Gm Global Technolgoy Operations, Inc.

Seoul National University

Daniel J Berry

Anno Yoo

Paul F Turnbull

Chia-Chou Yeh

Brian A Welchko

Young J Kim

Steven E Schulz

Young Joo Lee

Dylan M Day

Peter James Savagian

Wei D Wang

Bon Ho Bae

Min-Joong Kim

Brent S Gagas

Seung Ki Sul

Steven Lee Hayslett

Harry J Bauer

Brian J Gallert

Kerrie M Spaven

Wesley G Zanardelli

Jinming Liu

Hyun-Sam Jung

Pankaj Mithal

Milan Ashok Vadera

George D Dolan

Melissa R McNeely

Debanjan Deep

Jeffrey W Yambor

A system for controlling operation of a vehicle having a power inverter module includes an alternating current (AC) power bus coupled to the power inverter module. The AC power bus has a plurality of busbars for conducting an AC current having multiple phases. The AC power bus is coupled to a stator in an electric motor configured to generate torque to propel the vehicle. A controller is adapted to determine an estimated temperature of the AC power bus for the multiple phases based on a plurality of factors. The plurality of factors includes an oil flow rate of a motor oil and a coolant flow rate of an inverter coolant that are in respective direct or indirect thermal contact with the plurality of busbars. The controller is adapted to control operation of the vehicle based in part on a highest one of the estimated temperature of the multiple phases.

System and method for temperature estimation of inverter AC power bus

A system includes a battery configured for providing electrical energy in direct current and a drive unit configured for utilizing electrical energy in alternating current to provide an output torque. The system includes a power inverter configured for receiving the electrical energy in direct current, transforming the electrical energy to alternating current, and providing the electrical energy in alternating current to the drive unit. The power inverter includes a direct current bus bar. The system includes a computerized controller. The controller monitors an environmental temperature of the inverter and monitors a current flow of the electrical energy received by the inverter. The controller determines an estimated temperature of the bus bar based upon the environmental temperature and the current flow and determining an inverter percent available capability based upon the estimated temperature. The controller compares the capability to a threshold value and controls the drive unit based upon the comparing.

System and method estimating temperature of a direct current bus bar and direct current connector in a power inverter and providing control based upon the temperature

A method, apparatus, and control system are described for operating a multiphase motor drive system including a rotary electric machine and an inverter. An AC choke filter is arranged proximal to output leads from the inverter. A reference temperature associated with the AC choke filter is determined along with an operating point of the electric machine. Operation of the inverter is controlled based upon a temperature of the AC choke filter, the reference temperature, and an operating point of the electric machine. This includes modifying a switching frequency and a PWM type in a manner that reduces the AC choke filter temperature by reducing the occurrence of switching events to protect the AC choke filter based on temperature feedback.

Method and system for controlling common mode electric current in an electric machine

A vehicle is described that includes a multi-mode powertrain system having a first drive unit and a second drive unit. A controller is arranged to monitor the high-voltage DC power bus and is in communication with and operatively connected to first and second inverters. The controller is able to detect operation of one of the first inverter or the second inverter in an uncontrolled generating (UCG) mode, determine a driveline torque associated with the operating of the one of the first inverter or the second inverter in the UCG mode, and determine a compensating torque that is needed to counteract the driveline torque associated with the operating of the one of the first inverter or the second inverter in the UCG mode. The controller can further operate to detect a fault that may induce unintended lateral motion (ULM), and control torque outputs of the inverters based thereon.

Method and apparatus for controlling a multi-mode powertrain system of a vehicle

A method for estimating a magnet temperature of a rotor magnet within a rotary electric machine includes, while a rotor of the electric machine is stationary, injecting a high-frequency voltage component onto a control voltage of the electric machine, via a controller, to generate an adjusted voltage command, and extracting a high-frequency component of a resulting current as an extracted high-frequency component. The method also includes calculating an inductance value of the electric machine using the extracted high-frequency component of the resulting current. The magnet temperature is estimated using the calculated inductance value and an angular position of the rotor. The method includes controlling an operation of the electric machine using the estimated magnet temperature. An electric powertrain uses the electric machine and controller noted above.

Inductance-based estimation of rotor magnet temperature

A method, system, and apparatus for controlling and regulating operation of a permanent magnet rotary electric machine including a stator and a rotor includes determining a first reactive power term associated with the electric machine based upon voltage, and determining a second reactive power term associated with the electric machine based upon flux. A first motor temperature associated with the electric machine is determined based upon the first and second reactive power terms, and power output from the permanent magnet electric machine is controlled based upon the first motor temperature.

Method and apparatus for controlling operation of a permanent magnet rotary electric machine

A resolver disposed to monitor a rotatable member is described, along with an associated method for evaluating an output signal therefrom. The method for monitoring the resolver includes supplying an excitation signal to the resolver, and monitoring, at an oversampling rate, first and second output signals from the resolver. An oversampling routine is executed to determine averages of the first and second output signals from the resolver. A demodulation angle error is determined based upon the first and second output signals from the resolver, and provided as feedback. A position of the resolver is also determined based upon the first and second output signals from the resolver.

Method and apparatus for monitoring a resolver

A torque system includes a DC power device, a polyphase electric machine, a contactor pair, a power inverter module (PIM), and a controller. The PIM connects to the power device via the contactor pair and directly connects to the electric machine. The controller executes a method to control a fault response under a fault condition resulting in opening of the contactor pair and a polyphase short condition. The controller calculates a back EMF of the electric machine and transmits switching control signals to semiconductor switches of the PIM to transition from the polyphase short condition to a polyphase open condition only when the calculated back EMF is less than a calibrated value and a voltage rise on a DC side of the PIM is less than a calibrated voltage rise. A vehicle includes the DC power device, road wheels, electric machine, PIM, and controller.

Fault shutdown control of an electric machine in a vehicle or other DC-powered torque system

A method of exchanging data in a real-time operating system, between a primary core and a secondary core in a multi-core processor, includes executing a primary path via the primary core and executing a secondary path via the secondary core. The primary path is configured to be a relatively faster processing task and the secondary path is configured to be a relatively slower processing task. The method includes devising a freeze in process flag to have a respective flag status set and cleared by the primary path. The method includes devising a data frozen flag to have a respective flag status set and cleared by both the primary and the secondary paths. A component that is operatively connected to the multi-core processor may be controlled based at least partially on a difference between primary and secondary sets of calculations executed by the primary and secondary cores, respectively.

Control of data exchange between a primary core and a secondary core using a freeze process flag and a data frozen flag in real-time

A method for dynamically monitoring temperature of a fluid at a heat generating device includes monitoring, using a temperature sensor, temperature of the fluid held in a fluidic sump. A first fluidic flow rate and a second fluidic flow rate are determined. A third fluidic flow rate and a temperature drop of the fluid across the heat exchanger in the active coolant circuit are determined based upon the temperature of the fluid and the third fluidic flow rate through the active coolant circuit. A fluid temperature supplied to the electric machine through the active coolant circuit is determined based upon the third fluidic flow rate and the temperature drop of the fluid across the heat exchanger. An effective temperature of the fluid is determined based upon the temperature of the fluid in the sump and the temperature of the fluid supplied to the electric machine through the active coolant circuit.

Method and apparatus to determine an effective temperature of coolant fluid for a heat generating device

An electric motor powers a fluidic pump fluidly connected to a hydraulic circuit. Operating the electric motor includes determining a heat transfer coefficient for the electric motor based upon a temperature of hydraulic fluid in the hydraulic circuit. A temperature of the electric motor is determined based upon the heat transfer coefficient. Operation of the electric motor is controlled based upon the temperature of the electric motor.

Method and apparatus for controlling an electric motor employed to power a fluidic pump

A method for operating an electric machine of a ground vehicle includes periodically determining an aging parameter based upon a temperature of the electric machine and periodically determining a short-term aging effect based upon the periodically determined aging parameter. A long-term aging effect is determined based upon the short-term aging effect. A short-term temperature adjustment is determined based upon the short-term aging effect and a long-term temperature adjustment is determined based upon the long-term aging effect. A temperature-based derated motor torque is determined based upon the long-term temperature adjustment and the short-term temperature adjustment. Operation of the electric machine is controlled responsive to an operator command for torque based upon the temperature-based derated motor torque.

Method and apparatus for controlling an electric machine

Methods and systems are provided for determining a temperature of a motor of a vehicle having an ignition when the ignition is turned on following a period of time in which the ignition had been turned off. An amount of time for which the vehicle had been turned off is determined. A motor temperature model is run using a time step to simulate the amount of time for which the vehicle had been turned off to determine an initial value of the temperature of the motor.

Vehicle motor temperature determination

Methods, systems, and vehicles are provided pertaining to the determination of a temperature of a vehicle motor having an ignition when the ignition is turned on following a period of time in which the ignition had been turned off. A memory stores a function having a boundary condition that comprises a prior temperature from when the ignition was turned off. A processor is coupled to the memory. The processor is configured to determine an amount of time for which the ignition has been turned on and determine the temperature of the motor using the function if the amount of time for which the ignition has been turned on is less than a predetermined threshold.

A vehicle includes a power source, a motor, and a computing device. The power source provides electrical energy to the motor, and the motor generates rotational motion from the electrical energy received. The computing device is configured to estimate a temperature of the motor in real time based at least in part on a thermal model of the motor. The thermal model includes a plurality of nodes and at least one thermal resistance. Each node represents a region of the motor and each thermal resistance represents a heat transfer path between at least two of the nodes. A method includes solving one or more energy balance equations to determine a temperature change at each node and estimating the temperature of the motor in real time based at least in part on the temperature change at each node and at least one of the thermal resistances in the thermal model.

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Macomb Township, MI, United States of America

Daniel J Berry