A short circuit detection system and method that identifies a short circuit between turns of a winding of a permanent magnet machine having a three-phase winding in response to detection of imbalances between the three motor phases at an instant in time. The imbalances are identified by monitoring motor terminal voltages and currents.

Fault-tolerant electrical drive systems and methods of maintaining electrical balance or continuing operation of a rotary electric machine under a fault condition are provided. One such system comprises: a rotary electric machine comprising pn phases having a common connection point, where p is a prime number and n is an integer greater than or equal to 1; a drive circuit module having pn phase drive circuits and a reserve drive circuit; and a contactor module. The contactor module comprises: pn phase contactors each of which is operable to connect one of the pn phases of the rotary electric machine to a respective one of the pn phase drive circuits; and a phase fault contactor operable to connect the reserve drive circuit to the common connection point.

A communication system for use in a switching module includes a low-side control block coupled to control switching of a low-side switch of the switching module. The low-side control block is further coupled to be referenced with a low-side reference system ground. A high-side control block is coupled to control switching of a high-side switch of the switching module. The high-side control block is further coupled to be referenced with a floating node of the switching module. During steady state operation, the low-side control block is coupled to send signals during each switching cycle to the high-side control block to turn the high-side switch on and off. A status update is communicated from the high-side control block to the low-side control block through a first single-wire communication link.

Fault-tolerant electrical drive systems and methods of maintaining electrical balance or continuing operation of a rotary electric machine under a fault condition are provided. One such system comprises: a rotary electric machine comprising pn phases having a common connection point, where p is a prime number and n is an integer greater than or equal to 1; a drive circuit module having pn phase drive circuits and a reserve drive circuit; and a contactor module. The contactor module comprises: pn phase contactors each of which is operable to connect one of the pn phases of the rotary electric machine to a respective one of the pn phase drive circuits; and a phase fault contactor operable to connect the reserve drive circuit to the common connection point.

Monitoring conditions of an electric motor using stator current and voltage signals from power supplied to the motor is disclosed herein. The stator voltage and current signals may be used to calculate instantaneous power values which may be used to calculate slip. The slip may be used to monitor for a locked rotor condition during startup of the motor. The slip value may be used to provide thermal protection to the electric motor.

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.

A protection device provided between a synchronous motor having a plurality of windings and a motor driving device for driving the synchronous motor includes: a switching unit for making and breaking the connection between the motor driving device and the synchronous motor; a dynamic brake circuit including resistors and switches, to short-circuit the plurality of windings between the switching unit and the synchronous motor via the resistors; and a control device for controlling the switching unit and the dynamic brake circuit. The control device controls the switches in the dynamic brake circuit to short-circuit the plurality of windings, and then controls the switching unit to cut off the connection between the motor driving device and the synchronous motor.

Systems and methods are disclosed herein for monitoring and detecting a loss of synchronism in an electric motor, such as a synchronous motor. A monitoring system may compare a measured or provided electric power system frequency with a measured rotational frequency of the rotor of the electric motor. The rotational frequency of the rotor may be obtained from a shaft-mounted device. The monitoring system may determine a slip condition and/or a loss of synchronism of the electric motor.

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.

A communication system for use in a switching module includes a low-side control block coupled to control switching of a low-side switch of the switching module. The low-side control block is further coupled to be referenced with a low-side reference system ground. A high-side control block is coupled to control switching of a high-side switch of the switching module. The high-side control block is further coupled to be referenced with a floating node of the switching module. During steady state operation, the low-side control block is coupled to send signals during each switching cycle to the high-side control block to turn the high-side switch on and off. A status update is communicated from the high-side control block to the low-side control block through a first single-wire communication link.