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 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 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: A powertrain includes an electromechanical transmission operative to transmit torque between an input member and an electric machine and an output member to transmit tractive torque. The electric machine is electrically connected to an inverter device which is electrically connected to an energy storage device. A method for operating the powertrain includes detecting a shutdown event, commanding the transmission to neutral, commanding the electric machine to cease operating in a torque generating mode, and electrically disconnecting the energy storage device from the inverter device.

Abstract: A rotatable shaft is equipped with a measurement device that generates output signals corresponding to discrete angular positions of the shaft. Rotational angles of the shaft are measured for a complete rotational period. A true angular velocity of the shaft is determined. Angular velocity is calculated between contiguous pairs of the discrete angular positions. A velocity correction is determined, and a rotational angle error term is determined based upon the velocity correction.

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 method is provided for detecting an insufficient or missing phase current in a permanent magnet synchronous motor, and includes determining a composite vector position of a combined three-phase phase current with respect to a stationary portion of the motor, and assigning a sector to the position. The method includes comparing the phase current to a calibrated threshold current corresponding to the sector, and executing a response when the absolute value is less than the threshold. A vehicle includes an energy storage device (ESD), a motor/generator configured as a permanent magnet synchronous motor, a voltage inverter, and a bus for conducting DC current from the ESD to the inverter. A controller detects an insufficient phase current, determines a current vector position of the three-phase AC, assigns a sector to the position, and executes a response when an absolute value of the phase current is less than a calibrated threshold.

Abstract: A method sustains auxiliary power generation aboard a mild hybrid electric vehicle (HEV) in response to a high-voltage (HV) electrical fault condition and executes one of a pair of default limp-home modes depending on the state of the engine at the time of the fault. Each limp-home mode sustains auxiliary power generation during the fault, and at least one mode charges capacitors in the HV bus circuit to provide magnetizing current to a motor generator unit (MGU). An HEV includes a controller and algorithm for sustaining auxiliary power generation during the above fault condition, with the algorithm adapted to control output of an auxiliary power module (APM) and execute one of a pair of default limp-home modes, including a mode in which the APM charges the capacitors to enable a power inverter module (PIM) to provide an initial excitation current to the MGU after the starter motor restarts the engine.

Abstract: A control system and method to determine position of a rotor relative to a stator for a synchronous multipole electrical machine is presented, including one for application on a fuel/electric hybrid powertrain for a vehicle. The machine includes a stator, a rotor, and a rotor position sensing mechanism. The control system controls the electrical machine, in conjunction with an electrical storage device and an inverter, using algorithms and calibrations which derive a rotor position based upon a sensorless position sensing technique, and determine an offset from a sensed rotor position. Electrical output from the inverter to the machine is controlled based the offset, which is stored non-volatile memory. A rotor position is derived based upon a sensorless position sensing technique during initial machine operation after startup of the machine, and includes operation in a torque-generative mode and in an electrical energy-generative mode.

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: A method for evaluating a permanent magnet motor, which includes a rotor with a plurality of magnets mounted thereon, and a stator with a plurality of windings in proximity to the rotor and coupled to an inverter, includes spinning the motor such that a voltage is induced in the windings of the stator and the inverter; measuring the voltage on the inverter; calculating the voltage constant from the motor from the measured voltage; comparing the voltage constant to accepted voltage constants; and identifying the motor as not acceptable if the voltage constant is outside of a range of the accepted voltage constants.

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 zero 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: 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 method sustains auxiliary power generation aboard a mild hybrid electric vehicle (HEV) in response to a high-voltage (HV) electrical fault condition and executes one of a pair of default limp-home modes depending on the state of the engine at the time of the fault. Each limp-home mode sustains auxiliary power generation during the fault, and at least one mode charges capacitors in the HV bus circuit to provide magnetizing current to a motor generator unit (MGU). An HEV includes a controller and algorithm for sustaining auxiliary power generation during the above fault condition, with the algorithm adapted to control output of an auxiliary power module (APM) and execute one of a pair of default limp-home modes, including a mode in which the APM charges the capacitors to enable a power inverter module (PIM) to provide an initial excitation current to the MGU after the starter motor restarts the engine.

Abstract: A method for evaluating a permanent magnet motor, which includes a rotor with a plurality of magnets mounted thereon, and a stator with a plurality of windings in proximity to the rotor and coupled to an inverter, includes spinning the motor such that a voltage is induced in the windings of the stator and the inverter; measuring the voltage on the inverter; calculating the voltage constant from the motor from the measured voltage; comparing the voltage constant to accepted voltage constants; and identifying the motor as not acceptable if the voltage constant is outside of a range of the accepted voltage constants.