Systems and methods for detecting stator winding faults and degradation

    公开(公告)号:US11489471B2

    公开(公告)日:2022-11-01

    申请号:US16715102

    申请日:2019-12-16

    Abstract: 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.

    SYSTEM AND METHOD FOR MEASURING AND DIAGNOSING INITIAL OFFSETS OF AN ANALOG INPUT SENSOR

    公开(公告)号:US20180367077A1

    公开(公告)日:2018-12-20

    申请号:US15625591

    申请日:2017-06-16

    Abstract: 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.

    ELECTRIC MOTOR IN PROPULSION SYSTEM WITH AUXILIARY POWER GENERATION

    公开(公告)号:US20210021219A1

    公开(公告)日:2021-01-21

    申请号:US16515695

    申请日:2019-07-18

    Abstract: 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 (δ). The delta factor is set as a speed modifier (Δω=δ) when the cosine of an angle (θ), 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 (Δω).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.

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

    公开(公告)号:US10461678B2

    公开(公告)日:2019-10-29

    申请号:US15924823

    申请日:2018-03-19

    Abstract: 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.

    Electric motor in propulsion system with auxiliary power generation

    公开(公告)号:US11095240B2

    公开(公告)日:2021-08-17

    申请号:US16515695

    申请日:2019-07-18

    Abstract: 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 (δ). The delta factor is set as a speed modifier (Δω=δ) when the cosine of an angle (θ), 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 (Δω). 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.

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

    公开(公告)号:US10608567B1

    公开(公告)日:2020-03-31

    申请号:US16283060

    申请日:2019-02-22

    Abstract: 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 (λm) 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 (TD) 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 (TD).

    Integrated fault isolation and prognosis system for electric drive system

    公开(公告)号:US11133771B2

    公开(公告)日:2021-09-28

    申请号:US16702877

    申请日:2019-12-04

    Abstract: 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.

    METHODS AND SYSTEMS FOR DETERMINING WHEN TO APPLY AN ADAPTATIVE THERMAL COMPENSATION IN AN OPERATING REGION OF A MOTOR

    公开(公告)号:US20190288625A1

    公开(公告)日:2019-09-19

    申请号:US15924823

    申请日:2018-03-19

    Abstract: 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.

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

    公开(公告)号:US10164559B1

    公开(公告)日:2018-12-25

    申请号:US15625591

    申请日:2017-06-16

    Abstract: 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.

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