Steering Solutions IP Holding Corporation

Gm Global Technolgoy Operations, Inc.

Borgwarner Inc.

Siddharth Ballal

Julie Ann Kleinau

Caleb Wayne Secrest

Prerit Pramod

Wesley G Zanardelli

Lei Hao

Tomy Sebastian

Anno Yoo

Jiyu Zhang

Abraham Gebregergis

Bojian Cao

Ramakrishnan RajaVenkitasubramony

Hassan H Eldeeb

Brian A Welchko

Mutasim Abdurrahman Salman

Dennis B Skellenger

Dwarakanath V Simili

Arslan Qaiser

Brandon P Davis

Vignesh Namasivayam

Chikezie M Emeghara

James Smith

Timothy A Klinesmith

Abraham G Gebregergis

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 calibrating an electrical machine to determine an angular offset between a motor sensor indicated position and an actual rotor position, including the steps of: supplying electrical current to stator windings; identifying a quadrant of a rotor where a rotor pole is located; approximating a line between a torque value measured at a lower angular boundary of the identified quadrant and a torque value measured at an upper angular boundary of the identified quadrant; and determining an angular offset by locating an angular position where torque exerted by the rotor is zero.

Determining rotor position offset for electrical machines

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 diagnostic system includes: a current command module configured to, based on a motor torque request, a motor speed, a direct current (DC) bus voltage, generate a d-axis current command for an electric motor and a q-axis current command for the electric motor; a voltage command module configured to, based on the d-axis current command and the q-axis current command, generate a d-axis voltage command and a q-axis voltage command; a switching control module configured to control switching of an inverter module based on the d-axis voltage command and the q-axis voltage command, where the inverter module is configured to apply power to stator windings of the electric motor from the DC bus; and a fault module configured to selectively indicate that the stator windings of the electric motor are degraded when the d-axis voltage command is less than a predetermined nominal d-axis voltage of the electric motor.

Systems and methods for detecting stator winding faults and degradation

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

An electric drive system of a vehicle comprises a motor, a position sensor, an inverter, sensors to sense current and voltage supplied to the motor, and a controller to control the motor by controlling the inverter based on data from the position sensor and the sensors and a torque command. The controller estimates a motor torque using a motor model, calculates the motor torque, and generates a first state of health for the electric drive system based on a difference between the estimated and calculated motor torques. The controller generates, in response to the first state of health being less than or equal to a first threshold, a second state of health for at least one of the position sensor, the sensors, and the motor, and determines whether one of the position sensor, the sensors, and the motor is faulty based on the first and second states of health.

Integrated fault isolation and prognosis system for electric drive system

A propulsion system having an electric motor and corresponding method. A controller is configured to receive a torque request and selectively command the electric motor. The controller has a processor and tangible, non-transitory memory on which instructions are recorded for a method of generating an auxiliary power. The controller is configured to obtain a desired auxiliary power and a delta factor (&#x3b4;). The delta factor is set as a speed modifier (&#x394;&#x3c9;=&#x3b4;) when the cosine of an angle (&#x3b8;), between a constant torque unit vector and a decreasing voltage ellipse unit vector, is less than a predefined threshold. A modified rotor speed is obtained as a sum of an original rotor speed and a speed modifier (&#x394;&#x3c9;). The controller is configured to obtain modified stator current commands based on the modified rotor speed and torque request. The auxiliary power is generated by commanding the modified stator current commands.

Electric motor in propulsion system with auxiliary power generation

A propulsion system for a device having an electric motor configured to selectively provide a first torque contribution to propel the device. At least one sensor is configured to obtain a respective signal related to the electric motor. A controller is in communication with the sensors and configured to determine a magnet flux linkage (&#x3bb;) based in part on the respective signal. The controller has a processor and tangible, non-transitory memory on which instructions are recorded for a method of determining a demagnetized torque capability (T) for the electric motor in real-time. In the event of a threshold level of demagnetization of the electric motor, the method estimates the torque capability in real time of the electric motor, taking the demagnetization level into account. At least one operating parameter of the device is controlled based at least partially on the demagnetized torque capability (T).

Determination of demagnetized torque capability in real-time for electric motor in propulsion system

Methods and systems for applying adaptive thermal compensation when operating a rotor of a motor are provided. The method includes: receiving a plurality of parameter data of torque and temperature of the rotor and current and voltage of the motor by a region determination module; calculating, by the region determination module from the set of parameter data, a cosine value to determine a region for applying the adaptive thermal compensation wherein the cosine value is calculated from a constant torque direction vector and a voltage limit eclipse vector derived from a functional relationship of the one or more parameter data; and applying, by a reference modification module, a modification value to incrementally modify the motor current when the motor is operating within the region determined by the region determination module for the adaptive thermal compensation.

Methods and systems for determining when to apply an adaptative thermal compensation in an operating region of a motor

A method of controlling a motor in a motor control system is provided. The method determines a control voltage budget value based on an operating region of the motor. The method adjusts a supply voltage signal based on the control voltage budget value. The method determines a motor voltage command based on the adjusted supply voltage signal. The method applies a voltage corresponding to the motor voltage command to the motor in order to generate a desired motor torque.

Generating motor control reference signal with control voltage budget

An electric power system includes a polyphase electric machine, battery pack, power inverter module, analog input sensor, and diagnostic controller executing a method. The sensor measures an electrical parameter that differs from a true value of the parameter by an initial offset value. The controller collects sample sets of the parameter, compares the initial offset of each sample to an outlier threshold in a first diagnostic loop, and transmits a bit flag indicative of an outlier sample to a slower second diagnostic loop when the initial offset of a sample exceeds the outlier threshold. The second control loop calculates a rolling average of the initial offsets of the sample sets, discards the set containing the outlier sample in response to the bit flag, and executes a control action when the average exceeds a threshold that is lower than the outlier threshold.

System and method for measuring and diagnosing initial offsets of an analog input sensor

A system for reducing a torque ripple cancellation command is provided and includes a current regulator that provides motor voltage commands to a motor, and a torque ripple cancellation module that generates a torque ripple cancellation command based on input currents to the current regulator. A ramp-down command generator module that provides a ramp-down command to the torque ripple cancellation module is also provided. The ramp-down command is based on a voltage saturation indicator, and a voltage saturation indicator generator that generates a voltage saturation indicator signal. The voltage saturation indicator signal is based on a supply voltage signal and a motor voltage command.

Torque ripple cancellation algorithm involving supply voltage limit constraint

A system for detecting offset error in a power steering system is provided. The system includes a programmable high pass filter module configured to filter a final voltage command and generate a filtered final voltage command. The filtered final voltage command includes the sinusoidal component, a gain and phase compensation module configured to perform a gain compensation and a phase compensation on the filtered final voltage command to generate a compensated final voltage command. An error detection module is configured to determine an offset of the compensated final voltage command in a stator reference frame.

Detection of offset errors in phase current measurement for motor control system

A system for detecting offset error in a power steering system comprises a programmable high pass filter module configured to filter a final voltage command and generate a filtered final voltage command that includes the sinusoidal component, a gain and phase compensation module configured to perform a gain compensation and a phase compensation on the filtered final voltage command to generate a compensated final voltage command; and an error detection module configured to determine an offset of the compensated final voltage command in a stator reference frame.

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Shelby Township, MI, United States of America

Siddharth Ballal