Abstract: An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. Application of the voltage vector determined by the primary loop is delayed until initiation of the next primary control loop cycle. The secondary loop, utilizing a faster sampling rate than that of the primary loop, compares the measured phase current to a preset current limit. If the secondary loop determines that the measured phase current has exceeded the preset current limit, it sets a null voltage vector, thereby limiting transient over currents.

Abstract: An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. The secondary loop, utilizing a faster sampling rate than the primary loop, estimates a more up-to-date torque error which is compared to a secondary torque error band, where the secondary torque error band is preferably narrower that the primary torque error band. If the secondary loop determines that the up-to-date torque error has exceeded the secondary torque error band, it sets a null voltage vector, thereby limiting torque ripples.

Abstract: A method is provided for fabricating a rotor assembly for an electric motor which utilizes pre-fabricated conductive rotor bars and die cast end rings. Containment rings, which may be installed on the end rings either before or after casting, may be used to inhibit end ring creep at high rotational speeds.

Abstract: A motor assembly with an integrated cooling system is provided in which a coolant (e.g., oil) is injected into a hollow region of the rotor shaft. The coolant is expelled out of the rotor shaft and into the motor enclosure via multiple thru-holes, thereby allowing efficient cooling of both the stator and the rotor assemblies.

Abstract: A motor assembly with an integrated cooling system is provided in which a coolant (e.g., oil) is injected into a hollow region of the rotor shaft. The coolant is expelled out of the rotor shaft and into the motor enclosure via multiple thru-holes, thereby allowing efficient cooling of both the stator and the rotor assemblies.

Abstract: An induction motor controller is provided. The induction motor controller includes a first module that derives a commanded stator voltage vector, in a stator flux reference frame, via a rotor flux regulator loop and a torque regulator loop, which process at least partially in the stator flux reference frame. The induction motor controller includes a second module that processes the commanded stator voltage vector to produce AC (alternating current) power for an induction motor.

Abstract: A power device temperature monitor is provided. The power device temperature monitor includes a power device having a control terminal and an output terminal, where the output terminal is configured to output a current as directed by a voltage of the control terminal. The power device temperature monitor includes an inductor coupled to the output terminal of the power device and an amplifier coupled to the inductor. The power device temperature monitor includes a computing device that receives an output of the amplifier, the computing device is configured to derive a temperature of the power device based upon the output of the amplifier.

Abstract: An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. Application of the voltage vector determined by the primary loop is delayed until initiation of the next primary control loop cycle. The secondary loop, utilizing a faster sampling rate than that of the primary loop, compares the measured phase current to a preset current limit. If the secondary loop determines that the measured phase current has exceeded the preset current limit, it sets a null voltage vector, thereby limiting transient over currents.

Abstract: An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. The voltage vector determined by the primary loop is selected and applied immediately upon completion of the corresponding primary control loop computational cycle. The secondary loop, utilizing a faster sampling rate than that of the primary loop, compares the measured phase current to a preset current limit. If the secondary loop determines that the measured phase current has exceeded the preset current limit, it sets a null voltage vector, thereby limiting transient over currents.

Abstract: An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. The secondary loop, utilizing a faster sampling rate than the primary loop, estimates a more up-to-date torque error which is compared to a secondary torque error band, where the secondary torque error band is preferably narrower that the primary torque error band. If the secondary loop determines that the up-to-date torque error has exceeded the secondary torque error band, it sets a null voltage vector, thereby limiting torque ripples.

Abstract: Electric vehicles and, more particularly, a control system for an all-wheel drive electric vehicle.

Abstract: A power device temperature monitor is provided. The power device temperature monitor includes a power device having a control terminal and an output terminal, where the output terminal is configured to output a current as directed by a voltage of the control terminal. The power device temperature monitor includes an inductor coupled to the output terminal of the power device and an amplifier coupled to the inductor. The power device temperature monitor includes a computing device that receives an output of the amplifier, the computing device is configured to derive a temperature of the power device based upon the output of the amplifier.

Abstract: Electric vehicles and, more particularly, a control system for an all-wheel drive electric vehicle.

Abstract: An induction motor controller is provided. The induction motor controller includes a first module that derives a commanded stator voltage vector, in a rotor flux reference frame, via a rotor flux regulator loop and a torque regulator loop, which process at least partially in the rotor flux reference frame. The induction motor controller includes a second module that processes the commanded stator voltage vector to produce AC (alternating current) power for an induction motor.

Abstract: A vehicle torque safety monitor is provided. The safety monitor includes a vehicle power estimator configured to estimate a first mechanical power of a first electric motor and a second mechanical power of a second electric motor. The safety monitor includes an energy storage system power estimator and limiter, configured to estimate electrical power provided by an energy storage system, at least a portion of the electrical power converting to the first mechanical power and the second mechanical power. The system includes a vehicle power monitor, configured to indicate an inconsistency in the first mechanical power, the second mechanical power, and the electrical power.

Abstract: A safety system for an electric motor controller is provided. The safety system includes a torque safety monitor having a first processor distinct from a second processor of a main motor controller. The first processor is configured to one of decrease or shut down AC (alternating current) power, sent from a DC/AC (direct current to alternating current) inverter to an electric motor, in response to an estimated torque of the electric motor differing from a commanded torque associated with the main motor controller by more than a set amount.

Abstract: An induction motor controller is provided. The induction motor controller includes a first module that derives a commanded stator voltage vector, in a stator flux reference frame, via a rotor flux regulator loop and a torque regulator loop, which process at least partially in the stator flux reference frame. The induction motor controller includes a second module that processes the commanded stator voltage vector to produce AC (alternating current) power for an induction motor.

Abstract: A rotor flux estimator is provided. The rotor flux estimator includes an estimation module that generates a first rotor flux vector expressed in a phase voltage reference frame and a second rotor flux vector expressed in the phase voltage reference frame, from a stator voltage vector expressed in a phase voltage reference frame, a rotational speed of a rotor, and a stator current vector expressed in the phase voltage reference frame. The estimation module includes at least one processor and the estimation module includes a rotor flux current model and a rotor flux voltage model.

Abstract: A power drive apparatus is provided. The apparatus includes a first switch having a first plurality of power devices arranged in a back to back configuration within adjacent stacked rows of the first switch. The apparatus includes a second switch having a second plurality of power devices arranged in a back to back configuration within adjacent stacked rows of the second switch. A bus is shared with the first switch and the second switch. The apparatus includes a control drive device coupled to a gate of each power device of the first plurality of power devices and each power device of the second plurality of power devices.

Abstract: A heat sink is provided. The heat sink includes a single-piece housing having a floor and two walls, the walls perpendicular to the floor and the walls are parallel to each other. The heat sink includes the housing having an inlet and an outlet. The housing is configured to attach power modules to an outer surface of the floor and to outer surfaces of the two walls. The housing is configured to cool the power modules in response to fluid flow into the inlet.