Abstract: A temperature regulation system for a vehicle includes a drive system configured to be coupled to an engine of the vehicle. The drive system is configured to convert power produced by the engine into electrical power for use by at least one traction motor of the vehicle. The system further includes a control unit for controlling the engine and drive system. The control unit is configured to automatically regulate a temperature of a vehicle component in dependence upon a detected reference temperature.

Abstract: A system includes a retarder in electrical communication through an electric link with an alternator, and a controller that compares a power measurement with an accessory load on a system during a retard event, and can reduce an electrical load on the alternator, or can remove all electrical loads from an engine, when electric power that is generated from the retarder is measured to be greater than an accessory load on the system. The system may include an alternator that provides a motor function to rotate a shaft coupled to an engine that is mechanically coupled to one or more mechanically drivable accessories. The alternator powers the mechanically drivable accessories in place of or in addition to the engine.

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 system and method are provided for controlling a drivetrain of a vehicle which includes a prime mover operatively connected to at least one tractive element. The system and method include determining the vehicle's total weight and, using an electronic controller carried by the vehicle, causing the prime mover to apply power to the tractive element so as to propel the vehicle. The magnitude of the power can be a function of the vehicle's total weight.

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 method is provided for controlling a drivetrain of a vehicle which includes a prime mover operatively connected to at least one tractive element. The method includes: (a) determining the vehicle's total weight; and (b) using an electronic controller carried by the vehicle, causing the prime mover to apply power to the tractive element so as to propel the vehicle, the magnitude of the power being a function of the vehicle's total weight.

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 method of testing a braking device in a drivetrain of a vehicle which includes at least one tractive element coupled to a traction motor. The method includes: (a) applying the braking device to a tractive element of the vehicle; (b) using an electronic controller, causing the traction motor to apply a predetermined force to the tractive element; and (c) using the controller, monitoring the tractive element for movement while the force is being applied. A dynamic braking or “retarder” function may also be tested. A system for carrying out the method is provided.

Abstract: A driver alert and de-rate control system for a vehicle includes a sensor configured to monitor an engine operating condition, and a control unit in communication with the sensor. The control unit is configured to estimate a time until automatic de-rate of the engine based on the engine operating condition and to modify a performance parameter of the vehicle in dependence upon the estimated time until automatic de-rate.

Abstract: A system to optimize performance of a powered system, the system including a data device configured to provide current information about current operating conditions of the powered system and/or prior information about the powered system, a controller configured to control operation of the powered system, and a processor configured to provide at least one control command to the controller for use in operating the powered system and/or user information with at least one recommended command to a user to control the powered system, wherein the at least one control command and/or user information are based at least in part on the current information and/or the prior information. A system and computer software code, stored on a computer readable media and executable with a processor, are also disclosed.

Abstract: The present invention relates to an integrated cooling system for a vehicle. The system includes an engine cooling loop having a first fluid configured for circulation through an engine of the vehicle and a power electronics cooling loop having a second fluid configured for circulation through at least one power electronics component of the vehicle. The engine cooling loop is fluidly isolated from, and in thermal communication with, the power electronics cooling loop.

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.

Abstract: A capacitor bank includes a laminated bus bar having a high potential conductive layer and a low potential conductive layer disposed in close proximity at opposing surfaces of an intervening insulation layer. The bank also includes a plurality of bus capacitors electrically connected to the laminated bus bar. The laminated bus bar and the bus capacitors having a combined inductance sufficiently low such that the bus capacitors are electrically connected effectively in parallel with the laminated bus bar.

Abstract: A system to optimize performance of a powered system, the system including a data device configured to provide current information about current operating conditions of the powered system and/or prior information about the powered system, a controller configured to control operation of the powered system, and a processor configured to provide at least one control command to the controller for use in operating the powered system and/or user information with at least one recommended command to a user to control the powered system, wherein the at least one control command and/or user information are based at least in part on the current information and/or the prior information. A system and computer software code, stored on a computer readable media and executable with a processor, are also disclosed.

Abstract: An energy storage device that includes a housing, which includes at least one end panel that includes at least one aperture therethrough. The device further includes a battery cell housed in the housing. The battery cell includes mutually opposed first and second faces joined at their edges. The device also includes a heat sink adjacent to the battery cell and in thermal contact with the first face of the battery cell. The heat sink defines at least one cooling medium passage extending parallel to the face of the adjacent battery cell. The cooling medium passage opens onto the at least one aperture formed through the at least one end panel of the housing.

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.