Constraint handling for electric motor parameters

Patent metadata

Field	Value
Publication number	US-12384352-B2
Application number	US-202318341173-A
Country	US
Kind code	B2
Filing date	Jun 26, 2023
Priority date	Jun 26, 2023
Publication date	Aug 12, 2025
Grant date	Aug 12, 2025

Abstract

Some embodiments disclosed herein are directed to constraint handling for parameters of electric motors. In particular, embodiments of the present disclosure relate to handling constraints for parameters such as current, voltage, and torque associated with an electric motor. Other embodiments may be disclosed or claimed.

First claim

What is claimed is:

1. A control system for an electric motor, the control system comprising:
a processor; and
memory coupled to the processor and storing instructions that, when executed by the processor, cause the control system to:
determine a quadratic current constraint for the electric motor, the quadratic current constraint associated with a maximum phase current for the electric motor;
determine a current overload parameter by which the quadratic current constraint may be exceeded for a predetermined period of time;
generate a current constraint graph that includes a circular representation of the quadratic current constraint and a current constraint polygon having a vertex and a boundary defined by a plurality of sides, wherein the circular representation of the quadratic current constraint is inscribed within the boundary of the current constraint polygon, and wherein the vertex of the current constraint polygon is based on the current overload parameter;
receive a phase current measurement from a current sensor coupled to the electric motor;
generate, based on the phase current measurement, a d-q axis current measurement; and
based on the d-q axis current measurement:
transmit a current control command to the electric motor in response to the d-q axis current measurement being within the boundary of the current constraint polygon; or
transmit an overload notification to a fault management system in response to the d-q axis current measurement being beyond the boundary of the current constraint polygon.

2. The control system of claim 1 , wherein the d-q axis current measurement includes:
a d-axis current measurement associated with a d-axis along a direction of a north polarity of a magnet of the electric motor or a north polarity of a magnet field generated by a rotor field winding of the electric motor; and
a q-axis current measurement associated with a q-axis that is perpendicular to the d-axis, wherein the q-axis is ninety degrees ahead of the north polarity associated with the d-axis.

3. The control system of claim 1 , current control command includes a gate control signal provided to an inverter system coupled to the electric motor.

4. The control system of claim 1 , wherein determining the current overload parameter is based on overloading a predetermined current range of the electric motor by a predetermined percentage.

5. The control system of claim 4 , wherein the predetermined current range is between about 100 A and about 1500 A.

6. The control system of claim 4 , wherein the predetermined percentage is between about 10 percent and about 20 percent.

7. The control system of claim 1 , wherein the current constraint polygon has at least six sides.

8. The control system of claim 7 , wherein the current constraint polygon has at least eight sides.

9. The control system of claim 1 , wherein the memory further stores instructions to cause the control system to:
determine a quadratic voltage constraint for the electric motor, the quadratic voltage constraint associated with a maximum phase voltage for the electric motor;
generate a voltage constraint graph that includes a circular representation of the quadratic voltage constraint and a voltage constraint polygon having a vertex and a boundary defined by a plurality of sides, wherein the circular representation of the quadratic voltage constraint is circumscribed about the boundary of the voltage constraint polygon;
receive, from the electric motor, an inverter bus voltage measurement;
generate, using a model predictive controller (MPC), a d-q axis voltage command; and
based on the d-q axis voltage command:
transmit a control command to an inverter of the electric motor in response to the d-q axis voltage command being within the boundary of the voltage constraint polygon; or
adjust the d-q axis voltage command to be within the boundary of the voltage constraint polygon in response to the d-q axis voltage command being beyond the boundary of the voltage constraint polygon.

10. The control system of claim 9 , wherein the inverter bus voltage measurement is received from a voltage sensor coupled to the electric motor.

11. The control system of claim 9 , wherein the maximum phase voltage for the electric motor is between about 100V and about 1600V.

12. The control system of claim 9 , wherein the memory further stores instructions to cause the control system to determine a maximum voltage change constraint for a change in voltage of the electric motor over a predetermined period of time.

13. The control system of claim 12 , wherein the voltage constraint polygon has at least twelve sides.

14. The control system of claim 9 , wherein the voltage constraint polygon has at least six sides.

15. The control system of claim 1 , wherein the memory further stores instructions to cause the control system to determine a maximum torque constraint for the electric motor based on a maximum torque envelope for the electric motor.

16. The control system of claim 15 , wherein the maximum torque constraint is further determined based on a maximum allowed current change for the d-q axis current measurement.

17. The control system of claim 15 , wherein the maximum torque constraint for the electric motor is between about 50 Nm and about 1000 Nm.

18. The control system of claim 1 , wherein the memory further stores instructions to cause the control system to determine a torque measurement for the electric motor, and:
transmit a torque control command to a controller of the electric motor in response to the torque measurement being within a maximum torque constraint; or
transmit an overload notification to the fault management system in response to the torque measurement exceeding the maximum torque constraint.

19. An electric motor, comprising:
a control system coupled to the electric motor, the control system comprising:
a processor; and
memory coupled to the processor and storing instructions that, when executed by the processor, cause the control system to:
determine a quadratic current constraint for the electric motor, the quadratic current constraint associated with a maximum phase current for the electric motor;
determine a current overload parameter by which the quadratic current constraint may be exceeded for a predetermined period of time;
generate a current constraint graph that includes a circular representation of the quadratic current constraint and a current constraint polygon having a vertex and a boundary defined by a plurality of sides, wherein the circular representation of the quadratic current constraint is inscribed within the boundary of the current constraint polygon, and wherein the vertex of the current constraint polygon is based on the current overload parameter;
receive a phase current measurement from a current sensor coupled to the electric motor;
generate, based on the phase current measurement, a d-q axis current measurement; and
based on the d-q axis current measurement:
transmit a current control command to the electric motor in response to the d-q axis current measurement being within the boundary of the current constraint polygon; or
transmit an overload notification to a fault management system in response to the d-q axis current measurement being beyond the boundary of the current constraint polygon.

20. A vehicle comprising:
an electric motor;
a current sensor coupled to the electric motor; and
a control system coupled to electric motor, the control system comprising:
a processor; and

Assignees

• Gm Global Tech Operations Llc

Inventors

• Hao Lei
• Wang Yue-Yun
• Cao Bojian
• Gopalakrishnan Suresh
• Cimini Gionata

Classifications

• B60W2710/081

  Speed · CPC title

• B60W2710/083

  Torque · CPC title

• B60W2710/086

  Power · CPC title

• H02P21/22 Primary

  Current control, e.g. using a current control loop · CPC title

• H02P29/027

  the fault being an over-current · CPC title