Title of Invention

METHOD AND SYSTEM FOR CONTROLLING A POWER INVERTER IN ELECTRIC DRIVES OF VEHICLES WITH TWO-MODE TRANSMISSIONS

Abstract Methods and systems for controlling a power inverter in automobiles utilizing two-mode transmissions are provided. The various embodiments control the power inverter by, responsive to a commanded torque of the electric motor being below a first torque level, controlling the power inverter to set a switching frequency of the power inverter at a first set frequency; and, responsive to the commanded torque of the electric motor being between the first torque level and a second torque level, controlling the power inverter to determine the switching frequency of the power inverter as a function of the commanded torque of the electric motor while maintaining the switching frequency above a dynamic frequency limit. The method reduces switching frequencies in the inverter at high commanded torques, while maintaining the switching frequencies above dynamic frequency limit that provides effective control over the motor.
Full Text P000484-ATC-CD (003.0320)
METHOD AND SYSTEM FOR CONTROLLING A POWER INVERTER
IN ELECTRIC DRIVES OF VEHICLES WITH TWO-MODE
TRANSMISSIONS
TECHNICAL FIELD
[0001] The present invention generally relates to power inverters, and
more particularly relates to methods and systems for controlling power
inverters in electric drive systems of automobiles utilizing two-mode
transmissions.
BACKGROUND OF THE INVENTION
[0002] In recent years, advances in technology, as well as ever evolving
tastes in style, have led to substantial changes in the design of automobiles.
One of the changes involves the complexity of the electrical systems within
automobiles, particularly alternative fuel vehicles, such as hybrid, electric, and
fuel cell vehicles. Such alternative fuel vehicles typically use an electric
motor, perhaps in combination with another actuator, to drive the wheels.
[0003] These types of vehicles can offer significant improvements in
efficiency. There remains, however, an ever present need to improve the
efficiency of electric motor drives to reduce power losses, improve battery
life, and increase range. Additionally, it is generally desirable to reduce the
noise generated from the automobile. Unfortunately, some techniques for
reducing power losses in the electric motor system can increase acoustic noise
emissions beyond acceptable levels.
[0004] Accordingly, it is desirable to provide a control method that
reduces power losses and increases the efficiency of electric motors in
automobiles, without excessively increasing the acoustic noise generated by
the electrical motor. Furthermore, other desirable features and characteristics
of the present invention will become apparent from the subsequent detailed
description and the appended claims, taken in conjunction with the
accompanying drawings and the foregoing technical field and background.

SUMMARY OF THE INVENTION
[0005] In one embodiment, a method for controlling a power inverter in an
electric drive system of an automobile is provided. In general, the method
controls the power inverter by, responsive to a commanded torque of the
electric motor being below a first torque level, controlling the power inverter
to set a switching frequency of the power inverter at a first set frequency; and,
responsive to the commanded torque of the electric motor being between the
first torque level and a second torque level, controlling the power inverter to
determine the switching frequency of the power inverter as a function of the
commanded torque of the electric motor while maintaining the switching
frequency above a dynamic frequency limit. The method reduces switching
frequencies in the inverter at high commanded torques, while maintaining the
switching frequencies above a dynamic frequency limit that provides effective
control over the motor. This reduces power loss and thus improves the
efficiency of the system.
[0006] In a further embodiment, an automotive electric drive system is
provided. The system includes a prime mover power source and a two-mode,
compound-split, electro-mechanical transmission, including first and second
motors, coupled to the prime mover power source, a power inverter coupled to
the first and second motors, and a processor coupled to the first and second
motors and the power inverter. The at least one processor is configured to,
responsive to a commanded torque of the electric motor being below a first
torque level, provide a signal controlling the power inverter to set a switching
frequency of the power inverter at a first set frequency; and, responsive to the
commanded torque of the electric motor being between the first torque level
and a second torque level, provide a signal controlling the power inverter to
determine the switching frequency of the power inverter as a function of the
commanded torque of the electric motor while maintaining the switching
frequency above a dynamic frequency limit. The system reduces switching
frequencies in the inverter at high commanded torques, while maintaining the
switching frequencies above a dynamic frequency limit that provides effective

control over the motor. This reduces power loss and thus improves the
efficiency of the system.
[0007] In a further embodiment, an automotive electric drive system is
provided. The system includes a prime mover power source and a two-mode,
compound-split, electro-mechanical transmission, including first and second
motors, coupled to the prime mover power source, a power inverter coupled to
the first and second motors, and a processor coupled to the first and second
motors and the power inverter. The transmission includes an input member to
receive power from the prime mover, an output member to deliver power from
the transmission, first and second motors being coaxially aligned, first, second,
and third coaxially aligned planetary gear arrangements, each planetary gear
arrangement utilizing first, second and third gear members, the first and
second motors being coaxially aligned with the three planetary gear
arrangements, at least one of the first, second, and third gear members in the
first or second planetary gear arrangement being connected to the first motor,
and another one of the first, second, and third gear members in the second and
third planetary gear arrangements being connected to the second motor, one of
the gear members of the first planetary gear arrangement being continuously
connected to the input member, a first torque-transmitting mechanism to
selectively connect one of the gear members associated with each of the
planetary gear arrangements to each other and to the output member, a second
torque-transmitting mechanism to selectively connect one of the gear members
of the third planetary gear set with ground, a third torque-transmitting
mechanism to selectively connect one of the gear members of the second
planetary gear set with another of the gear members of the second planetary
gear set, a first interconnecting member continuously connecting one of the
members of the first planetary gear set with one of the members of the second
planetary gear set, and a second interconnecting member continuously
connecting one of the members of the second planetary gear set with one of
the members of the third planetary gear set. The at least one processor is
configured to, responsive to a commanded torque of the electric motor being

below a first torque level, provide a signal controlling the power inverter to set
a switching frequency of the power inverter at a first set frequency; and,
responsive to the commanded torque of the electric motor being between the
first torque level and a second torque level, provide a signal controlling the
power inverter to determine the switching frequency of the power inverter as a
function of the commanded torque of the electric motor while maintaining the
switching frequency above a dynamic frequency limit. The system reduces
switching frequencies in the inverter at high commanded torques, while
maintaining the switching frequencies above dynamic frequency limit that
provides effective control over the motor. This reduces power loss and thus
improves the efficiency of the system.
DESCRIPTION OF THE DRAWINGS
[0008] The present invention will hereinafter be described in conjunction
with the following drawing figures, wherein like numerals denote like
elements, and
[0009] FIG. 1 is a schematic view of an exemplary automobile according
to one embodiment of the present invention;
[0010] FIG. 2 is a block diagram of a voltage source inverter system
within the automobile of FIG. 1;
[0011] FIG. 3 is a schematic view of an inverter within the automobile of
FIG. 1;
[0012] FIG. 4 is a schematic view of a two-mode, compound-split, electro-
mechanical transmission within the automobile of FIG. 1;
[0013] FIG. 5 is a truth table presenting fixed ratios for the operation of
the transmission of FIG. 4;
[0014] FIG. 6 is a graphical representation of exemplary switching
frequency control scheme; and
[0015] FIG. 7 is a graphical representation of a dynamic frequency limit
control scheme.

DESCRIPTION OF AN EXEMPLARY EMBODIMENT
[0016] The following detailed description is merely exemplary in nature
and is not intended to limit the invention or the application and uses of the
invention. Furthermore, there is no intention to be bound by any expressed or
implied theory presented in the preceding technical field, background, brief
summary or the following detailed description.
[0017] The following description refers to elements or features being
"connected" or "coupled" together. As used herein, unless expressly stated
otherwise, "connected" means that one element/feature is directly joined to (or
directly communicates with) another element/feature, and not necessarily
mechanically. Likewise, unless expressly stated otherwise, "coupled" means
that one element/feature is directly or indirectly joined to (or directly or
indirectly communicates with) another element/feature, and not necessarily
mechanically. However, it should be understood that although two elements
may be described below, in one embodiment, as being "connected," in
alternative embodiments similar elements may be "coupled," and vice versa.
Thus, although the schematic diagrams shown herein depict example
arrangements of elements, additional intervening elements, devices, features,
or components may be present in an actual embodiment. It should also be
understood that the figures are merely illustrative and may not be drawn to
scale.
[0018] The figures illustrate a method and a system for controlling a
power inverter in an electric drive system of an automobile. The system
includes a prime mover power source and a two-mode, compound-split,
electro-mechanical transmission, including first and second motors, coupled to
the prime mover power source, a power inverter coupled to the first and
second motors, and at least one processor coupled to the first and second
motors and the power inverter. In general, the system and method controls the
power inverter by, responsive to a commanded torque of the electric motor
being below a first torque level, controlling the power inverter to set a
switching frequency of the power inverter at a first set frequency; and,

responsive to the commanded torque of the electric motor being between the
first torque level and a second torque level, controlling the power inverter to
determine the switching frequency of the power inverter as a function of the
commanded torque of the electric motor while maintaining the switching
frequency above a dynamic frequency limit. The method reduces switching
frequencies in the inverter at high commanded torques, while maintaining the
switching frequencies above dynamic frequency limit that provides effective
control over the motor. This reduces power loss and thus improves the
efficiency of the system.
[0019] FIG. 1 illustrates a vehicle 30, or "automobile," according to one
embodiment of the present invention. The automobile 30 includes a chassis
32, a body 34, four wheels 36, and an electronic control system 38. The body
34 is arranged on the chassis 32 and substantially encloses the other
components of the automobile 30. The body 34 and the chassis 32 may jointly
form a frame. The wheels 36 are each rotationally coupled to the chassis 32
near a respective corner of the body 34.
[0020] The automobile 30 may be any one of a number of different types
of automobiles, such as, for example, a sedan, a wagon, a truck, or a sport
utility vehicle (SUV), and may be two-wheel drive (2WD) (i.e., rear-wheel
drive or front-wheel drive), four-wheel drive (4WD) or all-wheel drive
(AWD). The vehicle 30 may also incorporate any one of, or combination of, a
number of different types of engines (or actuators), such as, for example, a
gasoline or diesel fueled combustion engine, a "flex fuel vehicle" (FFV)
engine (i.e., using a mixture of gasoline and alcohol), a gaseous compound
(e.g., hydrogen and/or natural gas) fueled engine or fuel cell energy source, a
combustion/electric motor hybrid engine, and an electric motor.
[0021] In the exemplary embodiment illustrated in FIG. 1, the automobile
30 is a hybrid vehicle, and further includes an actuator assembly 40, a battery
(or other electrical energy storage) 42, a power inverter (or inverter) 44, and a
radiator 46. The actuator assembly 40 includes a combustion engine 48 and an
electric motor/generator (or motor) 50. The electric motor 50 is, in one

embodiment, a sinusoidally-wound alternating current (AC) motor (e.g.,
permanent magnet or induction) such as commonly used in automotive
vehicles (e.g., traction drive control systems, and the like). As will be
appreciated by one skilled in the art, the electric motor 50 may include a
transmission therein, and although not illustrated also includes a stator
assembly (including conductive coils), a rotor assembly (including a
ferromagnetic core), and a cooling fluid (i.e., coolant). The stator assembly
and/or the rotor assembly within the electric motor 50 may include multiple
(e.g., twelve) electromagnetic poles, as is commonly understood.
[0022] Still referring to FIG. 1, in one embodiment, the combustion engine
48 and the electric motor 50 are integrated such that both are mechanically
coupled to at least some of the wheels 36 through one or more drive shafts 52.
The radiator 46 is connected to the frame at an outer portion thereof and
although not illustrated in detail, includes multiple cooling channels
therethough that contain a cooling fluid (i.e., coolant) such as water and/or
ethylene glycol (i.e., "antifreeze) and is coupled to the engine 48 and the
inverter 44. Referring again to FIG. 1, in the depicted embodiment, the
inverter 44 receives and shares coolant with the electric motor 50. The
radiator 46 may be similarly connected to the inverter 44 and/or the electric
motor 50.
[0023] The electronic control system 38 is in operable communication
with the actuator assembly 40, the battery 42, and the inverter 44. Although
not shown in detail, the electronic control system 38 includes various sensors
and automotive control modules, or electronic control units (ECUs), such as
an inverter control module and a vehicle controller, and at least one processor
and/or a memory which includes instructions stored thereon (or in another
computer-readable medium) for carrying out the processes and methods as
described below.
[0024] Referring to FIG. 2, a voltage source inverter system (or electric
drive system) 54 is shown in accordance with an exemplary embodiment of
the present invention. The voltage source inverter system 54 includes a

controller 56, the inverter 44 coupled to an output of the controller 56, and the
motor 50 coupled to a first output of the inverter 44. The controller 56 and
may be integral with the electronic control system 38 shown in FIG. 1.
[00251 FIG. 3 illustrates the inverter 44 of FIGS. 1 and 2 in greater detail.
The inverter 44 includes a three-phase circuit coupled to the motor 50. More
specifically, the inverter 44 includes a switch network having a first input
coupled to a voltage source Vdc (e.g., the battery 42) and an output coupled to
the motor 50.
[0026] The switch network comprises three pairs of series switches with
antiparallel diodes (i.e., antiparallel to each switch) corresponding to each of
the phases. Each of the pairs of series switches comprises a first switch (or
transistor) 60, 62, and 64 having a first terminal coupled to a positive electrode
of the voltage source 42 and a second switch 66, 68, and 70 having a second
terminal coupled to a negative electrode of the voltage source 42 and having a
first terminal coupled to a second terminal of the respective first switch 60, 62,
and 64.
[0027] FIG. 4 illustrates the powertrain transmission 110 within the
automobile 30 (FIG. 1), according to an exemplary embodiment. The depicted
embodiment is a two-mode, compound-split, electro-mechanical (or hybrid)
transmission. The hybrid transmission 110 has an input member 112 that may
be in the nature of a shaft which may be directly driven by the combustion
engine 48. A transient torque damper may be incorporated between an output
shaft 118 of the engine 48 and the input member 112 of the hybrid
transmission 110. An example of a transient torque damper of the type
recommended for the present usage is disclosed in detail in U.S. Pat. No.
5,009,301 which issued on Apr. 23, 1991 to General Motors Corporation,
which is hereby incorporated by reference in its entirety. The transient torque
damper may incorporate, or be employed in conjunction with, a torque transfer
device 120 to permit selective engagement of the engine 48 with the hybrid
transmission 110, but it should be understood that the torque transfer device

120 is not utilized to change, or control, the mode in which the hybrid
transmission 110 operates.
[0028] In the embodiment depicted, the engine 48 (or prime mover power
source) may be a fossil fuel engine, such as a diesel engine that is readily
adapted to provide its available power output delivered at a constant number
of revolutions per minute (RPM). Irrespective of the means by which the
engine 48 is connected to the input member 112 of the transmission 110, the
input member 112 is connected to a planetary gear set 124 in the transmission
110.
[0029] The hybrid transmission 110 utilizes three planetary gear sets (or
arrangements) 124, 126, and 128. The first planetary gear set 124 has an outer
gear member 130 that may generally be designated as the ring gear, which
circumscribes an inner gear member 132, generally designated as the sun gear.
A plurality of planet gear members 134 are rotatably mounted on a carrier 136
such that each planet gear member 134 meshingly engages both the outer gear
member 130 and the inner gear member 132.
[0030] The second planetary gear set 126 also has an outer gear member
138, generally designated as the ring gear, which circumscribes an inner gear
member 140, generally designated as the sun gear. A plurality of planet gear
members 142 are rotatably mounted on a carrier 144 such that each planet gear
142 meshingly engages both the outer gear member 138 and the inner gear
member 140.
[0031] The third planetary gear set 128 also has an outer gear member
146, generally designated as the ring gear, which circumscribes an inner gear
member 148, generally designated as the sun gear. A plurality of planet gear
members 150 are rotatably mounted on a carrier 152 such that each planet gear
150 meshingly engages both the outer gear member 146 and the inner gear
member 148.
[0032] In one embodiment, the ring gear/sun gear tooth ratio of the first
planetary gear set 124 is 65/33, the ring gear/sun gear tooth ratio of the second

planetary gear set 126 is 65/33, and the ring gear/sun gear tooth ratio of the
third planetary gear set 128 is 94/34.
[0033] While all three planetary gear sets 124, 126 and 128 are "simple"
planetary gear sets in their own right, the first and second planetary gear sets
124 and 126 are compounded in that the inner gear member 132 of the first
planetary gear set 124 is conjoined, as through a hub plate gear 154, to the
outer gear member 138 of the second planetary gear set 126. The conjoined
inner gear member 132 of the first planetary gear set 124 and the outer gear
member 138 of the second planetary gear set 126 are continuously connected
to a first motor/generator 156.
[0034] The planetary gear sets 124 and 126 are further compounded in that
the carrier 136 of the first planetary gear set 124 is conjoined, as through a
shaft 160, to the carrier 144 of the second planetary gear set 126. As such,
carriers 136 and 144 of the first and second planetary gear sets 124 and 126,
respectively, are conjoined. The shaft 160 is also selectively connected to the
carrier 152 of the third planetary gear set 128, as through a torque transfer
device 162 which, as will be hereinafter more fully explained, is employed to
assist in the selection of the operational modes of the hybrid transmission 110.
[0035] The carrier 152 of the third planetary gear set 128 is connected
directly to the transmission output member 164. When the hybrid transmission
110 is used in a land vehicle, the output member 164 may be connected to the
vehicular axles (not shown) that may, in turn, terminate in the drive shafts 52
(shown in FIG. I).
[0036] The inner gear member 140 of the second planetary gear set 126 is
connected to the inner gear member 148 of the third planetary gear set 128, as
through a sleeve shaft 166 that circumscribes shaft 160. The outer gear
member 146 of the third planetary gear set 128 is selectively connected to
ground, represented by the transmission housing 168, through a torque transfer
device 170. The torque transfer device 170, as is also hereinafter explained, is
also employed to assist in the selection of the operational modes of the hybrid
transmission 110. The sleeve shaft 166 is also continuously connected to a

second motor/generator 172. All the planetary gear sets 124, 126 and 128 as
well as the two motor/generators 156 and 172 are coaxially oriented, as about
the axially disposed shaft 160. It should be noted that both motor/generators
156 and 172 are of an annular configuration which permits them to
circumscribe the three planetary gear sets 124, 126 and 128 such that the
planetary gear sets 124, 126 and 128 are disposed radially inwardly of the
motor/generators 156 and 172. This configuration assures that the overall
envelope—i.e., the circumferential dimension—of the transmission 110 is
minimized.
[0037] A torque transfer device 173 selectively connects the sun gear 140
with ground (i.e., with transmission housing 168). A torque transfer device
175 is operative as a lock-up clutch, locking planetary gear sets 124, 126,
motors 156, 172 and the input to rotate as a group, by selectively connecting
the sun gear 140 with the carrier 144. The torque transfer devices 162, 170,
173, 175 are all friction clutches.
[0038] As was previously herein explained in conjunction with the
description of the engine 48, it should similarly be understood that the
rotational speed and horsepower output of the first and second
motor/generators 156 and 172 are also not critical to the invention, but for the
purpose of effecting an absolutely clear understanding of the hybrid
transmission 110, the motors/generators 156 and 172 have a continuous rating
of 30 horsepower and a maximum speed of approximately 10200 RPM. The
continuous power rating is approximately 1/10 that of the engine 48, and the
maximum speed is approximately 1.5x that of the engine 48, although these
depend on the type of engine, final gear schematic and duty cycle.
[0039] As should be apparent from the foregoing description, and with
particular reference to FIG. 2, the transmission 110 selectively receives power
from the engine 48. As will now be explained, the hybrid transmission 110
also receives power from the battery 42, the ECU 38 via transfer conductors
178A and 178B. The ECU 38 communicates with the first motor/generator
156 by transfer conductors 178C and I78D, and the ECU 38 similarly

communicates with the second motor/generator 172 by transfer conductors
178Eand I78F.
[0040] As apparent from the previous paragraph, a particular structural
member, component or arrangement may be employed at more than one
location. When referring generally to that type of structural member,
component or arrangement, a common numerical designation will be
employed. However, when one of the structural members, components or
arrangements so identified is to be individually identified, it will be referenced
by virtue of a letter suffix employed in combination with the numerical
designation employed for general identification of that structural member,
component or arrangement. Thus, there are at least six transfer conductors
which are generally identified by the numeral 178, but the specific, individual
transfer conductors are, therefore, identified as 178A, 178B, 178C, 178D,
178E and 178F in the specification and on the drawings. This same suffix
convention shall be employed throughout the specification.
[0041] A drive gear 180 may be presented from the input member 112. As
depicted, the drive gear 180 fixedly connects the input member 112 to the
outer gear member 130 of the first planetary gear set 124, and the drive gear
180, therefore, receives power from the engine 48 and/or the motor/generators
156 and/or 172. The drive gear 180 meshingly engages an idler gear 182
which, in turn, meshingly engages a transfer gear 184 that is secured to one
end of a shaft 186. The other end of the shaft 186 may be secured to a
transmission fluid pump and/or PTO unit, designated either individually or
collectively at 188.
[0042] The ECU 38 obtains information from both the first and second
motor/generators 156 and 172, respectively, the engine 48 and the battery 42.
In response to an operator's action, or "operator demand" (e.g., from a drive
range selector, an accelerator pedal, and/or a brake pedal), the ECU 38
determines what is required and then manipulates the selectively operated
components of the hybrid transmission 110 appropriately to respond to the
operator demand.

[0043] For example, in the exemplary embodiment shown in FIG. 4, when
the operator has selected a forward drive range and manipulates either the
accelerator pedal or the brake pedal, the ECU 38 determines if the vehicle
should accelerate or decelerate. The ECU 38 also monitors the state of the
power sources and determines the output of the transmission required to affect
the desired rate of acceleration or deceleration. Under the direction of the
ECU 38, the transmission is capable of providing a range of output speeds
from slow to fast in order to meet the operator demand.
[0044] The transmission 110 operates as a two-mode, compound-split,
electro-mechanical, vehicular transmission. In other words, the output
member 164 receives power through two distinct gear trains within the
transmission 110. A first mode, or gear train, is selected when the torque
transfer device 170 is actuated in order to "ground" the outer gear member 146
of the third planetary gear set 128. A second mode, or gear train, is selected
when the torque transfer device 170 is released and the torque transfer device
162 is simultaneously actuated to connect the shaft 160 to the carrier 152 of
the third planetary gear set 128.
[0045] Those skilled in the art will appreciate that the ECU 38 serves to
provide a range of output speeds from relatively slow to relatively fast within
each mode of operation. This combination of two modes with a slow to fast
output speed range in each mode allows the transmission 110 to propel a
vehicle from a stationary condition to highway speeds. Additionally, the ECU
38 coordinates operation of the transmission 110 so as to allow synchronized
shifts between the modes.
[0046] First and second "modes" of operation refer to circumstances in
which the transmission functions are controlled by one clutch (e.g., clutch 162
or clutch 170), and the controlled speed and torque of the motor/generators
156 and 172, all as described in U.S. Pat. No. 5,009,301 which issued on Apr.
23, 1991 to General Motors Corporation. Also, certain "ranges" of operation
may be achieved by applying an additional clutch (e.g., clutch 162, 173 or
175).

[0047] When the additional clutch is applied (i.e., when two clutching
mechanisms are applied), a fixed input to output speed ratio (i.e., a fixed gear
ratio) is achieved, as illustrated in the truth table of FIG. 5. The rotations of
the motor/generators 156 and 172 will then be dependent on internal rotation
of the mechanism as defined by the clutching and proportional to the input
speed. The motor/generators 156 and 172 are completely independent of
engine to output power flow, thereby enabling both to be motors, both to
function as generators, or any combination thereof. This allows, for instance,
during acceleration in the first fixed ratio that the engine power and both units
functioning as motors accepting power from the battery 42 to be additive into
propelling the vehicle through third planetary gear set 128 to the output 164.
[0048] It also should be noted that the function of the transmission can at
any time be switched from operation in fixed ratio to mode control by
actuating the additional clutch (i.e., on or off) during a mode of operation.
Determination of operation in fixed ratio or mode control is by algorithms in
the ECU 38 controlling the transmission.
[0049] Additionally, the modes of operation may overlap the fixed ratios
of operation. Selection of the mode or fixed ratio depends again on the
driver's input and response of the vehicle thereto. In one embodiment, the first
range falls within the first mode of operation when Cl and C4 (i.e., clutches
170 and 175) are engaged, and the second range falls within the first mode of
operation when C2 and Cl (clutches 162 and 170) are engaged. As illustrated
in FIG. 5, a third fixed ratio range is available during the second mode of
operation when C2 and C4 (clutches 162 and 175) are engaged, and a fourth
fixed ratio range is available during the second mode of operation when C2
and C3 (clutches 162 and 173) are engaged.
[0050] In the first mode of operation, and when the ECU 38 has
determined that the operator desires to move forwardly from a stationary
condition, and to accelerate, the torque transfer device 120 is engaged
operatively to connect the engine 48 to the hybrid transmission 110. The
torque transfer device 120 remains applied as the vehicle moves forwardly

through a speed range hereinafter more fully described. The torque transfer
device 162 is not applied and remains disengaged, while the torque transfer
device 170 is engaged. In this situation, the engine 48 applies driving power
to the outer gear member 130 of the first planetary gear set 124 such that the
outer member 130 rotates in unison with the input member 112 (and thus the
engine 48). The first motor/generator 156 simultaneously rotates the inner
gear member 132 of the first planetary gear set 124 and the outer gear member
138 of the second planetary gear set 126 in the same direction, thus driving the
carrier 136 in the same direction, which effects rotation of the inner gear
member 140 of the second planetary gear set 124.
[0051] The second motor/generator 172 operates as a motor during the
first mode, and as such drives sleeve shaft 166 in a direction which causes the
inner gear member 148 of the third planetary gear set 128 to rotate the planet
gears 150 of the third planetary gear set 128 against the outer gear member
146 of the third planetary gear set 128. The outer gear member 146 is fixed by
having been grounded so that the carrier 152 drives the output member 164 in
a direction required to effect forward movement of the vehicle.
[0052] The rotation of the sleeve shaft 166 affected by rotation of the
second motor/generator 172 operating as a motor also rotates the inner gear
member 140 of the second planetary gear set 126. Because the torque transfer
device 162 remains disengaged, the carriers 136 and 144 of the first and
second planetary gear sets 124 and 126, respectively, are freely rotatable, but
only in unison inasmuch as the two carriers 136 and 144 are compounded. As
a result, the rotation of the outer gear member 130 of the first planetary gear
set 124 caused by the engine 48 and the rotation of the inner gear member 140
caused by the second motor/generator 172 force the inner gear member 132 of
the first planetan gear set 124 and the conjoined outer gear member 138 of the
second planetan gear set 126 to drive the first motor/generator 156 in that
direction (and with that velocity), which causes the first motor/generator 56, at
least initially, to serve as a generator.

[0053] In one mode, the transmission operates in the first mode from rest
(i.e., the vehicle is not moving) to about 70 MPH. At speeds greater than
about 70 MPH the transmission operates in the second mode.
[0054] Fixed gear ratios can also be selected, overlapping the operation of
the modes, to further improve acceleration by increasing the power reaching
the output 164 and/or to improve efficiency.
[0055] At about 70 MPH, the lock-up clutch 175 is engaged while the
clutch 170 remains engaged. In this configuration, the transmission 110 is
engaged in the first fixed ratio as defined by the third planetary gear set 128,
as shown FIG. 5. When the clutch 175 is engaged, the first two gear sets 124
and 126 and motor/generators 156 and 172 rotate at the input speed and are
connected with the sun gear 148 of the third planetary gear set 128. With the
clutch 170 also engaged there is a speed reduction provided by the third
planetary gear set 128 which results in torque being multiplied. All power is
transmitted mechanically through the planetary gear sets (i.e., no torque is
present in the motors/generators 156 and 172), which minimizes electrical
losses and provides higher efficiency operation. However, with full torque
applied in the first and second motor/generators 156 and 172, a significant
increase in performance can be realized. With both motors locked together by
device 175, the first and second motor/generators 156 and 172 can also share
equally any regenerative power, resulting in higher braking performance with
improved cooling. Only the third planetary gear set 128 is active because the
torque transmitting device (or lock-up clutch) 175 locks up the first and
second planetary gear sets 124 and 126. Engagement of the torque
transmitting device 175 also protects the motor/generators 156 and 172 if the
power flow necessary for power split operation would overload the
motor/generators. Therefore, if the vehicle is towing or hauling up a hill, the
motors/generators are protected.
[0056] During normal operation, only the clutch 170 would be engaged at
low speeds, but if maximum power is demanded, the lock-up clutch 175 is
also engaged. The first and second motors 156 and 172 may be activated with

the clutch 175 to achieve maximum available horsepower. This clutch also
provides the ability for all three of the engine 48 and motor/generators 156 and
172 to simultaneously propel the vehicle for maximum acceleration.
[0057] In one embodiment, at about 40 MPH, the lock-up clutch 175 is
disengaged. Thereafter, the second motor/generator 172 operates as a motor.
The first motor/generator 156 operates as a generator up to a point at which
the first motor/generator 156 is stationary (e.g., approximately 52 MPH). The
motor/generator 156 then reverses direction and operates as a motor.
[0058] The clutch 162 is engaged at, for example, about 57 MPH. With
the clutches 162 and 170 engaged, a second fixed ratio is achieved (e.g., 1.7:1
as shown in FIG. 5). During the second fixed ratio, all three gear sets 124,
126, and 128 are active. The motor/generators 156 and 172 may be turned off
during the engagement of the clutches 162 and 170 for fully mechanical
operation. During the second fixed ratio, the motors 156 and 172 may spin
freely with no torque being present. The first mode ends when the clutch 170
is turned off and the clutch 162 remains engaged for the high-efficiency
second mode of operation.
[0059] In the above description, the transmission mode I as described in
U.S. Pat. No. 5,009,301 is supplemented with the ability to launch in mode I,
shift to fixed ratio 1, return to mode I, and then to fixed ratio 2. The actual
operation in the vehicle is determined by inputs to the ECU 38. The
transmission ma\ be operated in only mode I, or any combination as necessary
to improve efficiency, performance, or braking power.
[0060] In an exemplary embodiment, the outer gear members 130 and 138
in each of the first and second planetary gear sets 124 and 126 have 65 teeth,
and the inner gear members 132 and 140 in each of the first and second
planetary gear sets 124 and 126 have 33 teeth. The outer gear member 146 of
the third planetary gear set 128 has 94 teeth, and the inner gear member 148 of
the third planetary gear set 128 has 34 teeth. With the configuration of the
transmission 110 heretofore described, and with the aforesaid number of teeth
on the inner and outer gear members, the transmission provides a mechanical

point (i.e., at about 50 MPH) while operating in the first mode, at which the
first motor/generator 56 has a zero rotational speed. To complete the
description as to the operation of the motor/generators in the exemplary
environment described, one must consider operation of the transmission in the
second mode of operation.
[0061] The transition from the first (mode I) to the second mode (mode II)
of operation is achieved by disengaging the torque transfer device 170 and
continuing the application of the torque transfer device 162. In a manner
similar to the previously described first mode, the second mode overlaps fixed
ratios as shown in FIG. 5.
[0062J At the inception of the second mode of operation, the first
motor/generator 156 transitions from operating as a motor to operating as a
generator. The first motor/generator 156 continues to operate as a generator
during operation of the transmission 110 in the second mode while the vehicle
gains speed from, for example, about 70 MPH to about 88 MPH. At about 88
MPH, the first motor/generator 156 transitions from operation as a generator
back to operation as a motor as it transitions through a mechanical point
wherein the motor/generator 156 has zero rotational speed. The first
motor/generator 156 continues thereafter to operate as a motor.
[0063] At the beginning of the second mode of operation, the second
motor/generator 172 continues to operate as a motor. In fact, the second
motor/generator 172 operates as a motor until the vehicle reaches a speed of
about 88 MPH, at which point it transitions to operation as a generator, and
continues thereafter to operate as a generator.
[0064] With the configuration of the transmission 110 heretofore
described, and with the aforesaid number of teeth on the inner and outer gear
members, the transmission 110 provides two mechanical points while
operating in the second mode. That is, in one embodiment, the first
motor/generator 156 has a zero rotational speed at about 88 MPH, and the
second motor/generator 172 has a zero rotational speed at about 208 MPH.

[0065] As illustrated in FIG. 5, third and fourth fixed ratios are available
during the second mode. The third fixed ratio may be established with the
simultaneous engagement of the clutches 162 and 175, which locks all gear
sets into a 1:1 ratio so that the output 164 rotates at the same speed as the input
112.
[0066] The fourth fixed ratio is established with the engagement of the
clutches 162 and 173 to provide a fixed overdrive ratio of 0.74:1, as shown in
FIG. 2. In the fourth fixed ratio, the first and second planetary gear sets 124
and 126 are active, and the motors/generators 156 and 172 may freewheel with
no torque present.
[0067] Accordingly, the transmission 110 provides three mechanical
points and four available fixed ratios, thereby minimizing electrical losses in
the motors/generators while providing maximum power quickly in the first
mode via the lock-up clutch 175.
[0068] It should be understood that the exact location of the aforesaid
mechanical points is determined not only by the number of teeth on the inner
and outer gear members of the planetary gear sets, but also by the rotational
speed of the input shaft 112. Hence, with the number of teeth disclosed for the
inner and outer gear members in the exemplary embodiment, an increase in
the speed of the input shaft 112 will shift the locations of the mechanical
points to higher vehicular speeds, and conversely, a reduction in the speed of
the input member 112 will shift the mechanical points to lower vehicular
speeds.
[0069] The reverse mode of operation is effected by having the ECU 38
operate the second motor/generator 172 as a motor, but reversing its rotational
direction from the direction in which the second motor/generator 172 rotates
when the vehicle begins to move forwardly from a stationary position in the
first mode of operation.
[0070] Thus, the two-mode, compound-split, electro-mechanical
transmission 110 uses a lock-up clutch and provides four available mechanical
points. It enables maximum power to be reached more quickly for towing and

hauling, and enables the use of smaller electrical components. By providing
fixed ratios in an electrically variable transmission, maximum fuel economy is
achieved at a reasonable cost.
[0071] The lock-up clutch 175 shown schematically between the planet
carrier 144 and the sun gear 140 may also be located to connect the ring gear
138 and the sun gear 140 and will provide the same lockup function.
Alternatively, the lock-up clutch 175 may connect the sun gear 140 and ring
gear 148 of the second planetary gear set 126. As a further alternative, the
lock-up clutch 175 may connect the carrier 136 and ring gear 130 of the first
planetary gear set 124.
[0072] During operation, again referring to FIG. 1, the vehicle 30 is
operated by providing power to the wheels 36 with the combustion engine 48
and the electric motor 50 in an alternating manner and/or with the combustion
engine 48 and the electric motor 50 simultaneously. In order to power the
electric motor 50, DC power is provided from the battery 42 to the inverter 44,
which converts the DC power into AC power, before the power is sent to the
electric motor 50. As will be appreciated by one skilled in the art, the
conversion of DC power to AC power is substantially performed by operating
(i.e., repeatedly switching) the transistors within the inverter 44 at a
"switching frequency".
[0073] Generally, the controller 56 produces a signal for controlling the
switching action of the inverter 44. As one example, the controller 56
produces a discontinuous PWM (DPWM) signal having a single zero vector
associated with each switching cycle of the inverter 44. The inverter 44 then
converts the PWM signal to a modulated voltage waveform for operating the
motor 50. In a preferred embodiment, the controller 56 produces a PWM
signal that controls the power inverter 44 to maintain the switching frequency
of the power inverter 44 at a first, relatively high, set frequency responsive to a
commanded torque of the electric motor 50 being below a first level. The
controller 56 furthermore produces a PWM signal that controls the power
inverter to provide a signal controlling the power inverter to determine the

switching frequency of the power inverter as a function of the commanded
torque of the electric motor while maintaining the switching frequency above
a dynamic frequency limit, when the commanded torque is between the first
and second levels.
[0074] This configuration of the drive system ensures good control and
efficient use of power in the electric motor drive system. Specifically, the
switching frequency of a PWM inverter affects the power losses in
semiconductor switches. Thus, lowering the switching frequency can reduce
power losses. However, at higher motor speeds, a higher switching frequency
is desirable to maintain an adequate pulse ratio for precise controllability of
the electric motor. Additionally, it is desirable to maintain the switching
frequency above levels that cause excessive noise emissions. Third, the
switching frequency affects the maximum controllable stator fundamental
frequency. Fourth, the switching frequency can affect the phase ripple current,
which can affect losses in both the inverter and motor. Additionally, the ripple
current can cause unwanted torque ripple in the drive.
[0075] The inverter switching losses can be roughly described in equation
1. Specifically, equation 1 shows of switching losses Psw are proportionate to
voltage Vdc, phase current IPh and switching frequency fsw.

[0076] Thus, to maintain constant switching losses the switching
frequency could be adjusted to be inversely proportional to the phase current.
Since the phase current is roughly proportional to the motor torque (in the
unsaturated case, and below base speed), phase current can be roughly equated
to motor torque. Thus, adjusting the switching frequency as a function
inversely proportional to motor torque will tend to maintain constant switching
losses in the semiconductor devices
[0077] Furthermore, acoustic noise can be generated by the motor due to
the switching frequency. In general, the human ear is most sensitive to

frequencies in the range of 1 kHz to 5 kHz. Thus, to minimize acoustic noise
it is desirable to operate inverter at a much higher range, for example 8 kHz.
[0078J In general, the fundamental electrical frequency (fe) of an electric
motor is proportional to motor speed. To control the stator currents in a stable
manner, the ratio of switching frequency to fundamental electrical frequency
needs to remain sufficiently high. This ratio is sometimes referred to as a
pulse ratio. For example, in some typical motor controls a pulse ratio of about
10:1 is needed to guarantee stable operation. Thus, it is desirable to maintain
the switching frequency above a level that prevents the pulse ratio from
dropping below the amount needed to guarantee stable operation.
[0079] There are thus conflicting goals with respect to the switching
frequency. The embodiments of the invention are configured to control the
switching frequency to be at high value to reduce acoustic noise and improve
control at high speeds and low torque, and then reduce the switching
frequency at high torque and current to reduce power loss and protect
semiconductor switches from thermal overstress.
[0080] Returning to FIGS. 1-3, the controller 56 is thus configured to
produce a PWM signal that controls the power inverter 44 to maintain the
switching frequency of the power inverter 44 at a first, relatively high, set
frequency responsive to a commanded torque of the electric motor 50 being
below a first level. The controller 56 furthermore produces a PWM signal that
controls the power inverter to provide a signal controlling the power inverter
to determine the switching frequency of the power inverter as a function of the
commanded torque of the electric motor while maintaining the switching
frequency above a dynamic frequency limit, when the commanded torque is
between the first and second levels.
[0081] In general, the first set frequency is set at a relatively high level
that provides good control over the electric motor 50, without exceeding the
frequency response of the switches in the inverter 44, or causing excessive
heat due to switching losses. For example, in some embodiments the first set
frequency will comprise a switching frequency of 8 kHz.

[0082] At intermediate motor speeds, the inverter 44 is operated with the
switching frequency that varies as a function of torque. In general, the
switching frequency is reduced as commanded torque increases, and a variety
of functional relationships between switching frequency and torque can be
used to accomplish this. For example, the relationship between switching
frequency and torque can be linear, non-linear or any combination thereof
during intermediate motor speeds.
[0083] As stated above, during operation of the electric motor 50 the
switching frequency is varied as a function of commanded torque. However,
at the same time, the operation of the inverter 44 is controlled to ensure that
the switching frequency is maintained above a dynamic frequency limit. In
general, the dynamic frequency limit itself varies with, and is responsive to
motor speed. The dynamic frequency limit is preferably implemented to allow
a sufficient reduction in switching frequency to reduce power losses while
maintaining a high enough switching frequency to maintain good current
control at the motors present speed. Furthermore, the dynamic frequency limit
is preferably selected to limit acoustic noise to acceptable levels.
[0084] In one embodiment, the dynamic frequency limit is a function of
motor speed when the electric motor is being operated at intermediate speeds,
i.e., bet-veen a first speed level and a second speed level. Then, when the
motor speed is below first speed level, the dynamic frequency limit is
maintained at a relatively low specified, set frequency.
[0085] For example, the dynamic frequency limit can be selected to
njaintain a specified pulse ratio during operation of the electric motor, where
the pulse ratio is generally defined as a ratio of switching frequency to
fundamental frequency. As the fundamental frequency is related to motor
speed, configuring the dynamic limit to maintain a specified pulse ratio
effectively determines the dynamic frequency limit as a function of motor
speed. Maintaining a high pulse ratio assures a sufficient amount of cycles in
the inverter 44 to provide accurate control over the current in the electric
motor 50. Thus, the dynamic frequency limit is implemented to make sure

that as motor speed increases, the frequency limit also increases to ensure that
effective motor control is maintained.
[0086] Additionally, the dynamic frequency limit can be set to operate at a
relatively high frequency limit when the electric motor is operated at speeds
above the second speed level. In one specific embodiment, this high
frequency limit can be same frequency the inverter is operated at low torque
levels (e.g., 8 kHz ).
[0087] Turning now to FIG. 6, a graphical representation 400 of an
exemplar)' switching frequency control scheme is illustrated. In this
representation, the plot of the switching frequency as a function of the torque
command is illustrated for motor speed values of 100, 200, 400, 600, 800 and
800 RPM. Below a first torque value of m1 (e.g., 100 Nm), the switching
frequency is held to a predetermined maximum value (e.g., 8 kHz) regardless
of motor speed. As the torque command exceeds the first value, the switching
frequency is reduced inversely proportional to torque while maintaining the
switching frequency above a dynamic frequency limit.
[0088] The dynamic frequency limit itself varies with, and is responsive to
motor speed. This causes the separate plots for each of the illustrated motor
speed values. In the representation of FIG. 6, the dynamic frequency limit is a
function of motor speed when the electric motor is being operated at
intermediate speeds, i.e., between a first speed level and a second speed level.
Then, when the motor speed is below first speed level, the dynamic frequency
limit is maintained at a relatively low specified, set frequency of 1 kHz.
[0089] Turning now to FIG. 7, a graphical representation 500 of an
exemplary dynamic frequency limit scheme is illustrated. This is an example
of the type of representation, that when used with function to control
switching frequency as a function of torque, results in switching frequency
values illustrated in FIG. 6.
[0090] In the representation 500, the dynamic limit of the switching
frequency is plotted as function of motor speed. At low motor speeds below
speed n1 (e.g., 100 RPM), the dynamic limit of the switching frequency will be

held at a preset low set frequency (fs»_min_hm)- This level is selected to maintain
good control while avoiding excessive acoustic noise and power loss, and is
set at 1 kHz in this example. Of course, this is just one example, and other
limit values could also be used.
[0091] At intermediate motor speeds (between n1 and n2 (e.g., 800 RPM))
the switching frequency of the inverter will be determined as function of
motor speed. In the illustrated embodiment, the function is configured to
maintain a desired minimum pulse ratio (N) between the switching frequency
(fsw) and the fundamental frequency (fe). During operation of the electric
motor, the switching frequency of the inverters is operated as a function of
commanded torque, reducing the switching frequency as the commanded
torque is increased, while the switching frequency is maintained above
dynamic frequency limit that is dependent on motor speed. Stated another
way, motor speed determines the minimum possible switching frequency, with
the torque command slewing the actual switching frequency between the
maximum and the speed dependent minimum frequencies. Thus, the
operational range of switching frequency fsw is illustrated in FIG. 7 as the
hatched area above the dynamic frequency limit fsw_min and below the
maximum set switching frequency of fsw_mxa. It should be noted, that above
speeds of n2, the dynamic frequency limit fsw_min and the maximum frequency
fsw_ max converge, and thus the motor will operate at the maximum switching
frequency fsw_max above speeds of n2 regardless of torque.
[0092] It should again be noted that the RPM values of n1 and n2, and the
frequency values of fsw_max and fSw_mm_lim, and the slope and/or function of the
dynamic frequency limit fsw_min are merely exemplary, and that other values
and functions could be used depending on the details of the application.
[0093] Another exemplary illustration of the techniques for determining
the switching frequency are illustrated in Equation 2.


[0094] In equation 2, the switching frequency is determined as a function
of the commanded torque m* while being maintained above a dynamic
frequency limit fsw min. If the commanded torque is less than a torque level m1,
the switching frequency is set to the maximum frequency fsw_max- If the
commanded torque above a torque level m2, the switching frequency fsw is
reduced down to the dynamic frequency limit fsw_min- At intermediate torque
values, the switching frequency is a function of torque and the frequency
limits.
[0095] Also shown in the example of equation 2, the dynamic frequency
limit fsw_min is itself a function of motor speed, set equal to fSw_max at speeds
above ni, set equal to a minimum value fSw_min_lim at speeds below n1, and
determined as function of fundamental frequency fe and a desired pulse ratio N
at intermediate speeds.
[0096] Again, the values selected for these various parameters would be
selected based on the needs of a particular application. For example, the
frequency profile may be selected to minimize junction temperature swings for
frequent operating points, in order to extend the lifetime of the devices. For
example, m1 can be selected to maintain fsw at its maximum value during a

typical engine crank event, to avoid acoustic noise problems. Also, it should
be noted that equation 2 illustrates just one exemplary function for adjusting
switching frequencies as a function of torque (i.e., inversely proportional).
However, alternate functions could also be used. Likewise, while equation 2
illustrates the dynamic frequency limit fsw_min determined as a linear function
of fundamental frequency fe at intermediate speeds, alternate functions could
also be used.
[0097] The various embodiments thus provide a system and method that
controls the power inverter by, responsive to a commanded torque of the
electric motor being below a first torque level, controlling the power inverter
to set a switching frequency of the power inverter at a first set frequency; and,
responsive to the commanded torque of the electric motor being between the
first torque level and a second torque level, controlling the power inverter to
determine the switching frequency of the power inverter as a function of the
commanded torque of the electric motor while maintaining the switching
frequency above a dynamic frequency limit. The method reduces switching
frequencies in the inverter at high commanded torques, while maintaining the
switching frequencies above dynamic frequency limit that provides effective
control over the motor. This reduces power loss and thus improves the
efficiency of the system.
[0098] While at least one exemplary embodiment has been presented in
the foregoing detailed description, it should be appreciated that a vast number
of variations exist. It should also be appreciated that the exemplary
embodiment or exemplary embodiments are only examples, and are not
intended to limit the scope, applicability, or configuration of the invention in
any way. Rather, the foregoing detailed description will provide those skilled
in the art with a convenient road map for implementing the exemplary
embodiment or exemplary embodiments. It should be understood that various
changes can be made in the function and arrangement of elements without
departing from the scope of the invention as set forth in the appended claims
and the legal equivalents thereof.

CLAIMS
What is claimed is:
1. A method for controlling a power inverter coupled to an electric
motor in an electric drive system of an automobile, wherein the electric drive
system includes a prime mover power source, a two-mode, compound-split,
electro-mechanical transmission coupled to the prime mover power source, the
transmission comprising a first motor and a second motor, wherein the power
inverter is coupled to the first and second motors, the method comprising:
responsive to a commanded torque of the first motor being below a
first torque level, controlling the power inverter to set a switching frequency
of the power inverter at a first set frequency; and
responsive to the commanded torque of the first motor being between
the first torque level and a second torque level, controlling the power inverter
to determine the switching frequency of the power inverter as a function of the
commanded torque of the electric motor while maintaining the switching
frequency above a dynamic frequency limit.
2. The method of claim 1, wherein the dynamic frequency limit is
determined by:
responsive to the motor speed of the first motor being between a first
speed level and a second speed level, determining the dynamic frequency limit
as a function of the motor speed; and
responsive to the motor speed being below the first speed level,
determining the d\namic frequency limit to set the dynamic frequency limit at
a second set frequency.
3. The method of claim 2, wherein the dynamic frequency limit is
further determined by, responsive to the motor speed being above second

speed level, determining the dynamic frequency limit to set the dynamic
frequency limit at the first set frequency.
4. The method of claim 2, wherein the step of determining the dynamic
frequency limit as a function of the motor speed comprises determining the
dynamic frequency limit to maintain a set pulse ratio of switching frequency to
the motor speed.
5. The method of claim 1, wherein the step of controlling the power
inverter to determine the switching frequency of the power inverter as a
function of the commanded torque of the electric motor while maintaining the
switching frequency above the dynamic frequency limit comprises decreasing
the switching frequency as the commanded torque increases.
6. The method of claim 1, wherein the step of controlling the power
inverter to determine the switching frequency of the power inverter as a
function of the commanded torque of the electric motor while maintaining the
switching frequency above the dynamic frequency limit comprises
determining the switching frequency as:

where fsw is the switching frequency, m* is the commanded torque, fsw_max is
the first set frequency, fsw_min is the dynamic frequency limit, m1 is the first
torque level, and m2 is the second torque level.
7. The method of claim 1, wherein the electric drive system includes a
second power inverter corresponding to the second motor, further comprising:
responsive to a second commanded torque of the second motor being

below the first torque level, controlling the second power inverter to set a
switching frequency of the second power inverter at a first set frequency; and
responsive to the commanded torque of the second motor being
between the first torque level and a second torque level, controlling the second
power inverter to determine the switching frequency of the second power
inverter as the function of the commanded torque of the electric motor while
maintaining the switching frequency above the dynamic frequency limit.
8. An automotive electric drive system comprising:
a prime mover power source;
a two-mode, compound-split, electro-mechanical transmission
coupled to the prime mover power source, the transmission comprising first
and second motors;
a power inverter coupled to the first and second motors; and
a processor coupled to the first and second motors and the power
inverter, the processor being configured to:
responsive to a commanded torque of the first motor being
below a first torque level, provide a signal controlling
the power inverter to set a switching frequency of the
power inverter at a first set frequency;
responsive to the commanded torque of the first motor being
between the first torque level and a second torque level,
provide a signal controlling the power inverter to
determine the switching frequency of the power inverter
as a function of the commanded torque of the electric
motor while maintaining the switching frequency above
a dynamic frequency limit.
9. The automotive drive system of claim 8, wherein the transmission
further comprises:
an input member to receive power from the prime mover;

an output member to deliver power from the transmission;
first, second, and third coaxially-aligned planetary gear arrangements,
each planetary gear arrangement utilizing first, second and third gear
members, the first and second motors being coaxially aligned with each other
and with the three planetary gear arrangements, at least one of the first,
second, and third gear members in the first or second planetary gear
arrangement being connected to the first motor, and another one of the first,
second, and third gear members in the second and third planetary gear
arrangements being connected to the second motor, one of the gear members
of the first planetary gear arrangement being continuously connected to the
input member;
a first torque-transmitting mechanism to selectively connect one of
the gear members associated with each of the planetary gear arrangements to
each other and to the output member;
a second torque-transmitting mechanism to selectively connect one of
the gear members of the third planetary gear set with ground;
a third torque-transmitting mechanism to selectively connect one of
the gear members of the second planetary gear set with another of the gear
members of the second planetary gear set;
a first interconnecting member continuously connecting one of the
members of the first planetary gear set with one of the members of the second
planetary gear set; and
a second interconnecting member continuously connecting one of the
members of the second planetary gear set with one of the members of the third
planetary gear set.
10. The automotive electric drive system of claim 9, wherein the
processor is further configured to:
responsive to the motor speed of the first motor being between a first
speed level and a second speed level, determine the dynamic frequency limit
as a function of the motor speed; and

responsive to the motor speed being below the first speed level,
determine the dynamic frequency limit to set the dynamic frequency limit at a
second set frequency.
11. The automotive electric drive system of claim 10, wherein the
processor is further configured to, responsive to the motor speed being above
second speed level, determine the dynamic frequency limit to set the dynamic
frequency limit at the first set frequency.
12. The automotive electric drive system of claim 11, wherein the
processor is configured to determine the dynamic frequency limit as a function
of the motor speed to maintain a set pulse ratio of switching frequency to the
motor speed.
13. The automotive electric drive system of claim 8, wherein the function
of the commanded torque decreases the switching frequency as the
commanded torque increases.
14. The automotive electric drive system of claim 8, wherein the function
of the commanded torque comprises:

where fsw is the switching frequency, m* is the commanded torque, fsw_max is
the first set frequency, fsw_min is the dynamic frequency limit, m1 is the first
torque level, and m2 is the second torque level.
15. The automotive electric drive system of claim 8, wherein the electric
drive system includes a second power inverter corresponding to the second

motor, and wherein the processor is further configured to:
responsive to a second commanded torque of the second motor being
below the first torque level, controlling the second power inverter to set a
switching frequency of the second power inverter at a first set frequency; and
responsive to the commanded torque of the second motor being
between the first torque level and a second torque level, controlling the second
power inverter to determine the switching frequency of the second power
inverter as the function of the commanded torque of the electric motor while
maintaining the switching frequency above the dynamic frequency limit.
16. An automotive drive system comprising:
a prime mover power source;
a two-mode, compound-split, electro-mechanical transmission
coupled to the prime mover power source, the transmission comprising:
an input member to receive power from the prime mover;
an output member to deliver power from the transmission;
first and second motors being coaxially aligned;
first, second, and third coaxially aligned planetary gear
arrangements, each planetary gear arrangement utilizing
first, second and third gear members, the first and
second motors being coaxially aligned with the three
planetary gear arrangements, at least one of the first,
second, and third gear members in the first or second
planetary gear arrangement being connected to the first
motor, and another one of the first, second, and third
gear members in the second and third planetary gear
arrangements being connected to the second motor, one
of the gear members of the first planetary gear
arrangement being continuously connected to the input
member;
a first torque-transmitting mechanism to selectively connect

one of the gear members associated with each of the
planetary gear arrangements to each other and to the
output member;
a second torque-transmitting mechanism to selectively connect
one of the gear members of the third planetary gear set
with ground;
a third torque-transmitting mechanism to selectively connect
one of the gear members of the second planetary gear
set with another of the gear members of the second
planetary gear set;
a first interconnecting member continuously connecting one of
the members of the first planetary gear set with one of
the members of the second planetary gear set; and
a second interconnecting member continuously connecting one
of the members of the second planetary gear set with
one of the members of the third planetary gear set;
a power inverter coupled to the first and second motors;
an energy storage device coupled to the power inverter; and
a processor coupled to the first and second motors and the power
inverter, the processor being configured to:
responsive to a commanded torque of the first motor being
below a first torque level, provide a signal controlling
the power inverter to set a switching frequency of the
power inverter at a first set frequency;
responsive to the commanded torque of the first motor being
between the first torque level and a second torque level,
provide a signal controlling the power inverter to
determine the switching frequency of the power inverter
as a function of the commanded torque of the electric
motor while maintaining the switching frequency above
a dynamic frequency limit; wherein the function of the

commanded torque is selected to decrease switching
frequency as the commanded torque increases, and
wherein the dynamic frequency limit determined by:
responsive to the motor speed of the first motor
being between a first speed level and a second
speed level, determining the dynamic
frequency limit as a function of the motor
speed to maintain set pulse ratio of motor
switching frequency to motor speed;
responsive to the motor speed being below the first
speed level, determining the dynamic
frequency limit to set the dynamic frequency
limit at a second set frequency; and
responsive to the motor speed being above second
speed level, determining the dynamic
frequency limit to set the dynamic frequency
limit at the first set frequency.
17. The automotive electric drive system of claim 16, wherein the
function of the commanded torque comprises:

where fsw is the switching frequency, m* is the commanded torque, fsw_max is
the first set frequency, fsw_min is the dynamic frequency limit, m1 is the first
torque level, and m2 is the second torque level.

Methods and systems for controlling a power inverter in automobiles utilizing two-mode transmissions are provided. The various embodiments control the power inverter by, responsive to a commanded torque of the
electric motor being below a first torque level, controlling the power inverter to set a switching frequency of the power inverter at a first set frequency; and, responsive to the commanded torque of the electric motor being between the first torque level and a second torque level, controlling the power inverter to
determine the switching frequency of the power inverter as a function of the commanded torque of the electric motor while maintaining the switching frequency above a dynamic frequency limit. The method reduces switching frequencies in the inverter at high commanded torques, while maintaining the switching frequencies above dynamic frequency limit that provides effective
control over the motor.

Documents:

1800-KOL-2008-(10-01-2014)-ABSTRACT.pdf

1800-KOL-2008-(10-01-2014)-ANNEXURE TO FORM 3.pdf

1800-KOL-2008-(10-01-2014)-CLAIMS.pdf

1800-KOL-2008-(10-01-2014)-CORRESPONDENCE.pdf

1800-KOL-2008-(10-01-2014)-DESCRIPTION (COMPLETE).pdf

1800-KOL-2008-(10-01-2014)-DRAWINGS.pdf

1800-KOL-2008-(10-01-2014)-FORM-1.pdf

1800-KOL-2008-(10-01-2014)-FORM-2.pdf

1800-KOL-2008-(10-01-2014)-FORM-5.pdf

1800-KOL-2008-(10-01-2014)-OTHERS.pdf

1800-KOL-2008-(10-01-2014)-PA.pdf

1800-KOL-2008-(10-01-2014)-PETITION UNDER RULE 137.pdf

1800-kol-2008-abstract.pdf

1800-kol-2008-claims.pdf

1800-KOL-2008-CORRESPONDENCE 1.1.pdf

1800-kol-2008-correspondence.pdf

1800-kol-2008-description (complete).pdf

1800-kol-2008-drawings.pdf

1800-kol-2008-form 1.pdf

1800-kol-2008-form 18.pdf

1800-kol-2008-form 2.pdf

1800-kol-2008-form 3.pdf

1800-kol-2008-form 5.pdf

1800-kol-2008-gpa.pdf

1800-KOL-2008-INTERNATIONAL SEARCH REPORT.pdf

1800-kol-2008-specification.pdf

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Patent Number 263048
Indian Patent Application Number 1800/KOL/2008
PG Journal Number 41/2014
Publication Date 10-Oct-2014
Grant Date 29-Sep-2014
Date of Filing 23-Oct-2008
Name of Patentee GM GLOBAL TECHNOLOGY OPERATIONS, INC.
Applicant Address 300 GM RENAISSANCE CENTER DETROIT, MICHIGAN
Inventors:
# Inventor's Name Inventor's Address
1 STEPHEN T. WEST 11705 NORTH SHELBY 700 W NEW PALESTINE, INDIANA 46163
2 STEVEN E. SCHULZ 2112 BRIDGEPORT WAY TORRANCE, CALIFORNIA 90503
3 BRIAN A WELCHKO 23312 MARIGOLD AVENUE APT T204 TORRANCE, CALIFORNIA 90502
4 SILVA HITI 205 PASEO DE LAS DELICIAS REDONDO BEACH, CALIFORNIA 90277
PCT International Classification Number F6H3/66; B60K1/00; B60K6/00;
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 11/923,287 2007-10-24 U.S.A.