Abstract: An electric machine in accordance with the invention includes a stator core having first and second ends and having windings therein with end turns of the windings protruding from the first and second ends of the stator core. A rotor is rotatably positioned within the stator core. A thermal conductor, such as non-laminated aluminum or aluminum alloy ring, is disposed between each stator core end-turn and the housing for conducting heat from the stator core end-turns to the housing, and the cavity between each end-turn and the thermal conductor is filled with a flexible potting material to minimize gap formation caused, for example, by thermal cycling of the engine components.

Abstract: A power system, such as an integrated power module comprising a bi-directional converter, functionally combines a power inverter and a charger such as a charger for charging one or more electrical storage devices such as batteries and/or super- or ultra-capacitors. A first switch selectively couples one or more AC devices to the bi-directional converter, and/or a second switch selectively couples a boosting circuit to one or more DC devices and/or reverses polarity of the coupling. The power system may have electric vehicle and/or vehicle-to-grid applications.

Abstract: The present invention relates to a system and method for compensating the voltage distortion and minimizing the available voltage range loss both caused by switching dead-time of solid-state switch components in power conversion devices. As a result, the power quality supplied from the power conversion devices can be improved and the output voltage of such devices can be increased.

Abstract: System and method for enhancing the torque output of a field oriented induction motor including a controller having a plurality of predetermined control parameters operable for processing input signals to generate output signals. The plurality of predetermined control parameters are dependent upon the nature of the input signals and the operational state of the motor. A sensor system is operable for communicating feedback signals related to the output signals and the operational state of the motor from the motor to the controller.

Abstract: A device inserted between a grounded poly-phase external voltage source and a load providing low insertion loss for differential mode currents and high insertion loss for ground currents. The device receives voltages from the grounded poly-phase external voltage source over atone or more voltage lines. The voltages contain common mode voltages. A filter connected to each of the voltage lines reduces the ground current from the load. A summing block adds the voltages from each of the voltage lines to generate a total common mode voltage. A ground referenced controlled voltage source generates a cancellation voltage equal to the total common mode voltage in response to the generation of total common mode voltage. The total common mode voltage is injected into the filter and substantially reduces the common mode voltage on each voltage line thereby substantially reducing the ground currents associated with each common mode voltage on each voltage line.

Abstract: A control system for a permanent magnet motor having low-resolution speed measurement is taught. The control system is comprised of a speed regulator, voltage regulator and current regulator. The speed regulator uses a speed command and a measured speed for calculating a desired motor voltage; the voltage regulator uses a voltage command and an applied motor voltage for calculating a motor current command; and the current regulator uses a current command and a motor phase current for calculating a desired motor voltage for use by said voltage regulator; thereby providing a low resolution speed measurement to be used in a high performance application.

Abstract: The present invention relates to a system and method for compensating the voltage distortion and minimizing the available voltage range loss both caused by switching dead-time of solid switch components in power conversion devices. As a result, the power quality supplied from the power conversion devices can be improved and the output voltage of such devices can be increased.

Abstract: A closed-loop permanent magnet motor control method and system optimally partitions torque and flux-weakening currents to produce a desired torque without exceeding the capability of the DC source. A maximum limit for allowable torque current and a minimum threshold for the maximum torque current are determined, and the flux current is varied based at least in part on whether the maximum torque current limit is above or below the minimum threshold while operating in a flux-weakening region to compensate for the variability of the DC source voltage.

Abstract: A three-phase connector carries all three phases in one connector and keeps the phases properly isolated from each other and the motor case. The three-phase connector has metal connector components that are spaced from one another and supported in a nylon over molding covering each of the connector components, except for upper and lower exposed ends of the connector components, which are each drilled and tapped to receive bolts. First and second connector components extend above and below a flange of the three-phase connector with their respective exposed upper and lower ends offset in different planes than the exposed upper and lower ends of the third connector component.

Abstract: A method for diagnosing faults using a load. In the method IGBTs are controlled such that certain currents are expected. If the currents are not as expected, a fault may be diagnosed.

Abstract: A power conversion system which comprises a controller and conversion assemblies which selectively rectify and invert an electrical signal. Conversion assemblies comprise a plurality of integrated gate bipolar transistor assemblies. The power conversion system is effective to convert DC current to AC current, to convert AC current to DC current, and to control the output frequency of a received electrical signal to a conventional operating range.

Abstract: A process for the optimization of the design of an electric power train system comprising a plurality of subsystems including identifying a plurality of variables associated with the plurality of subsystems of the electric power train system, wherein the plurality of variables interact, applying a plurality of constraints associated with the plurality of subsystems of the electric power train system to the plurality of variables, and manipulating the plurality of variables such that the plurality of constraints are met.

Abstract: A hybrid use of a phase-locked-loop controller and a microprocessor-based controller to synchronize the phase angles of a three-phase AC power source, such as a static power converter, with those of a three-phase power grid. The phase-angle synchronization may enable the AC power source to be safely connected to the power grid to provide additional power capacity.

Abstract: Integrated power conversion systems and methods for use in an electric vehicle having an electric motor, a primary high-voltage energy source, and an auxiliary energy source including a traction inverter module operable for converting a DC current generated by the high-voltage energy source into an AC current capable of powering the electric motor, and a DC/DC converter operable to step-down a voltage of the high-voltage energy source or step-up a voltage of the auxiliary energy source, wherein the traction inverter module and the DC/DC converter may share one or more common components, such as a common high-voltage DC bus capacitor, a common DC bus bar, and/or a common high-voltage transistor.

Abstract: Circuits and methods for use with an integrated circuit chip having internal back EMF estimation to control a permanent magnet synchronous motor includes an AC current feedback circuit, a scaling circuit, and a current regulator. Additionally, a speed regulator may be employed. In one embodiment, during operation at very low speed, the speed regulator is in an open loop control mode due to a back EMF detection limitation of the IC chip, and only the current regulator is active. A feedback current signal, together with a user-defined command current signal, serves the input of the current regulator, which controls the AC motor current and drives the motor speed from standstill. Once the motor speed reaches a certain level, the measured back EMF from the IC chip is sufficient to estimate the motor speed, which is compared with a user-defined command speed, and an error of the these two signals provides the input of a speed regulator.

Abstract: A device inserted between a grounded poly-phase external voltage source and a load providing low insertion loss for differential mode currents and high insertion loss for ground currents. The device receives voltages from the grounded poly-phase external voltage source over atone or more voltage lines. The voltages contain common mode voltages. A filter connected to each of the voltage lines reduces the ground current from the load. A summing block adds the voltages from each of the voltage lines to generate a total common mode voltage. A ground referenced controlled voltage source generates a cancellation voltage equal to the total common mode voltage in response to the generation of total common mode voltage. The total common mode voltage is injected into the filter and substantially reduces the common mode voltage on each voltage line thereby substantially reducing the ground currents associated with each common mode voltage on each voltage line.

Abstract: An assembly for cooling an electric motor, the assembly comprising a housing, a stator, a rotor, a winding, an end-winding integrally formed with the winding, and a jet impingement device operable for exposing the end-winding to a temperature controlled stream of fluid. A method for transferring heat between a stream of impinging fluid and the surface of an electric motor end-winding. An electric motor comprising a jet impingement cooling assembly.

Abstract: A device and method of commutation control for an isolated boost converter provides a unique commutation logic to limit voltage spikes by utilizing switches on the secondary side to minimize a mismatch between current in the inductor and current in the leakage inductance of the transformer when commutation takes places. To minimize this mismatch, the current in the leakage inductance is preset at a certain level that approaches the current in the inductor prior to the commutation, thus significantly reducing the power rating for a clamp circuit and enabling use of a simple passive clamp circuit. In addition, through unique timing of the turn-on of the secondary switches, soft switching conditions are created that eliminate turn-on losses and the reverse recovery problems of free-wheeling diodes.

Abstract: A high frequency, low impedance network is integrated into the substrate level of a power module for the reduction of electromagnetic interference (“EMI”). In one embodiment, capacitance is electrically connected to at least one of the positive conducting layer in a substrate or the negative conducting layer in a substrate and a ground. Integrating a capacitive network of low stray inductance in a substrate of a power module allows relatively small, inexpensive capacitors to be used.

Abstract: Regenerative braking systems and methods for use in an electric vehicle, such as a battery-powered vehicle, a fuel cell vehicle, and a hybrid electric vehicle, including an electric motor system operable for generating torque to drive and control the electric vehicle, a traction controller operable for controlling the electric motor system, a brake system operable for generating torque to drive and control the electric vehicle, and a brake controller operable for controlling the brake system. Traction functions are strictly allocated to the traction controller, braking functions are strictly allocated to the brake controller, and the brake controller is subordinated to the traction controller. The regenerative braking systems and methods also including a communications system operable for transferring information between the traction controller and the brake controller.