Early fault detection and mitigation for electric motors

1. A method for controlling an electric motor, comprising:

calculating power input to the electric motor based on a direct current (DC) bus voltage and a current supplied to the electric motor;

calculating power output by the electric motor based on a torque of the electric motor and a rotor speed of the electric motor;

calculating power loss in the electric motor based on the power input and the power output;

comparing the power loss in the electric motor to one or more predetermined power loss thresholds;

altering operation of the electric motor in response to the power loss in the electric motor being greater than one or more predetermined power loss thresholds;

declaring that the electric motor is healthy when the power loss is less than a first predetermined power loss threshold of the one or more predetermined power loss thresholds;

generating a first warning and scheduling maintenance when the power loss is greater than the first predetermined power loss threshold and less than a second predetermined power loss threshold of the one or more predetermined power loss thresholds; and

generating a second warning and reducing torque output of the electric motor when the power loss is greater than the second predetermined power loss threshold.

2. The method of claim 1 , further comprising:

sensing the current and the DC bus voltage supplied to the electric motor.

3. The method of claim 1 , further comprising:

sensing the rotor speed of a rotor of the electric motor; and

calculating the torque output by the electric motor.

4. The method of claim 3 , further comprising calculating a quadrature axis current and a direct axis current based on a plurality of stator winding currents.

5. The method of claim 4 , further comprising calculating the torque output by the electric motor based on the quadrature axis current and the direct axis current.

6. A control system for an electric motor, comprising:

a power input calculating module configured to calculate power input to the electric motor based on a bus voltage and current supplied to the electric motor;

a power output calculating module configured to calculate power output by the electric motor based on a speed and a torque output of the electric motor;

a power loss calculating module configured to calculate power loss in the electric motor based on the power input and the power output; and

a fault module configured to compare the power loss in the electric motor to one or more predetermined power loss thresholds and to selectively alter operation of the electric motor based on the comparison,

wherein when the power loss is less than a first predetermined power loss threshold of the one or more predetermined power loss thresholds, the fault module declares that the electric motor is healthy,

wherein when the power loss is greater than the first predetermined power loss threshold and less than a second predetermined power loss threshold of the one or more predetermined power loss thresholds, the fault module at least one of generates a first warning and schedules maintenance, and

wherein when the power loss is greater than the second predetermined power loss threshold, the fault module generates a second warning and reduces torque output of the electric motor.

7. The control system of claim 6 , further comprising:

a current sensor configured to sense the current supplied to the electric motor; and

a voltage sensor configured to sense the bus voltage supplied to the electric motor.

8. The control system of claim 6 , further comprising:

a rotor sensor configured to sense the rotor speed of a rotor of the electric motor, and

a torque calculating module configured to calculate the torque output by the electric motor.

9. The control system of claim 8 , further comprising:

a plurality of current sensors to sense a plurality of stator winding currents, respectively; and

a current converting module configured to calculate a quadrature axis current and a direct axis current based on the plurality of stator winding currents.

10. The control system of claim 9 , wherein the torque calculating module is configured to calculate the torque output by the electric motor based on the quadrature axis current and the direct axis current.