Steering Solutions IP Holding Corporation

Delphi Technologies, Inc.

Gm Global Technolgoy Operations, Inc.

Dennis B Skellenger

Prerit Pramod

Julie Ann Kleinau

Sayeed Ahmad Mir

Mark Philip Colosky

Tejas M Varunjikar

Steven James Collier-Hallman

Roy Alan McCann

Ashok Chandy

Steven D Klein

Michael K Hales

Siddharth Ballal

Rangarajan Ramanujam

Michael A Eickholt

Jeffrey T Klass

Rakesh Mitra

Mark Dennis Kushion

Nicholas M Trewhella

Jeffrey A Zuraski

Nayeem Mahmud

Roy Alan Mc Cann

Selva Kumar Sengottaiyan

Timothy A Klinesmith

Technical solutions are described for providing driver warning using steering systems. An example steering system includes a motor control system that sends a command to a motor. The steering system further includes a fault monitoring system that sets a fault indication flag by monitoring one or more components of the steering system. The steering system further includes a driver warning feedback system that generates a warning injection signal based on and in response to the fault indication flag being set. Further, the motor control system generates a driver feedback by modifying the command to the motor using the warning injection signal, and sending the modified command to the motor.

Driver warning in electric power steering systems

According to one or more embodiments of the present invention a steer by wire steering system includes a deviation detection unit configured to determine a deviation signal that is indicative of a disturbance in one or more components coupled to a rack. The steer by wire steering system further includes a handwheel notification module configured to generate a modification signal based on the deviation signal, in response to the deviation signal being detected for at least a predetermined duration. The steer by wire steering system further includes a handwheel control module that generates an input command corresponding to a reference torque generated by a road wheel actuator, a feedback torque for a driver is generated based on the input command. The handwheel control module further modifies the input command using the modification signal, the modification providing a notification corresponding to the disturbance to the driver.

Driver notification using handwheel actuators in steer-by-wire systems

Technical solutions are described for detecting an error in an inverter associated with a motor of a power steering system and operating the power steering system in response to the error. An example system includes a transistor pair that selectively provides power to a corresponding phase coil of the motor. The system further includes a detection module that detects a resistance error in the transistor pair by monitoring a voltage across a shunt resistor of the transistor pair in response to a gate drive command applied to the transistor pair. The system further includes a mitigation module that selects a mode of operation of the inverter based on the resistance error. The system also includes a motor control module that controls the inverter according to the mode of operation.

Detection and mitigation of inverter errors in steering system motors

Technical solutions are described for mitigating braking torque in a motor of a steering system caused by a FET short. For example, an example mitigation system includes a mitigation module that adjusts a motor torque in response to a FET short. The mitigation system further includes a mitigation-enable module that selectively enables and disables the mitigation module based on a handwheel torque signal. Further, the mitigation system includes a damping module that reduces the motor torque based on a motor velocity signal for the motor.

Method of controlling an inverter during MOSFET shorts

A power steering system includes a torque modifier module that generates a modified torque command in response to a current sensor fault, a magnitude of the modified torque command changes over a time period. The power steering system also includes a feedforward selection module that applies a dynamic feedforward compensation to a motor current command, thereby generating a motor voltage that is applied to a motor of the power steering system, the dynamic feedforward compensation modifies a frequency response of the power steering system.

Motor control current sensor loss of assist mitigation for electric power steering

An embodiment of a system for determining a sensor failure in a motor control system with at least three phase current measurements includes a magnitude computation module that determines a magnitude of a diagnostic voltage, the diagnostic voltage represented in a stator frame and based on a difference between an input voltage command and a final voltage command, and a phase evaluation module that determines a phase value of the diagnostic voltage based on the diagnostic voltage. The system also includes a sensor failure identification module that identifies a current sensor failure based on the phase value of the diagnostic voltage, the sensor failure represented by a failure signal, and a current calculation transition module that modifies a calculation scheme for determining a measurement of motor current based on the sensor failure.

Fault tolerant phase current measurement for motor control systems

A method of controlling a motor of a power steering system is provided. The method generates a direct-axis voltage command and a quadrature-axis voltage command based on a current measurement signal received from the motor. The method transforms the direct-axis voltage command and the quadrature-axis voltage command into an alpha voltage command and a beta voltage command. The method determines an offset error in the phase current measurement based on the alpha and beta voltage commands.

Phase current measurement diagnostic

A method and system for determining a torque current in an electric machine coupled to a polyphase bus. The method comprises: detecting a rotational position of the electric machine with a position encoder; controlling an inverter comprising a plurality of switching devices, the inverter having an input coupled to a direct current bus, and an output coupled to the polyphase bus. Where the inverter is responsive to commands from a controller coupled to the inverter and to the position encoder. The method also includes measuring a current from the direct current bus; and capturing the current at a predefined interval of time.

Current determination in a permanent magnet electric machine

A method for implementing active deadtime control of an inverter associated with an electric motor is disclosed. In an exemplary embodiment, the method includes receiving a command voltage signal indicative of a desired load to be driven by the motor. Based upon the value of the command voltage signal, a determined value of deadtime is applied to switching circuitry in the inverter, wherein the value of deadtime relates to an amount of time in which the switching of a device in the switching circuitry is delayed so as to prevent a short circuit condition within the inverter.

Active deadtime control for improved torque ripple performance in electric machines

A brushless DC motor modifies motor commutation events to reduce noise by providing overlapping activation of the switch being deactivated with the switch being newly activated so that three switches are temporarily activated. The newly activated switch is pulse width modulated with a motor torque controlling duty cycle, and the switch being deactivated is pulse width modulated synchronously with the newly activated switch but with a duty cycle decreasing from the torque controlling duty cycle. The decreasing modulation of the switch being deactivated allows a slower current decrease in the phase turning off to reduce or eliminate the disturbances, and thus the noise. The decreasing modulation is preferably exponential in manner, with a time constant varying inversely with motor speed so that the duty cycle reaches a predetermined minimum in a predetermined maximum number of motor electrical degrees. The decreasing modulation may be switched on at low motor speeds where its noise reduction is required and switched off at higher motor speeds where the potential for interference with commutation is greater. The decreasing modulation is applicable in a dual switching mode in which each activated switch, except for the switch being deactivated in commutation, is pulse width modulated at the torque controlling duty cycle, or in a modified single switching mode in which the activated switch of one of the upper or lower groups is always closed continuously during its activation, except for commutation, during which the switch remaining on, which alternates between the groups, is closed continuously. Each mode of operation is applied in the motor speed/torque region to which it is best suited.

Apparatus and method for commutation noise reduction

An exemplary embodiment of the invention is a method of controlling a motor in an electric power steering system. The method includes obtaining a motor control signal having an initial duty cycle and linearizing the initial duty cycle to obtain a secondary duty cycle. An offset is added to the secondary duty cycle to obtain an adjusted duty cycle. The motor is controlled using the adjusted duty cycle. An alternative embodiment is a torque linearization device for linearizing torque produced by a motor in response to a motor control signal having an initial duty cycle. The torque linearization device includes a comparator for receiving the initial duty cycle and comparing the initial duty cycle to a threshold. A linearization table converts the initial duty cycle to a linearized duty cycle. A selector receives the initial duty cycle and the linearized duty cycle and selects one of the initial duty cycle and the linearized duty cycle as a secondary duty cycle in response to the comparing.

Method and apparatus for torque linearization in an electric power steering system

A method of minimizing the torque ripple produced by unbalanced phase currents in a sinusoidally excited motor is disclosed. The method comprises measuring the position of the motor; sampling the phase currents of the motor generating thereby at least one phase current; synchronizing the at least one phase current of the motor with the position of the motor; determining the imbalance in the magnitudes of the at least one phase current of the motor; generating a set of modulation index terms for reducing the imbalance in the magnitudes of the at least one phase current to ensure acceptable torque ripple characteristics over the operating velocity of the motor; and generating a set of minimized line-to-ground voltage commands.

Minimization of motor torque ripple due to unbalanced conditions

A method and system for diagnostics and ascertaining status of an electric machine coupled to a polyphase bus. The method and system include: detecting a rotational position with a position encoder coupled to the electric machine; controlling an inverter having an input coupled to a direct current bus and an output coupled to the polyphase bus, where the inverter is responsive to commands from a controller coupled to the inverter and to the position encoder. The method and system further include measuring a current from the direct current bus; capturing a torque current; calculating a current error; establishing a bound limit for the torque current; comparing the current error to the bound limit. The method and system also include: determining whether a fault exists by evaluating if the bound limit has been exceeded; incrementing a fault counter if a fault exists; decrementing a fault counter if no fault exists; and indicating a failure if the fault counter exceeds a predetermined limit.

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Saginaw, MI, United States of America

Dennis B Skellenger