Ford Global Technolgoies, LLC

Fca US LLC

Daniel Richard Luedtke

Fazal Urrahman Syed

Michael W Degner

Rimma Isayeva

Mustafa Mohamadian

Shailesh Shrikant Kozarekar

Balakrishna Rao

Siwei Cheng

Feng Liang

Franco Leonardi

Nitinkumar R Patel

Jonathan Andrew Butcher

Paul Stephen Bryan

Wei Xu

Bader M Badreddine

Susan Rebecca Cikanek

Ji Wu

Kent Hancock

Edward William Haran

Yulei Chen

Liwen Xu

Chang-jiang Wang

Kyle M Hanson

Johnathan Andrew Butcher

Lakshmi Narayanan Srivatchan

Rimma Paransky

Multi-loss torque control systems and methods for an electric motor of an electrified vehicle include determining a torque command for the electric motor from a set of sensors, determining a speed loss for the electric motor based on an actual speed and a desired heat energy loss for the electric motor from the set of sensors, generating current commands for the electric motor based on its determined torque command and speed loss, controlling the electric motor using the generated current commands, capturing heat energy lost by the electric motor using a heat exchanger system, and using the captured heat energy in the heat exchanger system to heat a component of the electrified vehicle.

Multi-loss mode electric motor torque control techniques for electrified vehicles

A temperature estimation system and method for an electric motor of a vehicle include a set of sensors configured to measure a set of operating parameters of the electric motor including at least (i) phase current, (ii) speed, and (iii) coolant temperature and a controller configured to access a trained artificial neural network (ANN) temperature estimation model, using the trained ANN temperature estimation model with the set of electric motor operating parameters as inputs, estimate temperatures of a stator and a rotor of the electric motor, and control operation of the electric motor based on the estimated stator and rotor temperatures.

Vehicle electric motor temperature estimation using neural network model

A sensorless position estimation and control system and method for a permanent magnet electric motor of a powertrain system of a vehicle involve determining a reference torque to be achieved by the electric motor based on a set of vehicle operating parameters, determining a reference current magnitude to achieve the determined reference torque using a lookup table, determining current commands for the electric motor based on the determined reference current magnitude and a fixed reference current angle, injecting a high frequency voltage into a voltage control loop for the electric motor and estimating, by the controller, a position of a rotor of the electric motor thereafter, and controlling a current provided to the electric motor based on the determined current commands and the estimated rotor position.

Sensorless position estimation for interior permanent magnet synchronous motor

A system comprises a high voltage (HV) battery system connected to an HV bus, a motor generator unit (MGU) connected to the HV bus, a main contactor disposed on the HV bus between the MGU and the HV battery system such that, when the main contactor is closed, the HV battery system stabilizes a voltage of the HV bus, a low voltage (LV) battery system connected to an LV bus and configured to stabilize a voltage of the LV bus when the main contactor is open or malfunctioning, a direct current to direct current (DC-DC) converter connected to the HV bus and the LV bus, and a controller configured to (i) when the main contactor is closed, control the DC-DC converter to stabilize the LV bus voltage, and (ii) when the main contactor is open or malfunctioning, control the DC-DC converter to stabilize the HV bus voltage.

Voltage control for alternator mode in electrified vehicles

A method according to an exemplary aspect of the present disclosure includes, among other things, detecting a position, including a polarity, of a rotor to detect incorrect rotor position offset of an electric machine without generating torque or motion within the electric machine.

System and method for determining rotor position offset of an electric machine

A method for controlling an electric machine of a vehicle drivetrain may include determining a rotational speed of the electric machine, determining a rotational speed of a drivetrain component other than the electric machine, and modifying a torque command to the electric machine based on a difference between the rotational speeds to dampen drivetrain vibrations.

Automotive vehicle and method of controlling an electric machine therein

A method according to an exemplary aspect of the present disclosure includes, among other things, controlling a vehicle using an estimated torque of an electric machine, the estimated torque based on one or more parameters associated with the electric machine that are independent from measured current feedback.

Torque monitoring system and method

An electric machine (e.g., motor or generator) for an electric drive system of an electric vehicle is adapted to be coupled to wheels of the vehicle for conversion between stored electrical energy and rotation of the wheels. A resolver is coupled to the electric machine having a rotor rotating with the electric machine, the resolver responding to an excitation signal to produce a position signal. A controller is coupled to the resolver to receive the position signal and coupled to the electric machine to control the conversion. The controller generates the excitation signal at a variable frequency selected as a function of an operating point of the electric machine to avoid harmonic noise peaks propagating at the electric machine. Consequently, the position signal is relatively less affected by electromagnetic noise.

Resolver excitation frequency scheduling for noise immunity

A vehicle having at least two electric machines includes an oil circulation path that circulates oil through the electric machines. A controller commands the electric machines to fulfill torque demands. The controller utilizes the oil temperature in the oil circulation path to control the commanded torque output by the electric machines. In the event of a failure or fault in an oil temperature sensor, the controller estimates the oil temperature from the temperature of coils within at least one of the electric machines. The estimated oil temperature is utilized instead of the sensed oil temperature to control the torque outputs to satisfy torque demands.

Temperature based electric machine control

A vehicle includes a traction battery, an electric machine, and a variable voltage converter. The variable voltage converter includes an inductor and is disposed electrically between the traction battery and electric machine. The vehicle also includes a controller programmed to issue duty cycle commands for the variable voltage converter based on a product of an AC component of current flowing through the inductor and a calibrated resistance.

Systems and methods for determining a duty cycle for a variable voltage converter

A vehicle comprises an electric machine configured with at least one controller issuing torque commands with the use of a voltage bus. The controller may be configured to respond to a torque requests based on multiple vehicle system inputs including vehicle speed, position of the accelerator pedal and brake pedal, and various other vehicle data. The controller may respond to a torque request that exceeds a threshold value by issuing torque commands for the electric machine based on a speed of the electric machine and a voltage on the bus. Based on the speed of the electric machine and voltage on the bus, the controller may issue a constant torque output by the electric machine as the speed and voltage vary. Calculating a ratio using speed of the electric machine to voltage on the bus to determine torque capability may result as a constant torque when the ratio is constant.

Electric machine torque capability determination

An example method includes operating an electric machine to produce a torque output and a non-torque output. The method maintains the torque output and intentionally increases the non-torque output to produce a desired condition in an electric vehicle.

Intentionally increasing a non-torque output of an electric machine in an electric vehicle

A vehicle includes one or more inverter-fed electric machines such as permanent magnet synchronous motors. A controller operates an inverter in either six-step mode or PWM mode depending upon motor speed, motor torque, and the inverter input voltage. A method of selecting the operating mode may determine a transition threshold based on the ratio of rotor speed to inverter input voltage, reducing the approximation error associated with multi-dimensional lookup tables. When the speed and voltage vary while maintaining a constant ratio and constant torque, the transition threshold does not change. Consequently, the controller remains in the same mode.

Electric motor mode control

A vehicle includes one or more inverter-fed electric machines such as permanent magnet synchronous motors. In response to a torque request, a controller issues commands to an inverter calculated to cause the motor to produce the requested torque. A method of operating the inverter may determine the commands based on the ratio of rotor speed to inverter input voltage, reducing the approximation error associated with multi-dimensional lookup tables. When the speed and voltage vary while maintaining a constant ratio and constant torque request, the issued commands produce a winding current in the electrical machine with constant direct and quadrature components.

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Beverly Hills, MI, United States of America

Daniel Richard Luedtke