Tesla Motors, Inc.

Atieva, Inc.

Other

Tesla, Inc.

Yifan Tang

Shyi-Perng Phillip Luan

Jeremy Franz Mayer

Benson Tsai

James Jan

Jean-Philippe Gauthier

Andrew David Baglino

Greg Grant Solberg

Anh Phung

An induction motor controller is provided. The induction motor controller includes a first module that derives a commanded stator voltage vector, in a rotor flux reference frame, via a rotor flux regulator loop and a torque regulator loop, which process at least partially in the rotor flux reference frame. The induction motor controller includes a second module that processes the commanded stator voltage vector to produce AC (alternating current) power for an induction motor.

Induction motor flux and torque control

A rotor flux estimator is provided. The rotor flux estimator includes an estimation module that generates a first rotor flux vector expressed in a phase voltage reference frame and a second rotor flux vector expressed in the phase voltage reference frame, from a stator voltage vector expressed in a phase voltage reference frame, a rotational speed of a rotor, and a stator current vector expressed in the phase voltage reference frame. The estimation module includes at least one processor and the estimation module includes a rotor flux current model and a rotor flux voltage model.

Induction motor flux and torque control with rotor flux estimation

A safety system for an electric motor controller is provided. The safety system includes a torque safety monitor having a first processor distinct from a second processor of a main motor controller. The first processor is configured to one of decrease or shut down AC (alternating current) power, sent from a DC/AC (direct current to alternating current) inverter to an electric motor, in response to an estimated torque of the electric motor differing from a commanded torque associated with the main motor controller by more than a set amount.

Electric vehicle motor torque safety monitor

A heat sink is provided. The heat sink includes a single-piece housing having a floor and two walls, the walls perpendicular to the floor and the walls are parallel to each other. The heat sink includes the housing having an inlet and an outlet. The housing is configured to attach power modules to an outer surface of the floor and to outer surfaces of the two walls. The housing is configured to cool the power modules in response to fluid flow into the inlet.

Inverter power module packaging with cold plate

An electric vehicle drive system includes first and second electric motors, first and second torque limiters and a torque splitter. The first and second torque limiters correspond to the first and second electric motors, respectively, and generate respective first and second maximum torques. The torque splitter receives a first input that includes at least a total torque request for the first and second electric motors and the first and second maximum torques and generates at least respective first and second torque requests for the first and second electric motors, wherein the torque splitter is configured to direct a torque request to the second motor only if the first maximum torque is less than a threshold. The torque splitter may generate a zero second torque request if a motor speed of the first electric motor exceeds a threshold.

Control system for an all-wheel drive electric vehicle

A method is provided for fabricating a rotor assembly for an electric motor which utilizes pre-fabricated conductive rotor bars and die cast end rings. Containment rings, which may be installed on the end rings either before or after casting, may be used to inhibit end ring creep at high rotational speeds.

Method of manufacturing the rotor assembly for an electric motor

A motor assembly with an integrated cooling system is provided in which a coolant (e.g., oil) is injected into a hollow region of the rotor shaft. The coolant is expelled out of the rotor shaft and into the motor enclosure via multiple thru-holes, thereby allowing efficient cooling of both the stator and the rotor assemblies.

Motor cooling system

A power device temperature monitor is provided. The power device temperature monitor includes a power device having a control terminal and an output terminal, where the output terminal is configured to output a current as directed by a voltage of the control terminal. The power device temperature monitor includes an inductor coupled to the output terminal of the power device and an amplifier coupled to the inductor. The power device temperature monitor includes a computing device that receives an output of the amplifier, the computing device is configured to derive a temperature of the power device based upon the output of the amplifier.

Power device temperature monitor

An electric vehicle drive system comprising first and second electric motors; a torque split unit configured to receive first input that includes at least a total torque request for the first and second electric motors, and respective first and second maximum torques for the first and second electric motors, the torque split unit configured to process the first input without taking into account wheel slip, and to generate at least respective first and second torque requests for the first and second electric motors; and a traction and stability control unit configured to receive second input that includes at least the first and second torque requests, the total torque request, a computed vehicle speed, and respective first and second slip errors relating to the first and second electric motors, the traction and stability control unit configured to process the second input and to generate respective first and second torque commands for the first and second electric motors.

An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. The voltage vector determined by the primary loop is selected and applied immediately upon completion of the corresponding primary control loop computational cycle. The secondary loop, utilizing a faster sampling rate than that of the primary loop, compares the measured phase current to a preset current limit. If the secondary loop determines that the measured phase current has exceeded the preset current limit, it sets a null voltage vector, thereby limiting transient over currents.

Direct torque control motor controller with transient current limiter

An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. Application of the voltage vector determined by the primary loop is delayed until initiation of the next primary control loop cycle. The secondary loop, utilizing a faster sampling rate than that of the primary loop, compares the measured phase current to a preset current limit. If the secondary loop determines that the measured phase current has exceeded the preset current limit, it sets a null voltage vector, thereby limiting transient over currents.

An AC motor controller is provided that utilizes a direct torque controller and primary and secondary control loops. The primary control loop operates in a relatively conventional manner, determining a voltage vector that sets the inverter switching variables for the motor's power inverter, where the voltage vector is based on the motor's torque and flux as estimated from the measured voltage and current of the motor. The secondary loop, utilizing a faster sampling rate than the primary loop, estimates a more up-to-date torque error which is compared to a secondary torque error band, where the secondary torque error band is preferably narrower that the primary torque error band. If the secondary loop determines that the up-to-date torque error has exceeded the secondary torque error band, it sets a null voltage vector, thereby limiting torque ripples.

Direct torque control motor controller with torque ripple reduction

An induction motor controller is provided. The induction motor controller includes a first module that derives a commanded stator voltage vector, in a stator flux reference frame, via a rotor flux regulator loop and a torque regulator loop, which process at least partially in the stator flux reference frame. The induction motor controller includes a second module that processes the commanded stator voltage vector to produce AC (alternating current) power for an induction motor.

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Los Altos, CA, United States of America

Yifan Tang