Abstract: A temperature estimation controller and methods are provided for controlling a torque command to prevent overheating of one or more of a plurality of phases of a permanent magnet motor. The temperature estimation controller includes a low speed temperature estimation module, a transition module and a temperature dependent torque command derater block. The low speed temperature estimation module determines a stator temperature of each of a plurality of phases of the permanent magnet motor in response to first thermal impedances measured for each of the plurality of phases with respect to a thermal neutral. The transition module is coupled to the low speed temperature estimation module and outputs the stator temperature of each of a plurality of phases of the permanent magnet motor as determined by the low speed temperature estimation module when a detected speed of the permanent magnet motor is less than a first predetermined speed.

Abstract: In various embodiments, a phase current sampling apparatus (300, 600, FIGS. 3, 6), an electric motor drive system (100, FIG. 1), and a motor vehicle (1200, FIG. 12) include switching circuitry adapted to receive first and second phase current waveforms. The switching circuitry provides the first phase current waveform during at least two offset sampling instants, and provides the second phase current waveform during a reference sampling instant. An analog-to-digital converter is adapted to sample the first phase current waveform at the offset sampling instants, and to sample the second phase current waveform at the reference sampling instant. An embodiment of a method for regulating phase current waveforms includes an analog-to-digital converter generating samples of a first phase current waveform at sampling instants that occur before and after a reference sampling instant, and generating a sample of a second phase current waveform at the reference sampling instant.

Abstract: In a motor controller, a modified interpolation technique uses an extrapolated torque command for the upper table to improve torque linearity under certain conditions. When the torque command input is greater than the max torque limit of a first look-up table, but less than the maximum torque limit of a second, adjacent look-up table, the desired current command is computed by interpolating between the maximum torque limit of the first table and a revised torque value for the second look-up table, wherein the revised torque value is determined by extrapolating from the maximum torque limit of the first look-up table through a torque value based on the torque command input.

Abstract: In an embodiment of a method, the method includes measuring currents and voltages that are coupled to a motor that includes an internal permanent magnet and determining a reactive power in response to the measured currents and voltages. The method further includes estimating a first flux orthogonal to an axis of the internal permanent motor and estimating a second flux aligned with the axis of the internal permanent motor. Additionally, the method includes estimating a torque in response to the measured currents and the first and second fluxes.

Abstract: A method of operating an isolated bi-directional dc/dc converter to provide voltage regulation at a no-load condition over a wide voltage range and also provide overshoot protection for the boost mode main switching transistors uses new boost mode drive waveforms. The new waveforms drive switches S2 and S4 to be turned off during boost mode and only S1 and S3 are switched to provide reverse energy flow at no-load. In boost mode, C1 and C2 provide overshoot protection caused by leakage inductance of the isolation transformer when boost mode drive transistors turn off during forward energy flow and provide stored energy for reverse energy flow during reverse energy flow periods used for voltage regulation in the boost mode. In buck mode, C1 and C2 provide soft switching for buck mode main switching transistors S2 and S4.

Abstract: Methods and systems are provided for reducing torque ripple in an electric motor. A method comprises receiving a torque command and determining a cancellation current command based on the torque command. The method further comprises generating a harmonic cancellation command based on the cancellation current command, wherein the harmonic cancellation command compensates for a phase shift and an attenuation introduced by a current regulated control module coupled to an inverter coupled to the electric motor. The method further comprises providing the harmonic cancellation command to the current regulated control module, wherein the current regulated control module is configured to control the inverter in response to the harmonic cancellation command and the torque command.

Abstract: Apparatus, systems, and methods are provided for reducing voltage source inverter losses. One apparatus includes a sensor couplable to the motor and configured to sense an operating frequency of the motor and an amount of torque produced by the motor. The apparatus also includes a controller coupled to the sensor, the controller configured to determine a zero vector modulation (ZVM) based on the sensed frequency and torque. A system includes means for sensing a threshold output frequency of the motor and means for sensing a threshold torque of the motor. The system also includes means for determining a ZVM for the inverter based on the sensed threshold frequency and threshold torque. One method includes sensing that a motor is operating below a threshold frequency and is producing torque above a threshold torque amount. The method also includes determining a ZVM for the inverter based on the sensed frequency and torque.

Abstract: Methods and apparatus are provided for aligning a control reference axis with a magnetic north of a permanent magnet motor. The method includes the steps of injecting a predetermined stator current on an estimated reference axis of the permanent magnet motor and introducing predetermined error on the estimated reference axis. The method further includes the steps of determining if a speed of the permanent magnet motor is greater than a predetermined threshold speed and setting the control reference axis to 180° added to the estimated reference axis if the speed of the permanent magnet motor is greater than the predetermined threshold speed or setting the control reference axis to the estimated reference axis if the speed of the permanent magnet motor is less than or equal to the predetermined threshold speed.

Abstract: A method and system for operating an automotive electric motor having first and second components is provided. A desired frequency of vibration for the electric motor is selected. A current is caused to flow through at least one of the first and second components such that the second component moves relative to the first component. The current is modulated such that the motor vibrates at the desired frequency.

Abstract: Method and system are provided for controlling an alternating current (AC) motor via an inverter. The method includes selecting a pulse sequencing method based on a modulation index of the inverter, and providing a voltage to the AC motor based on the pulse sequencing method. The system includes an inverter having a modulation index (Mi) and a controller coupled to the inverter. The controller selects a pulse sequencing method based on Mi and produces a signal based on the pulse sequencing method. The inverter includes a switch network producing a voltage in response to the signal, and the voltage drives the AC motor.

Abstract: Methods and systems for controlling a power inverter in an electric drive system of an automobile are provided. The various embodiments control the power inverter by, responsive to either a commanded torque of the electric motor being above a first torque level, or a commanded speed of the electric motor being above a first speed level, controlling the power inverter with a discontinuous pulse width modulated (DPWM) signal to generate a modulated voltage waveform for driving the electric motor. Additionally, the embodiments control the power inverter by, responsive to both a commanded torque of the electric motor being below the first torque level, and a commanded speed of the electric motor being below the first speed level, controlling the power inverter with a continuous pulse width modulated (CPWM) signal to generate the modulated voltage waveform for driving the electric motor.

Abstract: Methods and systems are provided for controlling an electric machine via an inverter while compensating for one or more hardware delays. The method includes receiving a control signal, producing a first sampling signal based on the control signal, and adjusting the sampling signal to compensate for a first delay of the one or more hardware delays. The inverter is operable to produce a voltage signal based on the control signal, and the electric machine is operable to produce a current based on the voltage signal. A sampling of the current is performed based on the first sampling signal.

Abstract: A method and system for operating a motor are provided. Power is provided to the motor through at least one switch operating at a first switching frequency. A pulse ratio of the motor is calculated based on the first switching frequency. The at least one switch is operated at a second switching frequency if the calculated pulse ratio is less than a first pulse ratio value and greater than a second pulse ratio value.

Abstract: Methods and systems are provided for aligning a resolver in an electric motor system. The method includes commanding a d-axis current command and a speed command, operating an electric motor without a load in response to the d-axis current command and the speed command, determining a rotor speed in response to the speed command, and determining an offset of the resolver based on the speed command and the rotor speed when the rotor speed has substantially stabilized.

Abstract: Methods and systems for controlling a power inverter in an electric drive system of an automobile are provided. The various embodiments control the power inverter by, responsive to a commanded torque of the electric motor being below a first torque level, controlling the power inverter to set a switching frequency of the power inverter at a first set frequency; and, responsive to the commanded torque of the electric motor being between the first torque level and a second torque level, controlling the power inverter to determine the switching frequency of the power inverter as a function of the commanded torque of the electric motor while maintaining the switching frequency above a dynamic frequency limit. The method reduces switching frequencies in the inverter at high commanded torques, while maintaining the switching frequencies above dynamic frequency limit that provides effective control over the motor.

Abstract: A control architecture for an electrical inverter includes a command limiter that is realized as a circular voltage limiter. The command limiter includes a Cartesian-to-polar converter coupled to a command source such as a synchronous frame current regulator. The Cartesian-to-polar converter provides magnitude and phase components for d-q command voltages. The command limiter further includes a magnitude limiter that limits the magnitude component to the maximum fundamental voltage component of the inverter, and a polar-to-Cartesian converter that converts the limited magnitude component and the phase component into modified d-q command voltages.

Abstract: Methods and systems are provided for controlling permanent magnet machines under varying loads. The method comprises generating a d-axis voltage command and a q-axis voltage command, producing a modified d-axis current command based on the q-axis voltage command and a d-axis current command, converting the modified d-axis current command to a modified d-axis voltage command, and transmitting the modified d-axis voltage command and the q-axis voltage command to the PM machine. The d-axis voltage command is based on a d-axis current command.

Abstract: Methods and systems are provided for reducing torque ripple in an electric motor. A method comprises receiving a torque command and determining a cancellation current command based on the torque command. The method further comprises generating a harmonic cancellation command based on the cancellation current command, wherein the harmonic cancellation command compensates for a phase shift and an attenuation introduced by a current regulated control module coupled to an inverter coupled to the electric motor. The method further comprises providing the harmonic cancellation command to the current regulated control module, wherein the current regulated control module is configured to control the inverter in response to the harmonic cancellation command and the torque command.

Abstract: Methods and apparatus are provided for reducing torque ripple in a permanent magnet motor system comprising a permanent magnet motor coupled to an inverter. The method comprises the steps of receiving a torque command, generating a torque ripple reduction signal in response to the torque command, modifying operational control signals in response to the torque ripple reduction signal to generate reduced ripple operational control signals, and providing the reduced ripple operational control signals to the inverter for control of the permanent magnet motor.

Abstract: Methods and systems are provided for controlling permanent magnet machines. The method includes determining a maximum torque of the PM machine based on an error between a commanded d-axis flux and an estimated d-axis flux of the PM machine, and adjusting a torque command based on the maximum torque. The error associated with a variation between a current temperature and a nominal temperature of the PM machine.