Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Embodiments of the present disclosure relate to methods, systems and apparatus for adjusting current and/or torque commands used to control operation of an asynchronous machine based on rotor flux of the asynchronous machine.

Abstract: Embodiments of the present disclosure relate to methods, systems and apparatus for generating voltage commands used to control operation of a permanent magnet machine.

Abstract: Methods and systems for controlling an electric motor are provided. An estimated rotor flux angular position error is generated based on estimated back electromotive force (EMF) values, and based on the estimated rotor flux angular position error, an estimated rotor flux angular position, an estimated electrical synchronous frequency and/or an estimated rotor frequency can be generated.

Abstract: A method for monitoring an electric motor employing a pulse-type rotational position sensor includes monitoring a signal output from the pulse-type rotational position sensor and a reference signal associated with a control signal for the electric motor. A position of a rotor of the electric motor coincident with the reference signal is determined based upon a nominal rotor position, a nominal rotational speed of the rotor and a time between the reference signal and a falling edge of the signal output from the pulse-type rotational position sensor. The electric motor is controlled based upon the position of the rotor.

Abstract: A method of increasing a current sensing range for a vehicle or other polyphase motor system includes measuring phase currents delivered to a motor of the system. A controller calculates an absolute value of each phase current, compares each calculated absolute value to a saturation limit to determine whether only one sensor is saturated, and extrapolates a phase current value of the saturated sensor. The calculated temporary phase current is used as the extrapolated phase current value for the saturated sensor, and a control action is executed using the extrapolated phase current value only when the calculated temporary phase current value exceeds the measured value for the saturated sensor and a sign of the calculated temporary phase current value matches that of the measured value for the saturated sensor. A system includes the motor, a power inverter module, phase current sensors, and a controller which executes the method.

Abstract: Controlling a synchronous electric machine includes determining a rotor field current of a wound rotor of the synchronous electric machine and determining a time-rate change in field flux linkage. A rotor field voltage is determined based upon the time-rate change in the field flux linkage, and a rotor field resistance is determined based upon the rotor field voltage and the rotor field current. A rotor temperature is determined based upon the rotor field resistance. Operation of the synchronous electric machine is controlled responsive to a torque command and the rotor temperature.

Abstract: A method of increasing a current sensing range for a vehicle or other polyphase motor system includes measuring phase currents delivered to a motor of the system. A controller calculates an absolute value of each phase current, compares each calculated absolute value to a saturation limit to determine whether only one sensor is saturated, and extrapolates a phase current value of the saturated sensor. The calculated temporary phase current is used as the extrapolated phase current value for the saturated sensor, and a control action is executed using the extrapolated phase current value only when the calculated temporary phase current value exceeds the measured value for the saturated sensor and a sign of the calculated temporary phase current value matches that of the measured value for the saturated sensor. A system includes the motor, a power inverter module, phase current sensors, and a controller which executes the method.

Abstract: A method for monitoring an electric motor employing a pulse-type rotational position sensor includes monitoring a signal output from the pulse-type rotational position sensor and a reference signal associated with a control signal for the electric motor. A position of a rotor of the electric motor coincident with the reference signal is determined based upon a nominal rotor position, a nominal rotational speed of the rotor and a time between the reference signal and a falling edge of the signal output from the pulse-type rotational position sensor. The electric motor is controlled based upon the position of the rotor.

Abstract: A powertrain system includes a torque machine rotatably coupled to an internal combustion engine via a pulley mechanism. The torque machine and the internal combustion engine are configured to transfer torque to a driveline and include a first sensor configured to monitor rotation of the engine and a second sensor configured to monitor rotation of the torque machine. The first sensor signally connects to a controller configured to control operation of the torque machine. A method for operating the powertrain system includes employing a signal output from the first sensor to monitor rotation of the torque machine to control operation thereof, said signal output from the first sensor adjusted for a pulley ratio of the pulley mechanism upon detecting a fault associated with the second sensor.

Abstract: Controlling a synchronous electric machine includes determining a rotor field current of a wound rotor of the synchronous electric machine and determining a time-rate change in field flux linkage. A rotor field voltage is determined based upon the time-rate change in the field flux linkage, and a rotor field resistance is determined based upon the rotor field voltage and the rotor field current. A rotor temperature is determined based upon the rotor field resistance. Operation of the synchronous electric machine is controlled responsive to a torque command and the rotor temperature.

Abstract: An electric machine electrically connects to an inverter via a multi-phase power circuit. A method for monitoring the multi-phase power circuit includes non-intrusively adjusting a commanded AC electric current from the inverter after a prescribed time period and comparing a measured magnitude of AC electric current in the multi-phase power circuit with a minimum threshold. Presence of an open circuit fault in the multi-phase power circuit can be detected based upon the comparison.

Abstract: A powertrain system includes an internal combustion engine, a first electric machine and an electro-mechanical transmission operative to transmit torque to a driveline. A method for controlling the powertrain system in the presence of a controlled neutral operation of the electro-mechanical transmission being selected includes monitoring vehicle speed, and only when the monitored vehicle speed is indicative of a low-speed zone restricting a transition from a current engine operating state.

Abstract: Methods, system and apparatus are provided for reducing power loss in an electric motor drive system that includes an electric machine and an inverter module. A controller determines whether a torque command (Tcmd) is less than a minimum torque threshold (Tmin) that is required to disable the inverter module, and if so, increments a counter and determines whether the torque command (Tcmd) remains less than the minimum torque threshold (Tmin). When the torque command (Tcmd) remains less than the minimum torque threshold (Tmin), the controller checks to determine whether a current count value (n) maintained at the counter is greater than a count threshold (nth), and if so, the controller can generate a disable signal to disable switching within the inverter module.

Abstract: Methods and systems are provided for assessing a vehicle transmission having a resolver. A memory is configured to store preliminary data pertaining to an error of the resolver. A processor is coupled to the memory, and is configured to determine a harmonic characteristic of the preliminary data, and to assess the vehicle transmission using the harmonic characteristic.

Abstract: A powertrain system includes an internal combustion engine, a first electric machine and an electro-mechanical transmission operative to transmit torque to a driveline. A method for controlling the powertrain system in the presence of a controlled neutral operation of the electro-mechanical transmission being selected includes monitoring vehicle speed, and only when the monitored vehicle speed is indicative of a low-speed zone restricting a transition from a current engine operating state.

Abstract: Methods, systems and apparatus are provided for estimating electrical angular speed of a permanent magnet machine based on two-phase stationary reference frame feedback stator current samples, and a dimensionless gain (K) that is computed based on a sampling time (T) and machine parameters.

Abstract: Embodiments of the present disclosure relate to methods, systems and apparatus for adjusting current and/or torque commands used to control operation of an asynchronous machine based on rotor flux of the asynchronous machine.

Abstract: Embodiments of the present disclosure relate to methods, systems and apparatus for generating voltage commands used to control operation of a permanent magnet machine.

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.