Delphi Technologies, Inc.

Allison Transmission, Inc.

Delphi Technologies IP Limited

James E Walters

Fani S Gunawan

Ronald John Krefta

Gabriel Gallegos-Lopez

Gerald Thomas Fattic

Kaushik Rajashekara

John Derek Williams

Gerald T Fattic

Clinton W Erickson

Karl A Schten

Michael Scott Sullivan

Yanhong Xue

A motor control system includes a shaft configured to be rotationally driven by a motor. A rotor position sensor is configured to detect rotation of the shaft and output a rotor position signal. A controller is in communication with the motor and the rotor position sensor. The controller converts the rotor position signal to an angle with error, tracks the angle with error to provide an angle that retains mechanical dynamics as stationary reference frame signals, transforms the stationary reference frame signals and the angle with mechanical dynamics to rotating reference frame signals, filters the rotating reference frame signals, transforms the filtered rotating reference frame signals to provide filtered stationary frame signals, and takes an arctangent of the filtered stationary reference frame signals to create a corrected motor control angle. The controller commands the motor based upon the corrected motor control angle.

Rotor position sensor signal correction

A system for detecting faults in a motor includes a drive circuit, a detection circuit, and a controller. The drive circuit is configured to apply a drive signal to a motor. The detection circuit is configured to detect a response signal generated when the drive signal is applied to the motor. The controller is configured to determine a motor fault based on a comparison of the response signal to an expected signal for the drive signal applied to the motor. The drive signal is selected to generate a rotating magnetic field in the motor with a rotation-frequency greater than a maximum mechanical-response-frequency of the motor.

System and method of electric motor fault detection

A system and method for controlling a rotating E-machine and for correcting a rotational position signal output by an angular position sensor operatively connected to the E-machine in conjunction with a sensor digital converter is disclosed. For each angular operating speed of interest, a set of signals as a function of position is taken such that the harmonics (or sub-harmonics) related to the position sensor may be determined and isolated from errors due to an associated digital converter. From this information, the magnitude and phase of the position sensor harmonics is determined. The effects of the sensor digital converter (or other signal processing equipment) are then determined and accounted for, allowing the control system to apply the total position error signal to the position sensor output signal to determine a corrected position sensor signal for use in controlling the E-machine.

System and method for error correction in angular position sensors

A control methodology for an engine-driven electric machine of a hybrid vehicle electrical system for enabling continued operation of the vehicle electrical system under failure mode conditions that require or result in disconnection of the battery pack from the electrical system. At the onset of a fault condition requiring battery disconnection, the electric machine is controlled to drive the battery pack current toward zero before disconnecting the battery pack. Once the battery pack is disconnected, whether by relay or fuse, the electric machine is controlled to maintain the bus voltage of the electrical system at a specified value. In both operating modes, the electric machine is controlled based on a synchronous vector current command that is determined directly as a function of the control objective (zero battery pack current or maintaining bus voltage) for improved response time compared to a traditional torque-based control.

Fast response failure mode control methodology for a hybrid vehicle having an electric machine

A computer implemented system for engine misfire detection employs a crankshaft-originated speed signal that includes normal variability due to target wheel tooth error and the like. A Discrete Fourier Transform (DFT) is performed on the speed signal to convert it into a frequency-domain raw misfire detection metric. The system is configured to normalize the raw misfire detection metric using a non-misfire metric that is obtained by and corresponds to non-misfire operation of an internal combustion engine. A resulting normalized misfire detection metric has such normal variations removed leaving variations attributable to misfire. The system detects a misfire when the normalized misfire detection metric exceeds a predetermined threshold and is bounded by a predetermined phase angle region. The system detects both continuous misfire as well as intermittent misfire. The system also detects single cylinder misfire and multiple cylinder misfire.

Fourier-based misfire detection strategy

A method/system for measuring cylinder pressures of an internal combustion engine includes a crank angle sensor utilized to generate pressure readings at known angular intervals. Additional time-based pressure measurements are taken in selected angular windows between a pair of the angle-based pressure readings. Because the angle-based pressure measurements and the time-based pressure measurements occur at known times, the pressure as a function of the crank angle for the time-based pressure measurements can be determined. The cylinder pressure measurements can be utilized to calculate combustion parameters used for closed-loop engine control of fuel supply or other engine inputs.

Method of cylinder pressure sensor data/angle capture for low and high resolution

A device to regulate current produced by a permanent magnet machine responsive to a plurality of phase current signals. The motor produces torque for application on a shaft. A processing and drive circuit responsive to a direct current command signal and a quadrature current command signal produces phase current signals for input to the motor. A command circuit responsive to the phase current signals, an angular position of said shaft, and a voltage input command signal to produce a direct current error signal and a quadrature current error signal. A control circuit responsive to the direct and quadrature current error signals produces the direct voltage signal command and the quadrature voltage signal command. The control circuit has a direct and quadrature proportional gain, integrator and clamp circuits. An algorithm produces limited or clamped voltage modulation index signals to obtain maximum efficiency and maximum torque per ampere in the speed range. The algorithm ensures that the current regulator does not run out of voltage by limiting the voltage vector to the achievable voltage vector range that provides maximum torque per ampere and maximum efficiency.

System and method for clamp current regulation in field-weakening operation of permanent magnet (PM) machines

The invention provides a method for controlling current in a direct current motor having a back emf constant (k), which may be a function of field current if the direct current motor is a field wound machine, and motor resistance (R) in all 4 quadrants of operation. The method includes the step of rotating a motor shaft of the direct current motor with a controller by applying a first voltage across the direct current motor's terminals. The first voltage corresponds to a first value of current passing through the armature windings of the direct current motor. The method also includes the step of determining a maximum value of current to pass through the armature windings of the direct current motor. The maximum value of current is selected to prevent undesirable over current conditions, such as thermal overload as one example. The method also includes the step of receiving a signal corresponding to a desired motor speed (&#x3c9;*) with the controller during the rotating step. The method also includes the step of first computing a second voltage to replace the first voltage from the controller after the receiving and determining steps and in view of the estimates of the back emf constant (k) and the armature resistance (R) of the direct current motor. The method also includes the step of limiting the second voltage, if necessary to limit the current, before replacing the first voltage based at least in part on a difference between the maximum value of current and the current polarity, a gain quantity, and the first value of current and voltage in order to dynamically control current during the operating step.

Current limiting strategy

Method for providing current regulation and a current controller () for an electric machine () are provided. The method includes receiving a state vector time signal () indicative of a time interval when a switching state vector is activated and comparing the received state vector time signal to a commanded state vector time signal (). The method further includes using the result of the comparison to regulate a direct axis current signal () input to an electric machine controller. The current controller () includes a state vector error comparator for comparing a received state vector time signal to a commanded state vector time signal and generating a state vector time error. This error is processed by a PI controller, coupled to the state vector error comparator, for providing a direct axis current signal output responsive to the state vector time error to an electric machine.

Method and controller for field weakening operation of AC machines

A device to regulate current produced by an induction machine responsive to a plurality of phase current signals. The motor produces torque for application on a shaft. A processing and drive circuit responsive to a direct current command signal and a quadrature current command signal produces phase current signals for input to the motor. A command circuit responsive to the phase current signals, an angular position of said shaft, and a voltage input command signal to produce a direct current error signal and a quadrature current error signal. A control circuit responsive to the direct and quadrature current error signals produces the direct voltage signal command and the quadrature signal command. The control circuit has a direct and quadrature proportional gain, integrator and clamp circuits. An algorithm produces limited or clamped voltage modulation index signals to obtain maximum efficiency and maximum torque per ampere in the speed range.

System and method for clamp current regulation of induction machines

Method and system for controlling a permanent magnet machine are provided. The method provides a sensor assembly for sensing rotor sector position relative to a plurality of angular sectors. The method allows starting the machine in a brushless direct current mode of operation using a calculated initial rotor position based on angular sector position information from the sensor assembly. Upon reaching a predefined mode-crossover criterion, the method allows switching to a sinusoidal mode of operation using rotor angle position based on extrapolating angular sector position information from the sensor assembly.

Method and system for controlling a permanent magnet machine

Method and system for controlling a permanent magnet machine driven by an inverter is provided. The method allows for monitoring a signal indicative of a fault condition. The method further allows for generating during the fault condition a respective signal configured to maintain a field weakening current even though electrical power from an energy source is absent during said fault condition. The level of the maintained field-weakening current enables the machine to operate in a safe mode so that the inverter is protected from excess voltage.

Method and system for controlling a permanent magnet machine during fault conditions

Method and system for controlling a permanent magnet machine are provided. The method provides a sensor assembly for sensing rotor sector position relative to a plurality of angular sectors. The method further provides a sensor for sensing angular increments in rotor position. The method allows starting the machine in a brushless direct current mode of operation using a calculated initial rotor position based on an initial angular sector position information from the sensor assembly. Upon determining a transition from the initial angular sector to the next angular sector, the method allows switching to a sinusoidal mode of operation using rotor position based on rotor position information from the incremental sensor.

Method and system for controlling start of a permanent magnet machine

Method and system for controlling an induction machine are provided. The method allows to sense rotor position of the induction machine using a relatively low-resolution rotor position sensor configured to supply a stream of pulses indicative of angular increments as the rotor position changes. A memory device is used for storing a synchronous angle boost function. The method further allows to retrieve from the memory device at least one function parameter for providing a synchronous angle boost during a start up mode of operation of the induction machine. Upon sensing a predetermined number of pulses from the rotor position sensor, the method allows to switch from the start up mode of operation to a normal mode of operation, wherein the boost provided to the synchronous angle is discontinued upon switching to the normal mode of operation.

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Carmel, IN, United States of America

James E Walters