Tula eTechnology, Inc.

Methods, systems, and devices for electric machine torque adjustment based on waveform multiples are disclosed herein. One electric machine controller, arranged to direct pulsed operation of an electric machine, utilizes a pulse controller that calculates a first average measured torque from sensed torque values over a first time period and a second average measured torque from sensed torque values over a second time period, wherein the first and second time periods are different time periods.

A boost circuit is arranged to reduce rise and fall times of pulsed power used for pulsed control operation of electric machines. Magnetic energy present in the electric machine at the end of a pulse is extracted by the boost circuit to reduce the pulse fall time. The energy is stored by the boost circuit and then applied at the beginning of a subsequent pulse to reduce the rise time. By reducing rise and fall times compared to not using such a boost circuit, machine efficiency is improved.

Methods, systems, and devices for electric machine drive calibration, verification, and efficiency improvement are disclosed herein. One electric machine controller for calibration includes a processor and memory and instructions that are stored in the memory and executable by the processor to identify a vehicle and/or electric machine frequency response during operation of the vehicle and use the electronic machine and a dynamic motor drive converter to provide source excitations based on the identified frequency response.

Methods, systems, and devices for electric machine drive calibration, verification, and efficiency improvement are disclosed herein. One electric machine controller for calibration includes a processor and memory and instructions that are stored in the memory and executable by the processor to identify a vehicle and/or electric machine frequency response during operation of the vehicle and use the electronic machine and a dynamic motor drive converter to provide source excitations based on the identified frequency response.

An electric machine is provided. A polyphase machine comprising at least one of an induction machine and an externally excited synchronous machine is provided. A power inverter is electrically connected to the polyphase machine. An inverter controller is electrically connected to the power inverter, wherein the inverter controller is configured to provide a torque command, wherein the torque command provides a torque signal to provide a plurality of pulses that pulse between a first demand torque level and a second demand torque level, wherein the second demand torque level is lower in amplitude than an amplitude of the first demand torque level and control an i d provided by the power inverter, so that when the torque signal is at the first demand torque level, rotor flux strictly increases and when the torque signal is at the second demand torque level, rotor flux strictly decreases.

An electric machine controller arranged to direct a power converter to cause a pulsed operation of an electric machine in selected operational ranges to deliver a desired output and to cause a continuous operation of the electric machine in selected operational ranges is provided. A ramp generator is adapted to provide a ramping between the pulsed operation and the continuous operation. In some embodiments, the ramp generator utilizes a quadratic, cubic or higher order ramping function. In some embodiments, during a first portion of the transitional period, the ramp generator causes pulsing between a first ramped transitional torque level and a second ramped transitional torque level that is lower than the first transitional torque level, and during a second portion of the transitional period, the ramp generator causes the electric machine to generate substantially zero torque in intervals between transitional pulses while ramping the first ramped transitional torque level.

An electric machine controller arranged to direct a power converter to cause a pulsed operation of an electric machine in selected operational ranges to deliver a desired output and to cause a continuous operation of the electric machine in selected operational ranges is provided. A ramp generator is adapted to provide a ramping between the pulsed operation and the continuous operation.

A variety of methods, controllers, and electric machine systems are described that facilitate pulsed control of multiple electric machines (e.g., electric motors and generators) to improve the machine's energy conversion efficiency. Under selected operating conditions, the electric machine is intermittently driven (pulsed). The pulsed operation causes the output of the electric machine to alternate between a first output level and a second output level that is lower than the first output level. The output levels are selected such that at least one of the electric machines and a system that includes the electric machine has a higher energy conversion efficiency during the pulsed operation than the electric machine would have when operated at a third output level that would be required to drive the electric machine in a continuous manner to deliver the desired output. In some embodiments, the second output level is zero torque.

Methods, controllers and electric machine systems are described that facilitate pulsed control of electric machines (e.g., electric motors and generators) to improve the machine's energy conversion efficiency. Under selected operating conditions, the electric machine is intermittently driven (pulsed). The pulsed operation causes the output of the electric machine to alternate between a first output level and an off state. The output levels are selected such that the electric machine has a higher energy conversion efficiency during the pulsed operation than the electric machine would have when operated at a third output level that would be required to drive the electric machine in a continuous manner to deliver the desired output. In some embodiments, the power converter it turned off during at least portions of the time that the electric machine is pulsed off.

Various boost circuits that are used to improve or reduce the time needed to transition an electric machine from an off-state to an on-state at the start of a next pulse during pulsed controlled operation. With these various boost circuits, the naturally generated Back Electromotive Force or “BEMF” that is induced when an electrical machine transitions from the on state to the off state at the end of an on pulse is harvested, rectified, and stored on a storage device. The harvested energy is then made available to the electric machine as a “boost” voltage at the onset of the next on pulse, resulting in a reduced transition time from the off-state to the on-state.