Abstract: A distributed control system includes an electronic control unit to establish secure communication with a distributed control module. Upon determination that a previously negotiated session key is stored on the electronic control unit, the electronic control unit transmits encrypted communications with the distributed control module using the previously negotiated session key, negotiates a new session key with the distributed control module, and stores the new session key. Upon determination that the previously negotiated session key is not stored on the electronic control unit, the electronic control unit negotiates the new session key with the distributed control module. After negotiating the new session key with the distributed control module, the electronic control unit ceases transmission of unencrypted communications with the distributed control module, transmits encrypted communications with the distributed control module using the new session key, and stores the new session key.

Abstract: An energy management system (EMS) for an aircraft is provided. The aircraft may have one of a plurality of propulsion systems such as a parallel hybrid electric propulsion system, a parallel turbo electric propulsion system, an electric propulsion system, a turbo electric propulsion system and a turbo hybrid electric propulsion system. The EMS comprises redundant control paths for controlling safety critical operation. Each redundant control path is configured to independently determine whether to electrically isolate a line replaceable unit (LRU) from a high voltage DC link (HVDC link) based on status information from the LRU. The isolation is based on the independent determination. The HVDC link is used for propulsion. The number of the redundant control paths and components may be depending on the type of the propulsion system.

Abstract: Charging apparatus and systems are provide for charging an energy storage system in respective vehicles using grid power where the vehicles are connected to the same transformer. The apparatus and system coordinate the charging and may use field weakening techniques to reduce a peak line-line voltage when a need is determined based on a minimum energy storage system voltage of the vehicles connected to the same transformer.

Abstract: A common-mode current sensor system and method for a traction inverter of an electric hybrid vehicle. The system and method detects/reduces excess common-mode currents that can be caused by the presence of alternating current (AC)-chassis type short circuit faults at the outputs of an inverter used for driving a two or more-phased load. In an embodiment, the system detects the presence of an AC-chassis fault of any varying strength, e.g., weak, medium, hard, in respective parallel paths. The system and method can isolate a particular AC-chassis type fault to a particular phase leg of the inverter thereby obviating a need of having to shut-down and/or re-program each phase leg of the whole power supply and vehicle operation. Rather, upon detecting a chassis short, a fault signal is asserted to control shutting down of one or more inverter switches without having to shut-down the vehicle or negatively impact the vehicle status.

Abstract: A system for partially pre-charging an electrical power system having a high voltage power source, a DC link device with a DC Link capacitor, a low voltage power source and a DC/DC converter. In one embodiment a partial pre-charge of the DC Link capacitor can be achieved in three ways: first, through a DC/DC converter boosting from the low voltage power source, second, through a first circuit provided to charge the DC link capacitor to a partial pre-charge state using the voltage directly from the low voltage power source, and third, through a second circuit provided to limit current flowing to the DC link capacitor from the high voltage power source to charge the DC Link capacitor only to a partial pre-charge level.

Abstract: A cooling system and method for cooling a contactor from the contactor-terminal side or both the contactor-mount side is provided. The contactors may be mounted to a base of a chassis. The cover may have one or more fluid channels associated with an exterior side of the cover. The interior side may have a plurality of thermally conductive bosses projecting from the interior surface configured to indirectly contact busbars which are respectively connected to contactor terminals of the contactors via thermal pads to provide a heat transfer path between the busbars and the fluid within the one or more fluid channels associated with the exterior side of the cover. Certain of the thermally conductive bosses are offset from the one or more fluid channels.

Abstract: A cooling system for a modular power control system (MPCS) is provided. The MPCS comprises modules. Each module has a chassis with a first manifold segment for first common manifold and a second manifold segment for second common manifold. When the modules are mounts to each other, the first manifold segments align to form the first common manifold and the second manifold segments align to form the second common manifold, providing two fluid channels between endcaps. The chassis of at least two modules further have a first opening providing a fluid interface region between the first common manifold and a module specific flow path, and a second opening providing a fluid interface region between the module specific flow path and the second common manifold. The module specific flow path provides at least one fluid branch between the first common manifold and the second common manifold.

Abstract: System and method for generating exportable power from a hydrogen fuel cell. A Modular Propulsion Control System (MPCS) includes a hydrogen fuel cell system interface activated to supply direct current signals from hydrogen fuel cells through a DC-to-DC converter used to power the vehicle; a power bus for receiving the direct current signals from the DC to DC converter; and an electrical port, the electrical port configured to interface with a plug-in charge receptacle connected to a charging station for receiving the directed current signals from the power bus, the dc signals used to provide power to the charging station. A control system employing a vehicle computer and System Control Unit, configures hydrogen fuel cells, a power bus and the plug-in charge receptacle to provide for a specified amount of power to flow out of the vehicle through the MPCS to the ground side charge station.

Abstract: A high voltage measurement port and a circuit contact wire assembly for vehicle high-voltage power decommissioning. The high voltage measurement port includes four externally accessible pins for obtaining an electrical characteristic measurement of a connected circuit. For redundancy, the assembly includes a resistor between a first measurement port pin and a first positive DC busbar at a first location, a resistor between a second pin and the first DC busbar at a second location different from the first location, a resistor between a third pin and a second negative DC busbar at a first location, and a resistor between a fourth pin and the second DC busbar at a second location different from the first location. Via the high voltage measurement port, a multi-meter can verify each resistance connection between the positive pins and then again between negative pins before a differential voltage measurement is made between positive and negative.

Abstract: A multi-wire choke filter is implemented in an inverter module of a modular power control system for a vehicle. Such an inverter module includes gate driver circuits to control switching power transistors used to power loads in a vehicle. The switching power transistors and gate drivers are configurable to support both a three-phase and a single phase current drive driver circuit topology in which switching power transistors are connected in parallel to share driving currents and dynamic switching losses. In any configured topology, the multi-wire choke is connected in series between gate driver circuit components and switching power transistors to mitigate any EMI threat to the gate driver circuitry by presenting an impedance to reduce circuit susceptibility to any differential and common mode noise currents that can flow through the gate driver circuit that can overwhelm gate driver circuitry and negatively effect power transistor switching performance at any time.

Abstract: A system for controlling load sharing between multiple generators mechanically coupleable to the output shaft of a prime mover is provided. The system may comprise a first processor; and at least two inverters operably connectable to at least two generators, respectively. The generators provide AC power to the respective inverter and each inverter provides DC power to a respective DC link. Each inverter may comprise a processor configured to control a respective generator. The processor may be configured to receive a common speed command from the first processor, adjust the common speed command based on a speed of the same output shaft to create a droop, determine a torque command based on the adjusted speed command and supply the determined torque command to the corresponding generator.

Abstract: A high voltage measurement port and a circuit contact wire assembly for vehicle high-voltage power decommissioning. The high voltage measurement port includes four externally accessible pins for obtaining an electrical characteristic measurement of a connected circuit. For redundancy, the assembly includes a resistor between a first measurement port pin and a first positive DC busbar at a first location, a resistor between a second pin and the first DC busbar at a second location different from the first location, a resistor between a third pin and a second negative DC busbar at a first location, and a resistor between a fourth pin and the second DC busbar at a second location different from the first location. Via the high voltage measurement port, a multi-meter can verify each resistance connection between the positive pins and then again between negative pins before a differential voltage measurement is made between positive and negative.

Abstract: A common-mode current sensor system and method for a traction inverter of an electric hybrid vehicle. The system and method detects/reduces excess common-mode currents that can be caused by the presence of alternating current (AC)-chassis type short circuit faults at the outputs of an inverter used for driving a two or more-phased load. In an embodiment, the system detects the presence of an AC-chassis fault of any varying strength, e.g., weak, medium, hard, in respective parallel paths. The system and method can isolate a particular AC-chassis type fault to a particular phase leg of the inverter thereby obviating a need of having to shut-down and/or re-program each phase leg of the whole power supply and vehicle operation. Rather, upon detecting a chassis short, a fault signal is asserted to control shutting down of one or more inverter switches without having to shut-down the vehicle or negatively impact the vehicle status.

Abstract: Methods and systems for arc detection are described. A controller can receive a bus voltage of a direct current (DC) bus connected to an energy source. The controller can determine whether the received bus voltage is less than a bus voltage threshold. The controller can, in response to determining the received bus voltage being less than the bus voltage threshold, determine an occurrence of an arc event in an apparatus that includes the DC bus and the energy source.

Abstract: Protection system and method for preventing damage to components in an inverter module caused by a permanent magnet (PM) electric machine being in an uncontrolled state is provided. The system has a back-up power supply to supply power to voltage rails for gate driver circuitry which controls at least one pair of semiconductor switches. At least one pair of semiconductor switches is electrically connected to the PM electric machine. The back-up power supply receives as input, a differential voltage of a DC bus. The protection system also has a control module electrically connected to the second power supply and receive power therefrom. The control module is configured to receive a sensed voltage of the DC bus and cause the gate driver circuitry to short respective phases when a differential voltage of the DC bus is greater than or equal to a first threshold and a condition is satisfied.

Abstract: A gate drive topology and gate drive power supply topology designed to allow for a single Printed Wiring Board (PWB) design to be configured for two applications. In one application, select paired locations of solder pads or connector locations in the circuitry are populated with connecting “spanning” resistors for integration within the gate driver and gate driver power supply topologies. The physical manifestation of these resistors on the PWB allows paralleled gate drive switching of corresponding power transistor devices for driving a load. A common gate-source voltage is applied to all three gates and the switching devices share dynamic switching and conduction loss. In an alternate application, the select paired locations are not populated with spanning resistors thereby rendering a circuit topology permitting independent operation independent power transistor gate driving switching operations.

Abstract: A common mode and a differential mode filter(s) between DC links are provided. Each link has a positive rail and a negative rail. The filter comprises a first inductor respectively connected to each of the positive rail and the negative rail, differential mode damping resistance connected in parallel to each of the first inductor, respectively, and a three-wire choke. The three-wire choke comprises a first wire connected in series with the differential mode damping resistance parallel to the positive rail, a second wire connected in series with the differential mode damping resistance parallel to the negative rail and a third wire connected to common mode damping resistance. The common mode damping resistance is galvanically isolated from differential mode transients flowing through the differential mode damping resistance. The differential mode filter has the differential mode damping resistance, and the common mode filter has the common mode damping resistance.

Abstract: A polyphase cable includes a first conductor, a first shield including conductive material coaxially around the first conductor, and a first insulating material between and separating the first conductor and the first shield. The polyphase cable further includes a second conductor, a second shield including conductive material coaxially around the second conductor, and a second insulating material between and separating the second conductor and the second shield. In an example, the first shield is in physical contact, and in electrical contact, with the second shield. In an example, the polyphase cable is configured to conduct polyphase Alternating Current (AC) having a frequency of at least 100 Hertz (Hz) and/or at most 10,000 Hz. In an example, one or both of a first end and a second end of one or both of the first shield and the second shield are configured to be grounded.

Abstract: A battery assembly includes an enclosure, and a plurality of battery modules within the enclosure. Each battery module includes an array of battery cells, one or more first sensors configured to measure one or more first parameters of the corresponding battery module, and a first processor configured to receive sense signals from the one or more first sensors of the corresponding battery module. One or more second sensors are within the enclosure, but external to the battery modules, and configured to measure one or more second parameters of the battery assembly. A second processor within the enclosure is to receive data from each of first processors and the one or more second sensors, and transmit controller input data to a controller external to the battery assembly, the controller input data based on the data received from the first processors and the one or more second sensors.

Abstract: A method includes forming a cold plate including conductive material and having a plurality of openings, and coating the cold plate with dielectric coating. The method further includes placing the cold plate proximal to a metal plate including one or more metals, and exposing the cold plate to moisture and/or water. In an example, a minimum lateral distance between the cold plate and the metal plate is at most 0.5 inch. The method further includes, while the cold plate is exposed to the moisture and/or the water, applying a voltage across the cold plate and the metal plate, and measuring a resultant leakage current through the cold plate. A thickness of the dielectric coating on an edge of an opening of the plurality of openings is at least 0.003 inch.