Abstract: A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter), the AC-DC converter including a bulk capacitor; a DC-DC converter connectable to the AC-DC converter; and one or more controllers configured to control the system by performing operations, the operations including: determining a current demand of a load, the load being connectable to the DC-DC converter, for a charging cycle of the load; performing a first comparison of the current demand to one or more current demand thresholds; and generating a voltage setpoint for the bulk capacitor based on the first comparison, wherein the generation of the voltage setpoint limits output current ripple of the DC-DC converter for the charging cycle.

Abstract: An electric machine includes a stator core and a winding. The stator core includes a plurality of radially extending teeth defining a number of slots in the stator core. The winding is positioned on the stator core and includes a plurality of conductors connected together to provide a plurality of parallel paths per phase for the winding. The winding defines a number of conductor layers in each slot, a number of poles, and a number of slots-per-pole-per-phase. The winding includes a plurality of standard-pitch end loops and a plurality of sets of over-under end loops. A plurality of crossover end loops for each of the plurality of parallel paths per phase are substantially aligned in a radial direction on the stator core.

Abstract: A system includes: an AC-DC converter; and a DC-DC converter, the DC-DC converter including: a first high voltage buck-boost converter having a secondary side connectable to a first high voltage battery; a second high voltage buck-boost converter having a secondary side connectable to a second high voltage battery; a first low voltage buck-boost converter having a secondary side connectable to a first low voltage battery; a second low voltage buck-boost converter having a secondary side connectable to a second low voltage battery; and one or more transformers having a primary side connected to the AC-DC converter and a secondary side connected to each of a primary side of the first high voltage buck-boost converter, a primary side of the second high voltage buck-boost converter, a primary side of the first low voltage buck-boost converter, and a primary side of the second low voltage buck-boost converter.

Abstract: A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter), the AC-DC converter connectable to a line voltage; and a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including: a high voltage buck-boost converter having a secondary side connectable to a high voltage battery; a low voltage buck-boost converter having a secondary side connectable to a low voltage battery; and one or more transformers having a primary side connected to the AC-DC converter, a secondary side connected to a primary side of the high voltage buck-boost converter, and a tertiary side connected to a primary side of the low voltage buck-boost converter.

Abstract: A system comprises: one or more point-of-use controllers configured to: assert a command-on signal to load a first turn-on gate driver profile; control, based on the loaded first turn-on gate driver profile, a gate driver to begin a first phase of a turn-on operation; receive a first power switch signal based on one or more of a detected voltage or a detected current; perform a comparison of the received first power switch signal to a first turn-on threshold value; load a second gate turn-on driver profile when the comparison indicates the first power switch signal is greater than the first turn-on threshold value; and control, based on the loaded second turn-on gate driver profile, the gate driver to end the first phase of the turn-on operation and begin a second phase of the turn-on operation.

Abstract: A conformal coating control method includes arranging at least one conformal control surface feature on a surface of a printed circuit board proximate perimeter pads of an integrated circuit. The method also includes soldering, to the printed circuit board, the integrated circuit. The method also includes applying a conformal coating material to the printed circuit board, wherein the conformal coating material is at least partially restricted from flowing between the integrated circuit and the printed circuit board by solder flux residue accumulated proximate the conformal control surface feature.

Abstract: A system for an AC to DC PFC converter includes a first phase switch group connected to a first node to receive power from a first phase of a voltage source; a second phase switch group connected to a second node to receive power from a second phase of the voltage source; a third phase switch group connected to a third node to receive power from a third phase of the voltage source; a neutral phase switch group connected to a fourth node to be connected to a ground terminal of the voltage source; a first switch connected to the first node and the second node; and a second switch connected to the second node and the third node.

Abstract: A bus bar assembly includes a first housing; a first bus bar extending through the first housing; a second bus bar extending through the first housing, the second bus bar including a second housing that defines at least one first receiver configured to engage a fastener; and a sensor assembly mounted to the receiver, the sensor assembly including a current sensor positioned between the first bus bar and the second bus bar. The sensor assembly may not include a magnetic core, and the current sensor may be a coreless sensor configured to detect a current through the bus bar assembly.

Abstract: A base for an electrical component includes: a body, the body defining: a rim, pin slots, and first engagement slots; contact terminals; and electrical connectors, each of the electrical connectors being positioned within a respective pin slot and including a pin terminal positioned on a first surface of the body; wherein the base is configured to provide an electrical connection between one or more power modules and a substrate.

Abstract: A system includes an inverter including: a point-of-use controller for a power module, the point-of-use controller including: a positive voltage connection configured to receive a positive control voltage from a high-voltage controller; a command connection configured to receive a command from the high-voltage controller; a message connection configured to send and receive a message to and from the high-voltage controller; a negative voltage connection configured to receive a positive control voltage from the high-voltage controller; a north gate connection configured to output a north gate control signal to a north group of one or more switches; a south gate connection configured to output a south gate control signal to a south group of one or more switches; a north sense connection configured to connect to a first portion of a sensing trace; and a south sense connection configured to receive a second portion of the sensing trace.

Abstract: A method of forming a tensioner arm bracket, chain guide, snubber or tensioner arm with two shot injection molding. The tensioner arm bracket, chain guide, snubber or tensioner arm each having a body and a chain sliding face. The body of the tensioner arm bracket, chain guide, snubber or tensioner arm bracket is formed of by a first shot of thermoplastic polymer or thermosetting resin and the chain sliding face is formed by a second shot of thermoset elastomer which is overmoulded onto the body. The body of the component is made of either a thermoplastic or thermosetting resin is fixed to its chain sliding face either by one or more of an anchor point generated by undercuts in the body and/or chemical bonds between the dissimilar materials.

Abstract: A system comprises: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power switch including a drain terminal, a source terminal, and a gate terminal; and one or more controllers configured to detect a voltage from the gate terminal to the source terminal of the power switch as a gate-to-source voltage, and control a gate control signal to the gate terminal based on the detected gate-to-source voltage.

Abstract: A multi-functional spacer element for spacing at least one printed circuit board from an opposite spacing surface. The spacer element can not only accomplish the spacing of one or more printed circuit boards, but can also support a fastening function to a carrier element and an electrical ground connection. A passageway extends through the main body. The spacer element includes a press-in element. The spacer element 1 includes an electrically conductive material for electrically conducting from at least a first contact surface to the press-in element.

Abstract: A subassembly for an electrical component includes: a first plate including: a wall, stepped walls extending from opposite sides of the wall, flange elements extending outwardly from the stepped walls, each flange element defining an engagement slot; a first heatsink positioned on the wall between the stepped walls; a second heatsink; a power module between the first heatsink and the second heatsink; and a second plate including: a plate wall extending across the second heatsink, transition walls extending from opposite sides of the plate wall, and prongs extending from the transition walls toward the first plate and substantially perpendicular to an inner surface of the plate wall in contact with the second heatsink, wherein the prongs are aligned with and configured to engage the engagement slots.

Abstract: A method for estimating energy consumption of a vehicle includes receiving, from a remotely located computing device, standardized energy consumption data corresponding to at least one other vehicle, the standardized energy consumption data corresponding to energy consumption of the at least one other vehicle as a function of speed. The method further includes generating a scaling factor by comparing the energy consumption data corresponding to the energy consumption of the vehicle as a function of speed with the standardized energy consumption data. The method further includes scaling the standardized energy consumption data to generate a profile of the energy consumption efficiency of the vehicle. The method further includes generating a signal to selectively adjust at least one of a speed of the vehicle, at least one route characteristic of a portion of a route being traversed by the vehicle, and a torque demand of the vehicle.

Abstract: An electric drive system in a battery electric vehicle (BEV) includes an output shaft, configured to couple with a drive wheel of the BEV, having a face gear at a distal end; a differential, including a pinion gear cage receiving pinion gears rotatably connected to the pinion gear cage via gear pins; and a housing that receives the differential having an outer surface that is configured to couple to a rotating electrical machine of the BEV, wherein the pinion gears engage the face gear and permit angular displacement of the output shaft relative to another output shaft.

Abstract: An inverter may include a housing having a body and a protruding rim extending from the body, wherein the protruding rim surrounds a cavity that extends through to the body. An inverter may include one or more electrical receptacles, wherein the one or more electrical receptacles are disposed within the cavity such that a portion of at least one of the one or more electrical receptacles extends above the protruding rim. An inverter may include a metal sheet, wherein the metal sheet is molded to an inner surface of the protruding rim such that the protruding rim extends past the metal sheet, and wherein the metal sheet circumferentially surrounds the cavity.

Abstract: A system includes: an inverter including: a first galvanic interface to separate a first high voltage area from a low voltage area; a first low voltage controller in the low voltage area, the first low voltage controller configured to send a first control signal using the first galvanic interface to a first high voltage controller in the first high voltage area; a second galvanic interface to separate a second high voltage area from the low voltage area; and a second low voltage controller in the low voltage area, the first low voltage controller configured to send a second control signal using the second galvanic interface to a second high voltage controller in the second high voltage area, wherein the second low voltage controller is configured to provide an output latch signal to the first low voltage controller and receive an input latch signal from the first low voltage controller.

Abstract: An inverter assembly may include a housing with a base and side walls, wherein one of the side walls includes an opening extending through the wall, and wherein the side walls form a periphery around an interior of the housing. An inverter assembly may include a header with a body, the body having a first end and a second end, wherein the body further includes a flange disposed between the first end and the second end, and wherein a portion of the body extends through the opening such that the flange abuts the side wall. An inverter assembly may include a bracket positioned within the interior of the housing and coupled to the housing. An inverter assembly may include a choke that is fully enclosed in a circumferential direction, wherein the choke is positioned within the bracket and against an inner surface of the bracket facing the opening.

Abstract: A system includes an inverter including: a first galvanic isolator separating a primary voltage area from a secondary voltage area; a second galvanic isolator separating the primary voltage area from the secondary voltage area; a first bias network in the secondary voltage area, and connected to the first galvanic isolator; a second bias network in the secondary voltage area, and connected to the second galvanic isolator; a first amplifier in the secondary voltage area, and connected to the first bias network; a second amplifier in the secondary voltage area, and connected to the second bias network; and an open connection detector in the secondary voltage area, the open connection detector connected to the first amplifier and connected to the second amplifier, wherein the open connection detector includes one or more voltage-to-current converters.