Ford Global Technolgoies, LLC

Wei Xu

Jiyao Wang

Silong Li

Fazal Urrahman Syed

Zhichun Ma

Shuzhen Liu

Yinghan Xu

Michael W Degner

Scott Vincent Myers

Venkatapathi Raju Nallapa

Daniel Richard Luedtke

Yulei Chen

Kyle M Hanson

Mohammad Sameer Khan

A system for controlling an electric machine of a vehicle includes, among other things, a controller module configured to attenuate noise from the electric machine by altering a corrective voltage in response to feedback about the noise. The corrective voltage and a fundamental voltage command are supplied to the electric machine as a combined voltage command. The corrective voltage is on a harmonic adjacent to a harmonic of the noise. A method of controlling noise associated with an electric machine of a vehicle includes, among other things, altering a corrective voltage to attenuate noise in response to feedback about the noise. The corrective voltage and a fundamental voltage command are supplied to the electric machine as a combined voltage command. The corrective voltage is on a harmonic adjacent to a harmonic of the noise.

Electric machine noise attenuation

A vehicle power system includes a battery bus between a traction battery and voltage converter, a high-voltage bus between the voltage converter and an inverter, and a controller. The controller, responsive to a contactor between the traction battery and voltage converter opening, controls an engine to maintain a speed of a generator electrically coupled with the inverter within a predefined range, controls the voltage converter to drive a measured voltage of the battery bus toward a first commanded value based on a first difference between the first commanded value and measured voltage of the battery bus, and controls the generator to drive a measured voltage of the high-voltage bus toward a second commanded value different than the first commanded value based on the first difference and a second difference between the second commanded value and the measured voltage of the high-voltage bus.

DC bus voltage regulation in automotive vehicle during contactor open events

A vehicle includes a battery, an electric machine, a rotor position sensor, an inverter, and a controller. The electric machine is configured to propel the vehicle. The electric machine has a stator and a rotor. The inverter is disposed between the battery and the electric machine. The inverter is configured to convert DC electrical power from the battery into AC electrical power. The inverter is configured to deliver the AC electrical power to the electric machine. The controller is programmed to adjust the offset position of the rotor position senor and control the torque of the electric machine based on the offset position of the rotor position sensor.

Electric machine torque control system

A vehicle includes an electric machine and a controller configured to inject a voltage into the electric machine. The controller measures the currents caused by the voltage and processes the currents using a discrete Fourier transform to determine positive and negative sequence currents. A phase rotation sequence is identified by comparing the sequence currents to expected positive and negative sequence currents that are associated with possible phase rotation sequences. The electric machine may be controlled according to the identified phase rotation sequence. A cable swapped diagnostic may be output when the phase rotation sequence is different than an expected phase rotation sequence.

Voltage injection-based cable swap detection

An electric drive system has a motor including a rotor, an inverter, and a controller. The controller perturbs a position of the rotor via a pulse width modulation (PWM) command to the inverter such that the motor receives an Id current that changes during the perturbing and an Iq current, and responsive to the Iq current settling at zero during the perturbing, alters the PWM command to cause the rotor to rotate.

Vehicle electric motor closed-loop position holding control

In an electrified vehicle having a synchronous traction motor, an inverter is connected to stator windings by three power cables. If these cables are accidentally connected to the wrong windings, the resulting torque will not match the desired torque, and may even be in the wrong direction. To avoid this problem, a test is performed any time that the cables may have been unplugged and re-connected. The inverter is commanded to generate a rotating magnetic field while the rotor is held stationary, resulting in a positive and a negative response current. A relationship between a phase angle of the negative response current and the rotor position indicates which cables are connected to which windings. If the cables are incorrectly connected, the controller disables the motor and informs an operator which cables to swap to achieve correct connection.

Hybrid transmission wiring verification

A vehicle power system includes an electric machine, an inverter electrically connected with the electric machine, and a controller. The controller, while injecting AC voltage output by the inverter into the electric machine as a DC voltage input to the inverter changes, drives a duty ratio of the inverter toward a constant value to obtain resolver offset information associated with the electric machine from a current response of the electric machine to the AC voltage.

Constant duty ratio high frequency voltage injection-based resolver offset detection

A vehicle includes a controller programmed to, responsive to injecting a high frequency voltage signal to an electric machine, determine an estimated negative sequence current phase associated with an electric machine current, and responsive to a rotor of the electric machine being at a predetermined rotor position, inject a pulse torque command to the electric machine and observe a speed change of the electric machine to determine a cable sequence.

High frequency voltage injection-based cable swap detection

An electric machine assembly for a vehicle is provided. The electric machine is in operational communication with a traction battery and includes a stator core defining a cavity and a rotor disposed within the cavity having an inner region defined by sets of triangle-shaped holes tessellated about respective central regions to form a truss structure such that the holes of the truss structure, during operational rotation, do not influence magnetic flux paths generated by magnets of the rotor. The rotor may have a strain energy value less than or equal to 16,100 Joules. The truss structure may include pairs of symmetrical portions each including segments arranged with adjacent rotor portions to define the triangle-shaped holes.

Rotor structure for electric machine assembly

A vehicle includes an electric machine. The vehicle includes a controller configured to repeatedly adjust power outputs for the two inverters so that they differ to drive the difference toward zero and such that power provided to the electric machine satisfies demand until the difference falls below a second predetermined threshold. The controller may be configured to adjust responsive to a temperature difference between two inverters associated with the electric machine exceeding a predetermined threshold.

Variable inverter output

An electric motor/generator includes a stator-core enclosing a rotor-core, which are each formed from stacked annular laminates. The stator-core laminates are configured to reduce vibration, and each have teeth extending radially inward from a root of an annular stator yoke/back-iron, to a flux-cap. Each tooth is formed to have opposite, lateral-edges spaced a distance-apart that changes between the root to the flux-cap, to establish a variable tooth-stiffness and a predetermined mechanical-resonance of the tooth. The opposite lateral-edges may each be configured with either a linear or a non-linear, curved edge-profile, and to have the variable tooth-stiffness and the lateral-edge distance-apart changing or decreasing between the root and the flux-cap. Each tooth may also have an edge-profile that is different from at least one adjacent tooth, and which is configured with a variable tooth-stiffness and a predetermined mechanical resonance that is different from the at least one adjacent tooth.

Optimized stator tooth for electric motor/generator

A vehicle includes an electric machine operated by an inverter. The electric machine includes a gate driver configured to energize a switch of the inverter with a pulse width modulation (PWM) signal. The gate driver is configured to delay the PWM signal by a dependent amount that is a function of a magnitude of current of a lead of the electric machine. The delay is responsive to a polarity of the current being positive.

Virtual resistance gate driver

An electric drive system for a vehicle includes an electric machine having first conductors arranged in slots of a stator to form phase windings and a second conductor arranged in the slots to form a secondary winding that produces a voltage indicative of a common mode voltage caused by voltages applied to the phase windings. The voltage can be used to supply power to electronic components and for diagnosis and control of the electric machine and an associated inverter.

Common mode current reduction hybrid drive system

A vehicle includes a five-phase electric machine with open windings driven at each side by phase legs of an inverter. A controller monitors for open-circuit windings. In response to detecting an open-circuit winding above a predetermined speed threshold, the controller operates the inverter to drive the windings that are not open-circuited in a square configuration.

Reconfigurable winding connection for five-phase permanent magnet electric machine

A vehicle powertrain includes an inverter coupled with an electric machine and a controller. The controller may be configured to dither a base frequency of a pulse width modulated (PWM) signal, by less than an amount that is based on a rotational speed of the machine and the base frequency, to operate the inverter such that energy at sidebands and harmonics of the base frequency are reduced by distributing the energy to reduce audible vibrations of the powertrain.

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Canton, MI, United States of America

Wei Xu