Abstract: A torque security system for a vehicle is provided. The system receives a signal from a sensor coupled to a motor shaft of an electric motor and determines an acceleration of the electric motor, based on the signal from the sensor that indicates an amount of rotation of the motor shaft. The system determines an internal torque between the motor shaft and an input gear coupled to the motor shaft, based on the acceleration of the electric motor and an inertia of the electric motor and a gearbox. The powertrain of the vehicle comprises the gearbox and the electric motor, and the input gear couples the electric motor to the gearbox. The system determines whether the internal torque exceeds a threshold torque, and in response to determining that the internal torque exceeds the threshold torque, the system reduces power output to the electric motor. The system also diagnoses the health of the gearbox.

Abstract: Systems and methods for controlling a dual active bridge converter are disclosed herein. An output voltage of a dual active bridge converter is sensed. Based at least in part on the output voltage, a target intra-bridge phase shift amount between two bridges of the dual active bridge converter is computed. A plurality of switch control signals, which are provided to respective switches of the dual active bridge converter, are caused to switch according to a time-based switching sequence based on the target intra-bridge phase shift amount to compensate for variations in the output voltage.

Abstract: Systems and methods for estimating input current are provided, particularly when input currents are applied to an electric motor of a motor system. An Electric Control Unit (ECU), according to one implementation, is configured to control the motor system. The ECU is configured to store computer logic having instructions that, when executed, cause one or more processing devices to obtain a duty cycle parameter at an output of the ECU. The duty cycle parameter, for example, relates to control actions enforced on one or more switches of a power electronics circuit of the motor system. Based on the duty cycle parameter, the instructions further cause the one or more processing devices to estimate an input current provided to the electric motor of the motor system. A more accurate input current estimation may thereby be used to better estimate torque.

Abstract: Systems and methods for controlling a dual active bridge converter are disclosed herein. An output voltage of a dual active bridge converter is sensed. Based at least in part on the output voltage, a target intra-bridge phase shift amount between two bridges of the dual active bridge converter is computed. A plurality of switch control signals, which are provided to respective switches of the dual active bridge converter, are caused to switch according to a time-based switching sequence based on the target intra-bridge phase shift amount to compensate for variations in the output voltage.

Abstract: Various disclosed embodiments include illustrative controller modules, direct current (DC) fast charging devices, and methods. In an illustrative embodiment, a controller module for a DC-DC converter includes a controller and computer-readable media configured to store computer-executable instructions configured to cause the controller to: receive an input voltage, an output voltage, and a requested power value.

Abstract: An online method of detecting and compensating for errors in flux estimation in operation of a motor system. The method includes determining a voltage compensation term by comparing an expected voltage and an actual voltage. The method also includes determining a flux compensation term by passing the voltage compensation term through a low-pass filter, and determining a corrected flux component value by comparing the flux compensation term with a flux value obtained from a look-up table, wherein the low-pass filter receives operating parameters based on data regarding an operating environment of the motor system. The method then further determines a corrected torque value based on the corrected flux component value.

Abstract: A torque security system for a vehicle is provided. The system receives a signal from a sensor coupled to a motor shaft of an electric motor and determines an acceleration of the electric motor, based on the signal from the sensor that indicates an amount of rotation of the motor shaft. The system determines an internal torque between the motor shaft and an input gear coupled to the motor shaft, based on the acceleration of the electric motor and an inertia of the electric motor and a gearbox. The powertrain of the vehicle comprises the gearbox and the electric motor, and the input gear couples the electric motor to the gearbox. The system determines whether the internal torque exceeds a threshold torque, and in response to determining that the internal torque exceeds the threshold torque, the system reduces power output to the electric motor. The system also diagnoses the health of the gearbox.

Abstract: An online method of detecting and compensating for errors in flux estimation in operation of a motor system. The method includes determining a voltage compensation term by comparing an expected voltage and an actual voltage. The method also includes determining a flux compensation term by passing the voltage compensation term through a low-pass filter, and determining a corrected flux component value by comparing the flux compensation term with a flux value obtained from a look-up table, wherein the low-pass filter receives operating parameters based on data regarding an operating environment of the motor system. The method then further determines a corrected torque value based on the corrected flux component value.

Abstract: A method of controlling an electric vehicle, wherein the electric vehicle comprises an electric motor, a controller, and an inverter, wherein the controller receives a control signal with an instruction to operate the electric motor. In one embodiment, the method includes collecting an operational data set on a plurality of output signals of the inverter and a rotation angle of the electric motor. In one embodiment, the method includes computing a voltage change of the inverter and a magnetic flux of the electric motor based on a predetermined data set and the operational data set. In one embodiment, the method includes adjusting an output of the inverter to offset the voltage change and the magnetic flux, the output being provided to the electric motor to control the electric motor in accordance with the instruction.

Abstract: An online method of detecting and compensating for errors in flux estimation in operation of a motor system. The method includes determining a voltage compensation term by comparing an expected voltage and an actual voltage. The method also includes determining a flux compensation term by passing the voltage compensation term through a low-pass filter, and determining a corrected flux component value by comparing the flux compensation term with a flux value obtained from a look-up table, wherein the low-pass filter receives operating parameters based on data regarding an operating environment of the motor system. The method then further determines a corrected torque value based on the corrected flux component value.

Abstract: Systems and configurations for open phase detection of a motor in a vehicle by a current detection module having a logic gate configuration. In one embodiment, a detection unit coupled to a control unit includes a current detection module configured to measure at least one current value of each phase of the multi-phase electric motor the vehicle. The current detection module compares current values of each phase to at least one reference value to determine an open phase condition. Current values are compared by digital logic components of the current detection module, and the control unit is configured to control operation of the motor in response to the open phase condition. An open phase condition is detected based on at least one phase current having a near zero level and an unchanged current component for one phase.

Abstract: Systems and configurations for open phase detection of a motor in a vehicle by a current detection module having a logic gate configuration. In one embodiment, a detection unit coupled to a control unit includes a current detection module configured to measure at least one current value of each phase of the multi-phase electric motor the vehicle. The current detection module compares current values of each phase to at least one reference value to determine an open phase condition. Current values are compared by digital logic components of the current detection module, and the control unit is configured to control operation of the motor in response to the open phase condition. An open phase condition is detected based on at least one phase current having a near zero level and an unchanged current component for one phase.

Abstract: A method of controlling an electric vehicle, wherein the electric vehicle comprises an electric motor, a controller, and an inverter, wherein the controller receives a control signal with an instruction to operate the electric motor. In one embodiment, the method includes collecting an operational data set on a plurality of output signals of the inverter and a rotation angle of the electric motor. In one embodiment, the method includes computing a voltage change of the inverter and a magnetic flux of the electric motor based on a predetermined data set and the operational data set. In one embodiment, the method includes adjusting an output of the inverter to offset the voltage change and the magnetic flux, the output being provided to the electric motor to control the electric motor in accordance with the instruction.