to charge the ESS without using an onboard battery charger module.

Abstract: A hybrid powertrain system has a high-voltage electric circuit including a high-voltage battery and a DC link coupled to first and second inverters electrically connected to first and second torque machines. A method for operating the hybrid powertrain system includes receiving a motor torque command for the second torque machine, determining a preferred DC link voltage for achieving the motor torque commanded from the second torque machine, selectively interrupting electric power flow between the high-voltage battery and the DC link to achieve the preferred DC link voltage.

Abstract: A vehicle includes a motor, an alternating current (AC) power bus, a power inverter module (PIM), and a controller. The PIM includes a semiconductor die assembly with semiconductor power switches arranged in electrical parallel for delivering AC power to the motor via the bus. The controller determines an operating mode of the vehicle, selects and activates a designated one of the switches during a threshold low-current state of the PIM, and selects and activates all of the switches during a high-current state of the PIM. A PIM assembly for the vehicle includes the die assembly and controller. A method for optimizing energy efficiency of the vehicle includes providing the die assembly noted above, automatically determining the operating mode, and selecting and activating one of the switches when the operating mode corresponds to the threshold low-current state, and all of the electrical switches during the threshold high-current state of the PIM.

Abstract: A vehicle includes a high-voltage (HV) energy storage system (ESS), an HV power bus, a DC-DC power converter electrically connected to the HV power bus, an HV bus connector, a low voltage (LV) battery power bus, and a pair of LV bus connectors. The vehicle includes a vehicle module electrically connected to the HV and LV bus connectors, an LV power bus electrically connected to the DC-DC power converter and to the module, and a controller. The controller has an algorithm that controls the converter to power the module via one of the LV bus connectors during a transient LV condition. The converter and a method of controlling the same are also provided, with the method including determining the LV condition, powering the vehicle module via one of the LV bus connectors during the transient LV condition, and powering the module via the other LV connector otherwise.

Abstract: A method for monitoring electric isolation of a high voltage DC bus to detect ground isolation faults includes monitoring voltage differentials between a positive DC electric power bus and a negative DC electric power bus and a chassis ground. Electrical isolation between each of the positive and negative DC electric power buses and the chassis ground is monitored using a ratio of the voltage differentials.

Abstract: A method of detecting a phase winding fault in a multi-phase electric machine is executable via a motor controller, and includes measuring feedback signals of the machine, including each phase current, and generating reference phase voltages for each phase. The method includes calculating a predetermined voltage value using the feedback signals and reference phase voltages, and comparing the voltage value to a corresponding threshold to determine the fault. A control action is executed when the voltage value exceeds the corresponding threshold. The voltage value is one or more of: a ratio of a normalized negative sequence voltage to a modulation index, an RMS voltage for each phase, and total harmonic distortion of each phase current. An apparatus detects the fault, and includes a motor controller and an algorithm as set forth above. The apparatus may include a voltage inverter for generating a multi-phase alternating current output for powering the machine.