Propulsion system with dual-wound electric motor and dual inverter configuration

A method of operating a propulsion system in a vehicle, the propulsion system having an electric motor configured to generate torque, and a controller having a processor and tangible, non-transitory memory, the method comprising:

• incorporating a stator assembly in the electric motor with a plurality of stator slots defining slot layers along a respective slot axis;
• forming a first winding set by positioning a first plurality of conductors in the plurality of stator slots;
• forming a second winding set by positioning a second plurality of conductors in the plurality of stator slots;
• coupling the first winding set to a first inverter adapted to drive the electric motor;
• coupling the second winding set to a second inverter adapted to drive the electric motor;
• and
• controlling operation of the first inverter and the second inverter based in part on a motor speed of the electric motor, via the controller, including setting the first current to be greater than the second current when the motor speed is above a predefined threshold, and setting the second current to be greater than the first current when the motor speed is below the predefined threshold.

A vehicle comprising:

• an electric motor having a stator assembly with a plurality of stator slots defining slot layers along a respective slot axis, the electric motor being configured to generate torque for propulsion;
• a first plurality of conductors at least partially positioned in the plurality of stator slots and forming a first winding set;
• a second plurality of conductors at least partially positioned in the plurality of stator slots and forming a second winding set;
• a first inverter adapted to drive the electric motor, the first winding set being coupled to the first inverter;
• a second inverter adapted to drive the electric motor, the second winding set being coupled to the second inverter;
• and
• a controller having a processor and tangible, non-transitory memory on which instructions are recorded, the controller being adapted to control operation of the first inverter and the second inverter based in part on a motor speed of the electric motor;
• wherein the first inverter is adapted to carry a first current and the second inverter is adapted to carry a second current, operation of the first inverter and the second inverter being controlled such that:
• the first current is greater than the second current when the motor speed is above a predefined threshold;
• and
• the second current is greater than the first current when the motor speed is above a predefined threshold.