Motor control controller system and methods

A charging system for charging a battery coupled to an electric motor, the system comprising:

• a bi-directional energy converter configured to operate in a first operating direction and a second operating direction wherein the bi-directional energy converter is coupled to a first waveform controller and to a second waveform controller;
• and,
• wherein in the first operating direction the bi-directional energy converter is configured to receive a first input voltage from said battery and generate a first output voltage;
• wherein in a second operating direction the bi-directional energy converter is configured to receive a second input voltage from said electric motor and generate a second output voltage;
• wherein the bi-directional energy converter is configured to either increase or decrease the first and second output voltages relative to the first and second input voltages;
• and
• wherein the first waveform controller is configured to modify the first output voltage waveform from the bi-directional energy converter to provide a first desired output voltage waveform and wherein the second waveform controller is configured to modify the second output voltage waveform from the bi-directional energy converter to provide a second desired output voltage waveform.

A four quadrant motor drive controller for an electric motor comprising:

• a bi-directional energy converter couplable to:
• a power supply and an electric motor;
• a first waveform controller;
• a second waveform controller;
• wherein the bi-directional energy converter is coupled to the first waveform controller and to the second waveform controller, wherein the first waveform controller is couplable to an electric motor and wherein the second waveform controller is couplable to a power supply;
• wherein the bi-directional energy converter is configured:
• to receive a first input voltage and generate a first output voltage in a first operating direction and receive a second input voltage and generate a second output voltage in a second operating direction;
• to operate in a primary mode and secondary mode wherein in the primary mode the bi-directional energy converter is configured to generate the output voltages from the input voltages wherein the output voltages are greater than the input voltages and wherein in the secondary mode the bi-directional energy converter is configured to generate the output voltages from the input voltages wherein the output voltages are less than the input voltages;
• wherein in the first operating direction and in primary mode the first waveform controller is configured to modify the first output voltage waveform from the bi-directional energy converter to provide a first desired output voltage waveform;
• wherein in the second operating direction and in primary mode the second waveform controller is configured to modify the second output voltage waveform from the bi-directional energy converter to provide a second desired output voltage waveform.

A method of operating a motor coupled to an energy management system, wherein a rotor of the motor is either (i) stationary (ii) accelerating or rotating at constant speed or (iii) decelerating, the method comprising:

• in response to determining that the rotor is stationary:
• reducing a supply voltage and modifying the supply voltage waveform to the motor to achieve a starting torque or a required starting speed of rotation of the rotor of the motor;
• determining that a back emf from the motor is at a certain threshold and increasing and modifying the voltage waveform of the supply voltage to the motor to achieve a desired operating torque or operating speed of rotation of the rotor;
• in response to an increased torque demand or required rotor speed:
• increasing and modifying the voltage waveform of the supply voltage to the motor to achieve a desired torque or a required speed of rotation of the rotor of the motor;
• in response to determining that the rotor is decelerating:
• comparing a voltage generated from the motor to the supply voltage;
• determining whether to increase or decrease the supply voltage based on the comparison.