Drive Motor Generator Control Module Description and Operation
Drive Motor Generator Control Module Description and Operation
Overview
The drive motor generator power inverter module (PIM) assembly converts high voltage direct current (DC) electrical energy to 3 phase alternating current (AC) electrical energy. The accessory DC power converter module (APM) converts high voltage DC electric energy into low voltage (14 V) and intermediate voltage (42 V) in order to charge the vehicles accessory battery and supply electric energy to the 42 V power steering system. The APM and PIM are fastened together and are referred to as the drive motor/generator control module assembly. The drive motor/generator control module assembly is cooled with pre-mixed Dexcool(R) circulating through a cooling system that is separate from the engine cooling system. The power electronics cooling system utilizes a heat exchanger at the front of the vehicle and an electric pump to circulate the coolant. The engine control module (ECM) monitors a temperature sensor in the power electronics cooling system and operates the radiator fan and the power electronics coolant pump in response to power electronics cooling system temperature.
High Voltage Circuits
Direct Current (DC)
The drive motor/generator control module assembly is connected to each pole of the high voltage (HV), direct current (DC) drive motor/generator battery. Both of the negative and positive HV DC battery poles are isolated from the vehicle chassis by a minimum amount of resistance. Each HV DC cable is switched ON or OFF by a high voltage, high current relay (or contactor) contained within the drive motor/generator battery assembly. All HV DC negative and positive DC cables are individually shielded and orange in color to alert the technician to the potential presence of high voltage. The electric air conditioning compressor high voltage DC cables are externally connected at the drive motor/generator control module assembly. The APM and PIM share an internal connection that supplies the APM with high voltage DC current.
Three Phase Alternating Current (AC)
Three cables connect each motor/generator to the PIM. Each individually shielded cable is orange in color to alert the technician to the potential presence of high voltage.
Intermediate and Low Voltage Circuits
The APM converts high voltage (300 V) DC current into both intermediate voltage (42 V) and low voltage (12 V) current.
Intermediate Voltage (42 V) Direct Current
Intermediate voltage (42 V) cables are individually shielded and are blue in color to alert the technician to the potential presence of intermediate voltage.
Low Voltage (12 V) Direct Current
Low voltage (12 V) cables on the hybrid-electric vehicle do not require unique coloring or servicing procedures.
Drive Motor/Generator Power Inverter Module (PIM) Assembly
Overview
Contained within the PIM assembly are the hybrid control module (HCM), and two motor control modules (MCM). Each MCM controls it's respective motor/generator. All three modules are flash-programmable micro-processors.
Hybrid Control Module (HCM)
Location
The HCM is a non-serviceable, flash-programmable micro-processor contained within the PIM assembly.
Operating Functions
The HCM is the main controller of hybrid operation. The HCM determines when to perform hybrid operation modes such as engine Auto-stop and regenerative braking. The HCM also operates in conjunction with the battery energy control module (BECM) to determine when to enable and disable the DC high voltage circuits. Each MCM operates the applicable electric motor/generator based upon HCM commands.
Communication and Hosted Diagnostics
The HCM is the host controller for diagnostic trouble code (DTC) information for the following control modules:
* Accessory DC power converter module (APM)
* Battery energy control module (BECM)
* Motor control module (MCM) 1
* Motor control module (MCM) 2
* Auxiliary transmission fluid pump (ATFP) control module
These modules diagnose their own operation and determine when a fault condition is present. Diagnostic status is communicated to the HCM through the following circuits:
* APM utilizes the GM Hi-speed, Hybrid LAN communication circuit
* BECM utilizes the GM Hi-speed, Hybrid LAN communication circuit
* Each MCM and the HCM exchange information and commands on the SPI bus internal communication circuit as well as the hi-speed hybrid GMLAN communication circuit.
* ATFP control module utilizes a dedicated diagnostic status circuit
In the event a hosted module communicates a fault condition, the HCM will determine if hybrid operation is effected and notify the vehicle operator by requesting the MIL illuminate and/or by displaying a hybrid service required message. In addition, the HCM will store the associated DTC information for retrieval by a scan tool. Some hosted modules may require an ignition cycle to clear certain DTCs from the HCM.
Circuit Inputs
In addition to GMLAN parameters, the HCM directly monitors the following signal circuits:
* Transmission shift selector internal mode switch (IMS) Direction and Park/Neutral switch signals
* Engine crankshaft position (CKP) sensor signal
* ATFP diagnostic circuit
* High voltage interlock loop (HVIL) circuit
Circuit Outputs
In addition to GMLAN and SPI bus commands, the HCM directly controls the following output circuits:
* ATFP control circuit
* BECM high voltage relay (contactor) pulse width modulated (PWM) control circuit
Motor Control Module (MCM) 1 and 2
Location
Each electric motor/generator located within the transmission assembly is controlled by its own motor control module (MCM) flash-programmable, micro-processor. Each MCM is contained within the PIM. Also contained within the PIM is the Hybrid Control Module (HCM) micro-processor.
Operating Functions
Each MCM operates the applicable electric motor/generator based upon HCM commands. Each MCM controls the speed, direction and output torque of its respective traction motor through the sequencing actuation of high current switching transistors called insulated gate bipolar transistors (IGBTs).
Communication and Hosted Diagnostics
In addition to the internal SPI bus communication circuit between the HCM and each MCM, the MCMs also communicate on the Hi-speed and Hybrid GMLAN communication circuits. The MCM does not store its own diagnostic trouble code (DTC) information. The HCM will store MCM associated DTC information for retrieval by a scan tool. The scan tool can communicate directly with each MCM in order to retrieve data parameters only.
Circuit Inputs
In addition to GMLAN parameters, each MCM monitors it's respective motor/generator for voltage, current, speed, direction and temperature. Additionally, the MCM monitors the IGBT components for temperature and proper operation. Some of the MCM operation data is shared with the HCM.
Circuit Outputs
Each MCM controls its respective IGBT driver board that in-turn controls each motor/generator. The motor/generator's operate using three-phase alternating current (AC) electricity. Three cables connect each motor/generator to the PIM. Each individually shielded cable is orange in color to alert the technician that the potential for high voltage is present.
Accessory DC Power Converter Module (APM)
Location
The APM is affixed to and located underneath the PIM. It is fastened to the PIM with external mounting fasteners and 2 internal high voltage circuit connection fasteners. The APM shares a coolant passage with the PIM and as such is gasketed to the PIM.
Operating Functions
The APM is the device which converts high voltage (300 V) direct current (DC) to low voltage (12 V) DC for accessory electrical operation and to charge the 12 volt accessory battery. The APM also converts HV DC to intermediate (42 V) DC to supply the electric power steering system with voltage. The APM is capable of supplying up to 185 Amps of 12 volt DC and up to 50 Amps of 42 volt DC. In Jump Assist mode the APM converts 12 Volt DC to HV DC to charge the high voltage hybrid batteries. The APM is capable of supplying up to 2.7 Amps at 290 volts DC on the high voltage circuit when operating in Jump Assist. An external 12 V DC battery charger is required during the Jump Assist mode because the APM and vehicle controllers may draw as much as 80 Amps current from the vehicles 12 volt DC system.
Communication and Hosted Diagnostics
The APM has internal diagnostic tests that run at both power-up and during operation. All DTCs from the APM are reported to and hosted by the HCM. The APM communicates directly only with the HCM and only on the high speed hybrid GMLAN communication circuit.
Circuit Inputs
Inputs supported by the APM include the high voltage and 12 volt circuits. The APM also monitors various internal components for current, voltage and temperature. The APM is also connected to the high speed hybrid GMLAN communication circuit. An individual 12 volt discrete circuit powers ON the APM. The APM will not begin conversion of voltage however, until the appropriate GMLAN enable signal is communicated to it by the HCM.
Circuit Outputs
The only outputs supported by the APM are the 12 volt and 42 volt conversion during normal vehicle operation and high voltage conversion during Jump Assist.