Abstract: In one aspect, an apparatus includes a motor and inverter configured to provide input power to the motor. The apparatus may also include a data store comprising at least one entry including a first torque command, a first motor speed, and a first DC voltage value, where the first torque command and the first motor speed and the first DC voltage value are associated with a first current output and a processor. The processor receives a torque input, a DC voltage input, and a motor speed input and identifies the current output associated with the torque input, the DC voltage input, and the motor speed input based on another motor speed different than the motor speed input and another DC voltage different than the DC voltage input and the motor speed input, and output the determined current output to cause the inverter to provide the input power to the motor.

Abstract: A system for interconnecting parallel insulated gate bipolar transistor (IGBT) modules is provided. A pair of switches selected from a plurality of the IGBT modules are assigned to a driver integrated circuit (IC). In the pair of switches, a master IGBT switch is selected, the other switch being a slave IGBT switch. A command signal from the driver IC is electrically coupled to both the master and slave IGBT switches. The master and slave IGBT switches both have protective circuits; however, the driver IC is electrically coupled to the protective circuits of the selected master IGBT switch only. The protective circuits include temperature and current sense circuits. The plurality of the IGBT modules may be formed by two hexpack power modules. The modules are configured such that only a single driver IC is needed for each pair of parallel IGBT switches, with equal current sharing of the paralleled modules.

Abstract: Systems and methods are disclosed for improving acceleration performance of an electric vehicle that includes an electric motor for propulsion. An exemplary system may include an inverter configured to drive the electric motor. The inverter may include at least one power electronic device. The system may also include a torque capability controller. The torque capability controller may be configured to receive information indicative of a selection between a first mode and a second mode. The second mode may correspond to a higher torque to be output by the electric motor than the first mode. The torque capability controller may also be configured to apply a switching frequency to the at least one power electronic device. The switching frequency may have a lower value when the received information indicates the selection of the second mode than when the received information indicates the selection of the first mode.

Abstract: Systems and methods are disclosed for improving acceleration performance of an electric vehicle that includes an electric motor for propulsion. An exemplary system may include an inverter configured to drive the electric motor. The inverter may include at least one power electronic device. The system may also include a torque capability controller. The torque capability controller may be configured to receive information indicative of a selection between a first mode and a second mode. The second mode may correspond to a higher torque to be output by the electric motor than the first mode. The torque capability controller may also be configured to apply a switching frequency to the at least one power electronic device. The switching frequency may have a lower value when the received information indicates the selection of the second mode than when the received information indicates the selection of the first mode.

Abstract: A method for measuring the isolation resistance between a chassis and a battery terminal in an electric vehicle. The method can include measuring an open voltage (VP(open)) of the positive terminal; measuring an open voltage (VN(open)) of the negative terminal; measuring a voltage (VN(S1 closed)) between the negative terminal and the chassis with switch S1 closed; measuring a voltage (VP(S1 closed)) between the positive terminal and the chassis with switch S1 closed; calculating the ratio (VP(open)/VN(closed)) of the voltages VP(open) and VN(closed); calculating the open ratio of the open voltages (VP(open)/VN(open)); calculating the difference between the ratio (VP(S1 closed)/VN(S1 closed)) and the open ratio (VP(open)/VN(open)); and multiplying the value of the test resistor (R0) by the difference between the ratio (VP(S1 closed)/(VN(S1 closed)) and the open ratio (VP(S2 open)/VN(S1 open)) to obtain the isolation resistance.

Abstract: Circuits and methods for driving a load are disclosed. An exemplary driving circuit may include first and second switching devices electrically connected with each other in parallel. The driving circuit may also include a current sensing circuit configured to generate a current sensing signal indicating a value of a current flowing through the first switching device. The current sensing signal may include an offset caused by parasitic inductance imbalance in electrical connections connecting the first and second switching devices. The driving circuit may further include a driver circuit configured to control switching operations of the first and second switching devices. The driver circuit may include an overcurrent protection circuit electrically connected to the current sensing circuit.

Abstract: A system for interconnecting parallel insulated gate bipolar transistor (IGBT) modules is provided. A pair of switches selected from a plurality of the IGBT modules are assigned to a driver integrated circuit (IC). In the pair of switches, a master IGBT switch is selected, the other switch being a slave IGBT switch. A command signal from the driver IC is electrically coupled to both the master and slave IGBT switches. The master and slave IGBT switches both have protective circuits; however, the driver IC is electrically coupled to the protective circuits of the selected master IGBT switch only. The protective circuits include temperature and current sense circuits. The plurality of the IGBT modules may be formed by two hexpack power modules. The modules are configured such that only a single driver IC is needed for each pair of parallel IGBT switches, with equal current sharing of the paralleled modules.

Abstract: Circuits and methods for driving a load are disclosed. An exemplary driving circuit may include a plurality of switching devices and a controller electrically connected to the plurality of switching devices. The controller may be configured to provide a switching signal for controlling switching operations of the switching devices. The controller may also be configured to determine whether the switching signal falls within a predetermined dead zone. When it is determined that the switching signal falls within the predetermined dead zone, the controller may be configured to modify the switching signal by moving a space vector corresponding to the switching signal to a boundary of the predetermined dead zone. In addition, the controller may be configured to provide the modified switching signal to the switching devices.

Abstract: In one aspect, an apparatus includes a motor and inverter configured to provide input power to the motor and a data store comprising at least one entry including a first torque command, a first motor speed, and a first DC voltage value. The first torque command and the first motor speed and the first DC voltage value are associated with a first current output. The apparatus includes a processor configured to receive a torque input, a DC voltage input, and a motor speed input and determine an output current associated with the torque input, the DC voltage input, and the motor speed input, correct the output current to be within a voltage constraint of the motor when the DC voltage input is than a reference voltage at the motor and output the corrected output current to cause the inverter to provide the input power to the motor.

Abstract: A three-phase current sensor for measuring currents running in three conductors of a three-phase conductor system includes at least a first magnetic measuring device. The magnetic measuring device includes a magnetic circuit provided with at least two gaps and a magnetic field sensor arranged in each gap of the magnetic circuit. The magnetic field sensors are positioned on both sides of a cavity sized to receive one of the three conductors. The gaps and thus the magnetic field sensors are positioned such that stray magnetic flux from an adjacent conductor has substantially equal amplitude passing through each of the sensors.

Abstract: In one aspect, an apparatus includes a motor and inverter configured to provide input power to the motor. The apparatus may also include a data store comprising at least one entry including a first torque command, a first motor speed, and a first DC voltage value, where the first torque command and the first motor speed and the first DC voltage value are associated with a first current output and a processor. The processor receives a torque input, a DC voltage input, and a motor speed input and identifies the current output associated with the torque input, the DC voltage input, and the motor speed input based on another motor speed different than the motor speed input and another DC voltage different than the DC voltage input and the motor speed input, and output the determined current output to cause the inverter to provide the input power to the motor.

Abstract: A three-phase current sensor for measuring currents running in three conductors of a three-phase conductor system includes at least a first magnetic measuring device. The magnetic measuring device includes a magnetic circuit provided with at least two gaps and a magnetic field sensor arranged in each gap of the magnetic circuit. The magnetic field sensors are positioned on both sides of a cavity sized to receive one of the three conductors. The gaps and thus the magnetic field sensors are positioned such that stray magnetic flux from an adjacent conductor has substantially equal amplitude passing through each of the sensors.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: A method for monitoring an electrically-powered torque machine configured to generate torque in a hybrid powertrain system includes monitoring signal outputs of a resolver configured to monitor rotational position of the torque machine. Upon detecting a fault warning state associated with the signal outputs of the resolver, a motor torque capacity of the torque machine is derated. Upon a clearing of the fault warning state, a torque ramp-up state to increase the motor torque capacity of the torque machine is executed. Notice of an incidence of a fault associated with the signal outputs of the resolver is provided only when the motor torque capacity fails to achieve a threshold motor torque capacity within a threshold recovery time period while executing the torque ramp-up state.

Abstract: Systems and methods are disclosed for improving acceleration performance of an electric vehicle that includes an electric motor for propulsion. An exemplary system may include an inverter configured to drive the electric motor. The inverter may include at least one power electronic device. The system may also include a torque capability controller. The torque capability controller may be configured to receive information indicative of a selection between a first mode and a second mode. The second mode may correspond to a higher torque to be output by the electric motor than the first mode. The torque capability controller may also be configured to apply a switching frequency to the at least one power electronic device. The switching frequency may have a lower value when the received information indicates the selection of the second mode than when the received information indicates the selection of the first mode.

Abstract: An electric machine electrically connects to an inverter via a multi-phase power circuit. A method for monitoring the multi-phase power circuit includes non-intrusively adjusting a commanded AC electric current from the inverter after a prescribed time period and comparing a measured magnitude of AC electric current in the multi-phase power circuit with a minimum threshold. Presence of an open circuit fault in the multi-phase power circuit can be detected based upon the comparison.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: A method of distributing processor loading in a real-time operating system between a high frequency processing task and a lower frequency processing task, the method including: making a processing request to the high frequency processing task from the lower frequency processing task, the processing request including a plurality of discrete processing commands; queuing the plurality of discrete processing commands; and executing a subset of the queued processing commands with the execution of each of a plurality of high frequency processing tasks such that the execution of the plurality of discrete processing commands is distributed across the plurality of high frequency processing tasks.