Controller and method for estimating, managing, and diagnosing motor parameters

A method comprising:

• determining output voltages for operating a motor based on a torque demand;
• generating switching signals, based on the output voltages, for an inverter that drives the motor;
• generating an out-of-volts (OOV) signal according to a comparison based on the output voltages, a maximum duty cycle, and a voltage of a direct current (DC) bus that provides power to the inverter;
• generating an OOV amount by filtering the OOV signal;
• and
• selectively limiting the torque demand based on the OOV amount.

A method comprising:

• generating a torque demand based on a commanded speed;
• mapping the torque demand to a q-axis current demand;
• selectively limiting the q-axis current demand based on an upper current limit and a d-axis current demand;
• setting a limit signal while limiting the q-axis current demand;
• generating a q-axis voltage command and a d-axis voltage command based on the q-axis current demand and the d-axis current demand, respectively;
• determining first, second, and third output voltages for operating first, second, and third windings, respectively, of a motor based on the voltage commands;
• determining first, second, and third duty cycle values based on dividing the first, second, and third output voltages, respectively, by a voltage of a direct current (DC) bus, wherein the DC bus provides power to an inverter that drives the motor;
• generating switching signals, based on the duty cycle values, for the inverter;
• setting an out-of-volts (OOV) signal to one when at least one of the duty cycle values is greater than a maximum duty cycle, and setting the OOV signal to zero otherwise;
• generating an OOV amount based on a weighted moving average of the OOV signal;
• pausing increasing the torque demand when the OOV amount is greater than a predetermined threshold;
• pausing increasing the torque demand when the limit signal is set;
• adjusting the d-axis current demand based on the OOV amount;
• and
• pausing increasing only the q-axis voltage command when the OOV signal is set to one.