Gm Global Technolgoy Operations, Inc.

Daimlerchrysler Corporation

Bayerische Motoren Werke Aktiengesellschaft

Daimler Ag

Chrysler Corporation

Chrysler Group LLC

Electronic Data Systems Corporation

Hewlett-packard Development, L.p.

Wei D Wang

Stephen T West

Bon Ho Bae

William R Cawthorne

Harry J Bauer

Brian A Welchko

Andrew M Zettel

Peter E Wu

Hanne Buur

Steven E Schulz

Jeong J Park

Silva Hiti

Lan Wang

Sean E Gleason

Aniket P Kothari

Bryan Nathaniel Roos

Richard K Moote

Jihoon Jang

Charles J Van Horn

Chris J Booms

Mark J Poublon

Douglas M Stander

Kevin P Houle

Danny K Schuelke

Rick H Schroeder

Jason E Wielenga

Abbas Raftari

Craig Summers

Jeffrey David

Wei Ren

Jackie L Cui

David T Fu

Nitinkumar R Patel

Yo Chan Son

Mohammad N Anwar

Daniel P Grenn

Leonard G Wozniak

Ryan D Martini

James E Tarchinski

Anson Lee

Sibaprasad Chakrabarti

Daniel J Berry

Syed Naqi

David P Tasky

Brian J Gallert

Robert Weiss

Leah Dunbar

Marek L Wilmanowicz

S M Nayeem Hasan

Nicholas Kokotovich

Jinming Liu

Wesley G Zanardelli

Brian R Medema

Thomas E Mathews

Thomas W Stephens

Michael J Taljonick

Reynaldo Arturo Suazo Zepeda

Darren Crewes

Jayanthi Padmanabhan

William E Leisenring

Slobodan Gataric

Tom Stephens

David J Carlson

Beth A Bezaire

Satish Godavarthy

Bo Zhang

Bill Leisenring

Melissa R McNeely

Dave Carlson

A diagnostic system for a resolve of a motor and a method of diagnosing the resolver. The diagnostic system includes an x-phase winding, a y-phase winding, and a processor. The x-phase winding generates an x-phase voltage and the y-phase winding generates a y-phase voltage. The processor obtains the x-phase voltage and the y-phase voltage, determines an adaptive cosine envelope from the x-phase voltage and an adaptive sine envelope from the y-phase voltage, determines an adaptive magnitude from the adaptive sine envelope and the adaptive cosine envelope, determines a magnitude average based on the adaptive magnitude, determines a fault of the resolver when a ratio of the adaptive magnitude and the magnitude average is greater than a threshold, and transmits a signal based on the fault.

Adaptive resolver envelope diagnostic

A torque system includes a DC power device, a polyphase electric machine, a contactor pair, a power inverter module (PIM), and a controller. The PIM connects to the power device via the contactor pair and directly connects to the electric machine. The controller executes a method to control a fault response under a fault condition resulting in opening of the contactor pair and a polyphase short condition. The controller calculates a back EMF of the electric machine and transmits switching control signals to semiconductor switches of the PIM to transition from the polyphase short condition to a polyphase open condition only when the calculated back EMF is less than a calibrated value and a voltage rise on a DC side of the PIM is less than a calibrated voltage rise. A vehicle includes the DC power device, road wheels, electric machine, PIM, and controller.

Fault shutdown control of an electric machine in a vehicle or other DC-powered torque system

Methods and systems are provided for controlling an electrical system of a vehicle. Sensors are used to obtain first data for a first path of calculations and second data for a second path of calculations. The first path comprises a first plurality of calculations of generating a value of a parameter pertaining to the electrical system, and the second path comprises a second plurality of calculations of monitoring the electrical system with respect to the first path. A processor is coupled to the plurality of sensors, and is configured to determine whether a data frozen flag is active, perform the first plurality of calculations of the first path using the first data if the first data flag is inactive, and perform the second plurality of calculations of the second path if the first data flag is active.

Method and system for controlling electrical systems of vehicles

A method for monitoring an electrically-powered torque machine configured to generate torque in a hybrid powertrain system includes monitoring signal outputs of a resolver configured to monitor rotational position of the torque machine. Upon detecting a fault warning state associated with the signal outputs of the resolver, a motor torque capacity of the torque machine is derated. Upon a clearing of the fault warning state, a torque ramp-up state to increase the motor torque capacity of the torque machine is executed. Notice of an incidence of a fault associated with the signal outputs of the resolver is provided only when the motor torque capacity fails to achieve a threshold motor torque capacity within a threshold recovery time period while executing the torque ramp-up state.

Method and apparatus for monitoring a resolver in a torque machine

A plug-in hybrid vehicle includes a hybrid powertrain system and an energy storage device. A method for operating the hybrid powertrain system includes initially operating the hybrid powertrain system in a charge-depletion mode to reduce a state-of-charge (SOC) of an energy storage device. In response to an operator request, the hybrid powertrain system operates in an opportunity charging mode to opportunistically charge the energy storage device to increase the SOC of the energy storage device during a trip prior to achieving a minimum SOC that is associated with triggering operation in a charge sustaining mode.

Method and apparatus for managing charge depletion in a plug-in hybrid vehicle

A method includes detecting a first event and executing a first procedure to identify a sensor offset in response to detecting the first event. The method further includes determining, via a computing device, whether the sensor offset was measured during the execution of the first procedure, scheduling a second procedure to execute in response to detecting a second event if the sensor offset was not measured during the first procedure, and scheduling the first procedure to execute in response to detecting a subsequent occurrence of the first event if the sensor offset was measured during the first procedure.

System and method of measuring a sensor offset

A method for operating a powertrain system including a torque machine mechanically coupled to an internal combustion engine includes, upon detecting a pending fault associated with a power switch configured to control power flow to the torque machine, disabling torque output from the torque machine and executing retry events. The retry events are iteratively executed with a debounce time period preceding each retry event. Presence of a fault associated with the power switch is detected when a quantity of the retry events during a time window exceeds a threshold.

Method and apparatus for fault detection in a torque machine of a powertrain system

A method of controlling a powertrain system includes determining a torque request; selecting feasible input torque and input speed operating points; calculating aggregate system power losses; determining turbo efficiency as a function of a difference between a feasible input torque rate of change and a desired input torque rate of change required to reach the desired output torque; summing the turbo efficiency to the aggregate system power losses to determine total system losses corresponding to feasible input torques and input speed capable of producing the desired output torque; determining a feasible input torque and input speed corresponding to a substantially minimum total system power loss; and selecting as a desired input speed and input torque that corresponds to the substantially minimum total system power loss.

Method and system of controlling a powertrain system to reduce turbo lag in a hybrid vehicle

A method to control a powertrain having an electric motor includes monitoring a torque command to the motor, predicting a motor torque for the motor based upon the torque command, monitoring an actual motor torque of the motor, comparing the actual motor torque to the predicted torque, and indicating a motor fault when the actual motor torque and the predicted torque differ by more than a calibratable threshold.

Robust motor torque performance diagnostics algorithm for electric drive systems in hybrid vehicles

A vehicle includes electrical components, current sensors which determine current flowing through the electrical components, and a control system. The control system calculates and records error index values over an interval using the currents. The control system increments a first counter with every sample in the series, increments a second counter whenever a given error index value exceeds a calibrated high threshold, and decrements the second counter whenever the given error index value is less than a calibrated low threshold. A control action, e.g., recording a PASS or FAIL value, executes when either the absolute value of the second counter or the present value of the first counter reaches a corresponding limit or threshold. A method enhances the robustness of a hybrid vehicle torque security diagnostic using the control system. The vehicle and method use a signed X of Y debouncing or error signal processing method as noted above.

Method and apparatus for enhancing the robustness of a hybrid vehicle torque security diagnostic

A method for monitoring electric isolation of a high voltage DC bus to detect ground isolation faults includes monitoring voltage differentials between a positive DC electric power bus and a negative DC electric power bus and a chassis ground. Electrical isolation between each of the positive and negative DC electric power buses and the chassis ground is monitored using a ratio of the voltage differentials.

Method and apparatus to monitor loss of ground isolation of an electric motor drive circuit

A distributed on-board diagnostic (OBD) architecture for a control system of a vehicle includes a plurality of control modules that are in communication with one another and a designated master OBD control module that is one of the plurality of control modules. The master OBD control module performs functions that a remainder of the plurality of control modules are incapable of performing including at least one of arbitrating a malfunction indicator lamp (MIL) state, arbitrating and storing OBD freeze frame data and determining OBD status flags of the remainder of the plurality of control modules.

Distributed diagnostics architecture

A method for monitoring operation of a vehicle including a high voltage electrical system including an electrical energy storage device electrically connected to switching circuits of an inverter device via a high voltage bus, the inverter device configured to transfer electric power to an electric machine via activation of a plurality of switch devices, includes monitoring electrical ground isolation of the high voltage electrical system during ongoing operation of the vehicle, detecting an electrical ground isolation fault in the high voltage electrical system, and detecting a location of the electrical ground isolation fault associated with at least one of the electrical energy storage device, the high voltage bus, the inverter device, and the electric machine subsequent to a vehicle key-off event.

Method and apparatus for monitoring electrical ground isolation in a powertrain system

Methods and systems are provided for motor torque control for hybrid vehicles having a motor and a communications bus. The motor torque is controlled using a first motor torque capacity if the communications bus is healthy. The motor torque is controlled using a second motor torque capacity if the communications bus is unhealthy. The first motor torque capacity has a first absolute value. The second motor torque capacity has a second absolute value that is less than the first absolute value.

Method and system for controlling motor torque in hybrid vehicles

Methods and systems are provided for monitoring an electrical system of a vehicle. Data pertaining to the electrical system is obtained. Calculation modules are performed using the data to generate intermediate determinations. An aggregate calculation module is performed using each of the intermediate determinations to generate an aggregate determination pertaining to the electrical system. Redundant intermediate calculations are performed using the data to generate redundant intermediate determinations. Each of the redundant intermediate determinations is used for comparison with a respective intermediate determination.

Method and system for monitoring vehicle electrical systems

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Troy, MI, United States of America

Wei D Wang