Abstract: Integrated power conversion systems and methods for use in an electric vehicle having an electric motor, a primary high-voltage energy source, and an auxiliary energy source including a traction inverter module operable for converting a DC current generated by the high-voltage energy source into an AC current capable of powering the electric motor, and a DC/DC converter operable to step-down a voltage of the high-voltage energy source or step-up a voltage of the auxiliary energy source, wherein the traction inverter module and the DC/DC converter may share one or more common components, such as a common high-voltage DC bus capacitor, a common DC bus bar, and/or a common high-voltage transistor.

Abstract: A device and method of commutation control for an isolated boost converter provides a unique commutation logic to limit voltage spikes by utilizing switches on the secondary side to minimize a mismatch between current in the inductor and current in the leakage inductance of the transformer when commutation takes places. To minimize this mismatch, the current in the leakage inductance is preset at a certain level that approaches the current in the inductor prior to the commutation, thus significantly reducing the power rating for a clamp circuit and enabling use of a simple passive clamp circuit. In addition, through unique timing of the turn-on of the secondary switches, soft switching conditions are created that eliminate turn-on losses and the reverse recovery problems of free-wheeling diodes.

Abstract: Systems and methods for controlling and/or calculating the torque for a field oriented induction motor operating at a given stator frequency. The systems and methods include calculating the torque using a first algorithm when the motor is at or below a first predetermined stator frequency, a second algorithm when the motor is at or above a second predetermined stator frequency, and a third algorithm when the motor is between the first predetermined stator frequency and the second predetermined stator frequency.

Abstract: An electric machine in accordance with the invention includes a stator core having first and second ends and having windings therein with end turns of the windings protruding from the first and second ends of the stator core. A rotor is rotatably positioned within the stator core. A thermal conductor, such as non-laminated aluminum or aluminum alloy ring, is disposed between each stator core end-turn and the housing for conducting heat from the stator core end-turns to the housing, and the cavity between each end-turn and the thermal conductor is filled with a flexible potting material to minimize gap formation caused, for example, by thermal cycling of the engine components.

Abstract: Systems and methods for controlling and/or calculating the torque for a field oriented induction motor operating at a given stator frequency. The systems and methods include calculating the torque using a first algorithm when the motor is at or below a first predetermined stator frequency, a second algorithm when the motor is at or above a second predetermined stator frequency, and a third algorithm when the motor is between the first predetermined stator frequency and the second predetermined stator frequency.

Abstract: System and method for enhancing the torque output of a field oriented induction motor including a controller having a plurality of predetermined control parameters operable for processing input signals to generate output signals. The plurality of predetermined control parameters are dependent upon the nature of the input signals and the operational state of the motor. A sensor system is operable for communicating feedback signals related to the output signals and the operational state of the motor from the motor to the controller.

Abstract: Integrated power conversion systems and methods for use in an electric vehicle having an electric motor, a primary high-voltage energy source, and an auxiliary energy source including a traction inverter module operable for converting a DC current generated by the high-voltage energy source into an AC current capable of powering the electric motor, and a DC/DC converter operable to step-down a voltage of the high-voltage energy source or step-up a voltage of the auxiliary energy source, wherein the traction inverter module and the DC/DC converter may share one or more common components, such as a common high-voltage DC bus capacitor, a common DC bus bar, and/or a common high-voltage transistor.

Abstract: A device and method of commutation control for an isolated boost converter provides a unique commutation logic to limit voltage spikes by utilizing switches on the secondary side to minimize a mismatch between current in the inductor and current in the leakage inductance of the transformer when commutation takes places. To minimize this mismatch, the current in the leakage inductance is preset at a certain level that approaches the current in the inductor prior to the commutation, thus significantly reducing the power rating for a clamp circuit and enabling use of a simple passive clamp circuit. In addition, through unique timing of the turn-on of the secondary switches, soft switching conditions are created that eliminate turn-on losses and the reverse recovery problems of free-wheeling diodes.

Abstract: Field oriented induction motor system including a field oriented induction motor having an associated torque current and an associated flux current and a predetermined current ratio, wherein the predetermined current ratio is defined as the ratio of the torque current to the flux current, and wherein the predetermined current ratio is dependent upon the saturation state of the motor. A method for selecting the ratio of torque current to flux current for a field oriented induction motor including applying an allocation factor to the torque current and flux current, wherein the allocation factor is dependent upon the saturation state of the motor. The saturation state of the motor is determined based upon motor parameters.

Abstract: Field oriented induction motor system including a field oriented induction motor having an associated torque current and an associated flux current and a predetermined current ratio, wherein the predetermined current ratio is defined as the ratio of the torque current to the flux current, and wherein the predetermined current ratio is dependent upon the saturation state of the motor. A method for selecting the ratio of torque current to flux current for a field oriented induction motor including applying an allocation factor to the torque current and flux current, wherein the allocation factor is dependent upon the saturation state of the motor. The saturation state of the motor is determined based upon motor parameters.

Abstract: System and method for enhancing the torque output of a field oriented induction motor including a controller having a plurality of predetermined control parameters operable for processing input signals to generate output signals. The plurality of predetermined control parameters are dependent upon the nature of the input signals and the operational state of the motor. A sensor system is operable for communicating feedback signals related to the output signals and the operational state of the motor from the motor to the controller.

Abstract: A rotor 33, 133 for use in an electrical machine 100 having permanent magnets 34, 134 included therein, each permanent magnet 34, 134 between an adjacent pair of poles 32, 132, wherein each adjacent pole 32, 132 has an opposite polarity. Each permanent magnet 34, 134 has a magnetization polarity on its radially-outward surface 38, 138, and each adjacent permanent magnet 34, 134 has the opposite polarity on its radially-outward surface 38, 138. In addition, each pair of permanent magnets 34, 134 have the same magnetic polarity on their adjacently facing surfaces. This arrangement of permanent magnets 34, 134 may be used on electrical machines 100 having either a Lundell-type rotor 33 or salient pole rotor 133. The arrangement of permanent magnets 34, 134 increases the output power and efficiency of the electrical machine 100 while decreasing magnetic noise.

Abstract: An electric machine in accordance with the invention includes a stator core having first and second ends and having windings therein with end turns of the windings protruding from the first and second ends of the stator core. A rotor is rotatably positioned within the stator core. A thermal conductor, such as non-laminated aluminum or aluminum alloy ring, is disposed between each stator core end-turn and the housing for conducting heat from the stator core end-turns to the housing, and the cavity between each end-turn and the thermal conductor is filled with a flexible potting material to minimize gap formation caused, for example, by thermal cycling of the engine components.

Abstract: A hybrid electric vehicle contains a powerplant for propelling the vehicle. The powerplant comprises a combustion engine (6) and a dynamoelectric machine (8). A control system (10) issues a wheel torque command corresponding to torque desired at road-engaging wheels, and includes an engine controller (16) for issuing an engine torque command and a dynamoelectric machine controller (18) for issuing a dynamoelectric machine torque command. Controller (18) contains one or more maps and/or profiles defining functional relationship of torque to engine crankshaft speed and/or position over a range of crankshaft speeds and/or positions. The maps and/or profiles are used to develop make-up torque that is delivered by the dynamoelectric machine to accomplish certain smoothing functions. Transmission gear shifts can be smoothed by using the dynamoelectric machine controller to slew the engine to a new target speed appropriate to the new gear.

Abstract: A motor control system 16 for use within an electric vehicle 10 having an induction motor 12. Control system 16 utilizes a torque control module 18, a vector control module 20 and a space vector PWM module 22 to efficiently and accurately control the torque provided by motor 12.

Abstract: A rotor 33, 133 for use in an electrical machine 100 having permanent magnets 34, 134 included therein, each permanent magnet 34, 134 between an adjacent pair of poles 32, 132, wherein each adjacent pole 32, 132 has an opposite polarity. Each permanent magnet 34, 134 has a magnetization polarity on its radially-outward surface 38, 138, and each adjacent permanent magnet 34, 134 has the opposite polarity on its radially-outward surface 38, 138. In addition, each pair of permanent magnets 34, 134 have the same magnetic polarity on their adjacently facing surfaces. This arrangement of permanent magnets 34, 134 may be used on electrical machines 100 having either a Lundell-type rotor 33 or salient pole rotor 133. The arrangement of permanent magnets 34, 134 increases the output power and efficiency of the electrical machine 100 while decreasing magnetic noise.

Abstract: A rotor 33, 133 for use in an electrical machine 100 having permanent magnets 34, 134 included therein, each permanent magnet 34, 134 between an adjacent pair of poles 32, 132, wherein each adjacent pole 32, 132 has an opposite polarity. Each permanent magnet 34, 134 has a magnetization polarity on its radially-outward surface 38, 138, and each adjacent permanent magnet 34, 134 has the opposite polarity on its radially-outward surface 38, 138. In addition, each pair of permanent magnets 34, 134 have the same magnetic polarity on their adjacently facing surfaces. This arrangement of permanent magnets 34, 134 may be used on electrical machines 100 having either a Lundell-type rotor 33 or salient pole rotor 133. The arrangement of permanent magnets 34, 134 increases the output power and efficiency of the electrical machine 100 while decreasing magnetic noise.

Abstract: A method and system for increasing the output of an alternator for an automotive vehicle has a first three-phase winding (18) and a second three-phase winding (20) that are coupled to a respective first rectifier circuit (26) and a second rectifier circuit (28). A switch circuit (30) is located between the first rectifier circuit (26) and the second rectifier circuit (28). A controller (32) that is coupled to a speed sensor (34) and provides a signal indicative of the speed of the alternator, controls the operation of the switch circuit (30). When the speed sensor (34) indicates that the speed of the alternator is below a predetermined threshold, the first rectifier circuit (26) and second rectifier circuit (28) are coupled together through switch circuit (30). When the speed sensor (34) indicates that the speed of the alternator is above a predetermined speed, the switch circuit (32) is controlled to an open state so that two parallel half-wave rectifier circuits are formed.

Abstract: A rotor 33, 133 for use in an electrical machine 100 having permanent magnets 34, 134 included therein, each permanent magnet 34, 134 between an adjacent pair of poles 32, 132, wherein each adjacent pole 32, 132 has an opposite polarity. Each permanent magnet 34, 134 has a magnetization polarity on its radially-outward surface 38, 138, and each adjacent permanent magnet 34, 134 has the opposite polarity on its radially-outward surface 38, 138. In addition, each pair of permanent magnets 34, 134 have the same magnetic polarity on their adjacently facing surfaces. This arrangement of permanent magnets 34, 134 may be used on electrical machines 100 having either a Lundell-type rotor 33 or salient pole rotor 133. The arrangement of permanent magnets 34, 134 increases the output power and efficiency of the electrical machine 100 while decreasing magnetic noise.

Abstract: A "claw pole" or Lundell rotor has permanent magnets included therein, each permanent magnet disposed between an adjacent pair of pole fingers. The permanent magnets each have a magnetization polarity at an angle between radial and tangential with respect to the axis of rotation of the rotor.