Gm Global Technolgoy Operations, Inc.

Song He

Edward L Kaiser

Seongchan Pack

Vinod Chowdary Peddi

Brent S Gagas

Yew Sum Leong

Pavan Kumar Patruni

Anil Kumar Sachdev

Qigui Wang

Brian A Welchko

Alireza Fatemi

John Stilianos Agapiou

Anthony M Coppola

Scott M Reilly

Yo Chan Son

Bradley Allen Newcomb

David Yuang Tang

Arianna T Morales

Hongliang Wang

Martin Stephen Kramer

Anno Yoo

Sean R Wagner

William T Ivan

Su Jung Han

John P Miller

Seok-Joo Jang

Kerrie M Spaven

Caleb W Secrest

Khiet Le

Cheng Gong

Michael C Muir

Mithun Sunny

Hung-Yih Isaac Du

Gregory D Rosdahl

Angela P Willis

Gilsu Choi

Le Chang

Peng Zhang

Aja Anjilivelil

Xuan Q Tran

Embodiments include a method for controlling a torque of an electric motor. The method includes receiving a requested output torque for the electric motor and obtaining a rotational speed of the electric motor. Based on determining that the rotational speed of the electric motor is within a predefined range, the method includes instructing the electric motor to operate at the requested output torque based on determining that the requested output torque is greater than a first threshold or less than a second threshold, instructing the electric motor to operate with a torque that is at least the first threshold based on determining that the requested output torque is less than the first threshold and greater than zero, and instructing the electric motor to operate with the torque that is at most the second threshold based on determining that the requested output torque is greater than the second threshold.

Controlling the torque output of an electric motor to mitigate gear rattle

A damping panel includes a first metal and a second metal. The first metal has a first surface and a second surface opposite the first surface. The second metal portion has a third surface and a fourth surface opposite the third surface. A fixed region is where the second surface of the first metal is fixed to the third surface of the second metal. A non-fixed region is where the second surface is not fixed to the third surface. A cavity is disposed between the second surface and the third surface at the non-fixed region. A damping material is disposed on at least one of: at least a portion of the cavity on the second surface, at least a portion of the cavity on the third surface, at least a portion of the first surface, and at least a portion of the fourth surface.

Damping enhancement for bubble sheet components

A method to suppress tonal noises over a wide speed range in an alternating current electric machine by current injection and voltage injection is provided. The method includes, within a computerized processor, monitoring a position sensor measuring a current electric machine frequency of the electric machine, comparing the current electric machine frequency to a sampling frequency of the position sensor, and operating one of a current injection mode and a voltage injection mode to suppress the tonal noises in the electric machine based upon the comparing.

Method and system to suppress tonal noises over a wide speed range in alternating current electric machines

A propulsion system for a device includes an electric motor configured to generate torque to propel the device. A controller is in communication with the electric motor and is adapted to select at least one harmonic order for a harmonic current command. The controller is adapted to define a plurality of operating regions, including a first operating region, a second operating region and a third operating region, each associated with a respective objective function for generating the harmonic current command. The controller is adapted to operate the harmonic current command with four degrees of freedom by selectively varying a q-axis current magnitude, a d-axis current magnitude, a q-axis phase and a d-axis phase as a function of the torque and a motor speed.

Harmonic current command with four degrees of freedom for electric motor

Control of an AC motor includes rotation over an operating speed range with the output from an inverter by operating the inverter at switching frequencies that vary in proportion to rotor speed. The operating speed range is parsed into a plurality of speed regions and the switching frequencies within each operating speed region may correspond to a respective pulse ratio that is different from the respective pulse ratio corresponding to an adjacent speed region.

Electric vehicle sound enhancement

An electric motor assembly includes a housing having a generally cylindrical inner surface defining a generally cylindrical cavity within the housing, a stator operatively disposed within the generally cylindrical cavity, the stator including a plurality of stacked laminations wherein each lamination has an outer circumferential edge and a plurality of finger elements extending inward, and a layer of polymer disposed between a generally cylindrical outer surface of the stator and the generally cylindrical inner surface of the housing, such that the stator is fastened to the housing by the polymer. A method of manufacturing the electric motor assembly includes disposing a stator within a housing such that a gap is defined between the stator and the housing and the stator is not directly connected to the housing, and substantially filling the gap with a polymer capable of fastening the stator to the housing by only the polymer.

Electric motor assembly using polymer-only fastening and methods of manufacturing the same

A method for controlling operation of a rotary electric machine includes receiving, via a bandwidth-partitioning harmonic compensation regulator (HCR) of a controller, a commanded torque and rotational speed of the electric machine, and calculating, via the HCR in response to enabling conditions, a dq harmonic compensation current and a dq harmonic compensation voltage for one or more predetermined harmonic orders using the commanded torque and the rotational speed. The harmonic compensation current and voltage cancel torque ripple and current ripple in the one or more predetermined harmonic orders. The method may include injecting an acoustic tone at a predetermined harmonic order. The method additionally includes adding the dq harmonic compensation current and voltage to a dq current and voltage command, respectively, to generate adjusted dq current and voltage commands. The electric machine is then controlled using the adjusted dq current and voltage commands.

Bandwidth-partitioning harmonic regulation for improved acoustic behavior of an electric drive system

A rotor assembly for an electric machine, e.g., of an electrified powertrain, includes a rotor having inner and outer diameter surfaces, and a rotor shaft connected to and surrounded by the rotor. The rotor has equally-spaced rotor magnetic poles each having a quadrature-axis ('q-axis') and a pair of direct-axes ('d-axes'). At each of magnetic pole of the rotor, the rotor defines at least three arcuate notches, including a center notch bisected by the q-axis and a pair of additional arcuate notches symmetrically flanking the center notch. The rotor may include embedded permanent magnets, which may be arranged in a dual V-shaped configuration. Each additional notch may be positioned within a sweep of a top-layer opening angle of the magnets. The center notch and/or the pair of additional notches may define tangentially-continuous fillets which smoothly transition the notch into the outer diameter surface.

Electric machine with noise-reducing rotor notches

An electric machine may include a substantially annular stator stack having a plurality of laminations which include mounting ears. A fraction of the laminations may be oriented such that the mounting ears are angularly offset from the others. The stator may be secured to a housing at both mounting ear locations thus improving structural rigidity and enhancing performance.

Electric machine and method for manufacture

A damping cover for an integrated power electronics module (IPEM), the damping cover generally defined by a top side and a bottom side, wherein the bottom side is configured to mate adjacent with or contiguous to a power inverter module (PIM) of the IPEM. The damping cover can include an aluminum foam core including a top surface generally corresponding to the top side of the damping cover and a bottom surface generally corresponding to the bottom side of the damping cover and a polymeric over-molding or non-porous aluminum outer layer covering the top surface and/or a polymeric over-molding or non-porous aluminum outer layer covering the bottom surface. The bottom side of the damping cover can mate adjacent with or contiguous to the PIM. The polymeric material over-molding can completely impregnate the aluminum foam core. The aluminum foam core can have a density of about 0.15 g/cmto about 1.0 g/cm.

Damping covers for power inverter modules and integrated power electronics modules utilizing the same

An integrated power electronics component configured for mitigating noise, vibration, and harshness includes a case formed from metal and configured to dampen a sound wave having a first frequency and a first amplitude and propagatable in a first direction. The case has a first surface and a second surface spaced apart from the first surface, a first stiffness, and a first strength, and the first and second surfaces include a structure defining a plurality of recessions therein. The component includes a cured polymer formed from a composition disposed on at least one of the first and second surfaces in each of the recessions to thereby dampen the sound wave in the first direction and in a second direction that is perpendicular to the first direction to a second frequency that is less than the first frequency and a second amplitude that is less than the first amplitude.

Integrated power electronics component for mitigating noise, vibration, and harshness

A stator for an electromagnetic machine includes a first lamination stack defining a first cavity therein and having a central longitudinal axis. The first lamination stack includes a first plurality of mounting ears disposed opposite the first cavity and each spaced apart from one another about the central longitudinal axis. The stator further includes a second lamination stack abutting the first lamination stack and defining a second cavity therein aligned with the first cavity along the central longitudinal axis. The second lamination stack includes a second plurality of mounting ears disposed opposite the second cavity and each spaced apart from the first plurality of mounting ears and from one another about the central longitudinal axis. An electromagnetic machine including the stator and a device including the electromagnetic machine are also described.

Stator having skewed mounting ears

An electromagnetic machine includes a motor housing defining a cavity therein, and a stator disposed within the cavity. The stator has an external surface and a plurality of mounting ears each configured to receive a fastener and extending from the external surface towards the motor housing. The assembly includes a tunable insert ring disposed between the motor housing and the stator. The tunable insert ring and the stator define at least one cooling channel therebetween. The tunable insert ring encircles the external surface and includes a plurality of projections each extending towards and disposed in contact with the stator to thereby stiffen the electromagnetic machine and minimize vibration of the stator within the motor housing. A device including the electromagnetic machine is also described.

Electromagnetic machine and tunable insert ring

Motor housings with controlled radial thermal expansion include a cylindrical body with at least one circumferential groove extending inward from an outer surface of the cylindrical body, and a fiber composite band disposed within each groove. The grooves can be dovetail shaped and extend inward from the outer surface of the cylindrical body to a groove bottom, wherein each groove has a first width at the outer surface and a second width at the groove bottom that is greater than the first width. Methods for controlling radial thermal expansion of motor housings include providing a motor housing including a cylindrical aluminum body with a plurality of circumferential grooves extending inward from an outer surface of the cylindrical body, disposing a plurality of continuous fibers within the grooves, applying a matrix to the continuous fibers, and curing the matrix to form a fiber composite band within the grooves.

Motor housings and motor assemblies with controlled radial thermal expansion

In various embodiments, methods, systems, and vehicles are provided for masking a tonal noise of a motor. In certain embodiments, a vehicle includes a drive system and an active masking acoustic signal generator (AMAG). The drive system includes a motor generating a tonal noise. The AMAG is configured to at least facilitate masking the tonal noise, by introducing a complementary harmonic tone, injecting dithering into the motor, or both.

Growing community of inventors

Troy, MI, United States of America

Song He