Borgwarner Inc.

Caleb Wayne Secrest

Siddharth Ballal

Hassan H Eldeeb

Dwarakanath V Simili

Ujjwal Kumar

James R Smith

Vignesh Namasivayam

Ronald J Krefta

Chikezie M Emeghara

Yang Sun

James Smith

A method of operating a power inverter for an electric machine includes selecting an inverter switching technique; determining a frequency range for inverter switching; determining a direct current (DC) voltage range for inverter switching; determining an optimal switching map including an inverter switching technique and frequency selection for each value of torque-speed on a torque-speed curve; and controlling switches included in the power inverter using the optimal switching map.

Optimization of switching frequency and pulse width modulation technique for traction power inverters

A control system configured to control an electric motor of an electric vehicle (EV) includes a current sensor offset detector that determines an offset of one or more current sensors; a gain compensator that determines a second order harmonic component in d- and q-axis currents due to gain errors in one or more sensors; and a controller that generates a control signal that compensates for the offset or gain error mismatch of the current sensor(s).

Control system for compensating for current sensor offset/gain errors

A control system for generating a torque command for an electric motor carried by an electric vehicle (EV) including a motion observer configured to receive an angular position of an output shaft of the electric motor and an ideal torque command and output an estimated disturbance torque value; and a controller configured to receive the estimated disturbance torque value as well as output a harmonic disturbance torque value.

Control system for regulating harmonic torque disturbances in an electric vehicle

A method of controlling a motor controlled by a motor controller that includes a complex vector flux regulator (CVλR). The method includes: receiving at a field weakening regulator of the motor controller a modulation index that is a scaled version of an available voltage available to be provided to the motor by a voltage source; comparing the modulation index to a feedback modulation index to produce an error scalar that has a magnitude in a flux domain; determining a final direction (α) of the error scalar in the flux domain; and providing the CVλR with flux commands in the d and q domain based on the error scalar and the direction.

Field weakening regulator for CVFR current regulator

A control system configured to control a rotating electrical machine of a battery electric vehicle (BEV), having one or more microprocessors that execute a low-efficiency mode of operation for the BEV, such that the low-efficiency mode of operation includes determining a high-efficiency mode current command corresponding to operation at a determined physical rotor angular velocity of a rotor of the rotating electrical machine at a commanded torque value, and increasing current supplied to the rotating electrical machine to a level corresponding to operation at an angular velocity higher than the determined physical angular velocity of the rotor at the commanded torque value.

Operating an electric drive system with low efficiency

A method of evaluating current sensor measurements of an electric machine system includes acquiring a first current signal corresponding to a first measurement of a first phase current of a three phase electric current supply to an electric machine, and acquiring a second current signal corresponding to a second measurement of a second phase current of the three phase electric current supply. The method also includes determining a machine velocity, shifting the first current signal by a signal processing component to generate a shifted first current signal having a shifted phase, the signal processing component including a tuning parameter that is a function of the machine velocity, calculating an amplitude difference between the shifted first current signal and the second current signal, and determining a plausibility of the first measurement and the second measurement based on the difference.

Determination of diagnostic plausibility of phase current measurements

A method is provided for producing a smooth transition between overmodulation and six-step operation of a SVPWM-controlled 3-phase electric machine. In one aspect, the method predicts the PWM sample for which the control voltage vector will cross the middle of each SVPWM hexagon sector. Then, based on the current voltage angle and duty cycle, as well as on an estimated future voltage angle and duty cycle, an average duty cycle is calculated and inserted. In addition, a PWM carrier waveform is selected to ensure the PWM pulses applied to each period result in continuous switching states.

Smooth transition control between overmodulation and six step pulse width modulation

Examples described herein provide a rotary system that includes a rotor having an axis of rotation, a position sensor to measure an angular position of the rotor with respect to the axis of rotation, and a processing system to perform operations. The operations include receiving an output from the position sensor, the output being a measure of an angular position of the rotor with respect to the axis of rotation. The operations further include generating, based on the output from the position sensor, an error signal, an estimated angular velocity, and an estimated position. The operations further include performing a position sensor harmonic adaptation based at least in part on the error signal, the estimated angular velocity, and the estimated position to generate adaptation coefficients. The operations further include performing a position sensor harmonic compensation based on the adaptation coefficients and the estimated position to generate a difference in position.

Compensation for multiple non-ideal position sensor harmonic components in a rotary system

A control system and method of controlling a multi-phase electric machine for controlling the flow of electrical current between a voltage source and the multi-phase electric machine or other application/load. The control system includes, between each phase of the multi-phase electric machine and the voltage source: a high side diode and a high side switch positioned in parallel between a positive terminal of the voltage source and the electric machine with the high side diode being reverse biased with regard to the positive terminal; and a low side diode and a low side switch positioned in parallel between a negative terminal of the voltage source and the electric machine with the low side diode being reverse biased with regard to the electric machine. The control system operates the high side and low side switches to provide efficient operation of the electric machine.

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Noblesville, IN, United States of America

Caleb Wayne Secrest