Abstract: A gate driver circuit for the power switch is disclosed. The gate driver circuit includes a resistor network coupled to the power switch. The resistor network includes a plurality of resistors and a control unit operatively coupled to the resistor network. The control unit detects an occurrence of a commutation phase and a saturation phase based on an identity of the power switch and corresponding time stamps associated with a start of a delay phase, the commutation phase, and the saturation phase. The control unit further controls the resistor network to provide different resistance values in at least two of a delay phase, a commutation phase, and a saturation phase when the power switch is transitioned to a first state. A method for driving the power switch is also disclosed.

Abstract: A gate driver circuit for the power switch is disclosed. The gate driver circuit includes a resistor network coupled to the power switch. The resistor network includes a plurality of resistors. The gate driver circuit further includes a control unit operatively coupled to the resistor network. The control unit is configured to control the resistor network such that the resistor network provides different resistance values in at least two of a delay phase, a commutation phase, and a saturation phase when the power switch is transitioned to a first state. A method for driving the power switch is also disclosed.

Abstract: A power converter apparatus includes a primary bridge having a plurality of diagonally opposed primary power elements, and a secondary bridge having a plurality of diagonally opposed secondary power elements. The primary and secondary bridges are electrically coupled by a transformer. At least one control unit is configured to phase-shift switch the primary and secondary power elements, such that one or more of the primary and secondary power elements are switched off under near-zero current conditions to reduce voltage and current stresses and commutation losses within the power converter.

Abstract: A power converter includes a plurality of switches that interconnect first and second input terminals of the power converter with first and second output terminals of the power converter. The switches are switched to convert power from the input terminals to the output terminals. During the switching, voltage spikes are mitigated by a first RLC branch connected from the first input terminal to the first output terminal and by a second RLC branch connected from the second input terminal to the second output terminal.

Abstract: A gate drive unit includes a measurement unit, a multi-resistive driving device, and a processing unit. The measurement unit measures a voltage across main terminals of a power switch. The driving device includes plural individually controllable resistive elements. The processing unit controls a control voltage applied to a control electrode of the power switch to activate the power switch. The processing unit individually activates or deactivates the resistive elements of the multi-resistive driving device to change which of the resistive elements at least partially conducts the control voltage to the power switch at different times responsive to the voltage across the main terminals representing a short circuit event. The processing unit changes which of the resistive elements are activated or deactivated to control a rate at which the control voltage decreases.

Abstract: A gate drive unit includes a measurement unit, a multi-resistive driving device, and a processing unit. The measurement unit measures a voltage across main terminals of a power switch. The driving device includes plural individually controllable resistive elements. The processing unit controls a control voltage applied to a control electrode of the power switch to activate the power switch. The processing unit individually activates or deactivates the resistive elements of the multi-resistive driving device to change which of the resistive elements at least partially conducts the control voltage to the power switch at different times responsive to the voltage across the main terminals representing a short circuit event. The processing unit changes which of the resistive elements are activated or deactivated to control a rate at which the control voltage decreases.

Abstract: A controller for a power converter includes one or more controller modules operably linked to a transformer core of the power converter, to primary bridge switches of the power converter, and to secondary bridge switches of the power converter, wherein the one or more controller modules are configured to avoid saturation of the transformer core by modulating pulse widths of first electrical pulses sent to the primary bridge switches, based at least on measurements of DC components of current through primary and secondary windings adjacent the transformer core, and by modulating pulse widths of second electrical pulses sent to the secondary bridge switches, based at least on measurements of DC components of current through the primary and secondary windings.

Abstract: A heat sink has a base plate that has a first central portion, a second central portion, and a periphery, a first plurality of heat pipes embedded in the base plate that are arranged to convey heat away from the first central portion, and a second plurality of the heat pipes embedded in the base plate that are arranged to convey heat away from the second central portion, each of the heat pipes of the first and second pluralities having a hot end for receiving heat flow and a cool end for releasing heat flow. A switch package comprises an inner casing half mounted to a module facing surface of the heat sink base plate, a semiconductor module mounted to the module facing surface of the heat sink within the inner casing half, and an outer casing half that encloses the heat sink.

Abstract: A power converter control system includes primary bridge controller that is configured to actuate a first plurality of gate drive units that switch a first plurality of power elements in a primary bridge of a power converter. The control system further includes a secondary bridge controller separate from the primary bridge controller that is configured to actuate a second plurality of gate drive units to switch a second plurality of power elements in a secondary bridge of the power converter.

Abstract: An integrated power converter includes first and second auxiliary switch modules, and one or more braking switch modules. The first auxiliary switch module is mounted at a first location of a laminated bus bar, and connects a first auxiliary lead with a first power layer and a second power layer of the bus bar. The second auxiliary switch module is mounted at a second location of the bus bar, and connects a second auxiliary lead with the first and second power layers. The braking switch modules are mounted at additional locations of the bus bar, adjacent to the first and second locations. Each braking switch module connects a braking lead with one of the power layers of the bus bar, and with a dual diode module or with the other power layer of the bus bar.

Abstract: A method includes obtaining a standard value for a characteristic of a power switch and obtaining a measured value of the characteristic, via a gate drive unit connected to a gate terminal of the power switch. The method also includes determining a health state of the power switch by comparing the measured value to the standard value of the characteristic.

Abstract: An apparatus includes a switch module, a sense circuit coupled to the switch module and configured to indicate an operating conduction mode of the switch module, and a drive circuit operatively coupled to the switch module to enable and disable forward conducting mode of the switch module. Once the switch module is in forward conducting mode, the drive circuit is configured to maintain enablement of the forward conducting mode even if the sense circuit indicates reverse conduction mode.

Abstract: A communication method includes detecting at a gate drive unit a change of state of a command signal that is received via a command link of the gate drive unit and initiating, responsive to the change of state of the command signal, a blanking period in which the gate drive unit will process as incoming data any further changes of state of the command signal. The method also includes receiving incoming data at the gate drive unit, by processing modulations of the command signal, within the blanking period.

Abstract: A method for reducing thermal cycling of a semiconductor power switch includes obtaining a value indicative of a junction temperature of the power switch. The method also includes selecting one of several pre-determined gate drive voltages, based on the obtained value, and providing the selected gate drive voltage to a gate of the power switch. This reduces thermal cycling of a power switch relative to the thermal cycling that would be present during operation at a single gate voltage.

Abstract: A power delivery system includes a bus bar and a housing coupled to the bus bar. A semiconductor power device is enclosed within the housing. The housing comprises an outlet configured to direct failure material of the power semiconductor device away from any remaining components connected to the bus bar. In another aspect, the power delivery system additionally or alternatively comprises two bus bars. A first of the two bus bars has a first landing, a riser, and a second landing, which is parallel to the first landing and in effect spatially offset from the first landing. A second of the two bus bars is attached to the second landing of the first bus bar, such that the second bus bar is parallel to but offset from the first landing of the bus bar.

Abstract: A power conversion system includes a bus bar, a switch coupled to the bus bar and configured to receive a DC input voltage from a voltage source through the bus bar, and a parallel fuse system. The parallel fuse system may be disposed on the bus bar in series with the voltage source and the switch. The parallel fuse system includes two or more parallel fuses, and may be configured for an inductance imbalance between the fuses, such that there is an asymmetric flow of currents through the fuses when the power conversion system is in operation. For the inductance imbalance, for example, the fuses may be positioned asymmetrically with regard to a shortest conductive path from the voltage source to the switch.

Abstract: A power converter includes a plurality of switches that interconnect first and second input terminals of the power converter with first and second output terminals of the power converter. The switches are switched to convert power from the input terminals to the output terminals. During the switching, voltage spikes are mitigated by a first RLC branch connected from the first input terminal to the first output terminal and by a second RLC branch connected from the second input terminal to the second output terminal.

Abstract: A controller for a power converter includes one or more controller modules operably linked to a transformer core of the power converter, to primary bridge switches of the power converter, and to secondary bridge switches of the power converter, wherein the one or more controller modules are configured to avoid saturation of the transformer core by modulating pulse widths of first electrical pulses sent to the primary bridge switches, based at least on measurements of DC components of current through primary and secondary windings adjacent the transformer core, and by modulating pulse widths of second electrical pulses sent to the secondary bridge switches, based at least on measurements of DC components of current through the primary and secondary windings.

Abstract: An integrated power converter includes first and second auxiliary switch modules, and one or more braking switch modules. The first auxiliary switch module is mounted at a first location of a laminated bus bar, and connects a first auxiliary lead with a first power layer and a second power layer of the bus bar. The second auxiliary switch module is mounted at a second location of the bus bar, and connects a second auxiliary lead with the first and second power layers. The braking switch modules are mounted at additional locations of the bus bar, adjacent to the first and second locations. Each braking switch module connects a braking lead with one of the power layers of the bus bar, and with a dual diode module or with the other power layer of the bus bar.

Abstract: A power unit (e.g., inverter module) includes a housing and a switch attached to the housing. The switch may be configured to be electrically coupled to a remotely-mounted drive circuit through two or more wire leads. The power unit also includes a clamping circuit electrically coupled to terminals of the switch and in parallel with the switch. The clamping circuit may be disposed inside the housing or on an outer surface of the housing, and is configured to limit a voltage across the switch.