Abstract: A method for estimating a remaining range of a vehicle battery charge includes identifying at least one route characteristic of a portion of a selected route, determining a vehicle energy consumption profile for a vehicle, and determining a current state of charge of a vehicle battery of the vehicle. The method also includes determining, for the selected route, a route energy consumption profile and calculating an estimated remaining charge for the vehicle battery at an end of the selected route based on the state of charge of the vehicle battery and the route energy consumption profile. The method also includes, in response to a determination that the estimated remaining charge is less than a lower limit of the vehicle battery charge range, determining a target vehicle speed profile based on the at least one route characteristic, the vehicle energy consumption profile, and the state of charge of the vehicle battery.

Abstract: A method for assignment of vehicle control includes receiving route data indicating a route between a starting location of a vehicle and a destination location, and determining an optimal vehicle configuration for the route based on a target vehicle speed and a hybrid torque split. The method further includes receiving a driver requested torque value and determining a passive pedal torque value based on the route data and vehicle powertrain data. The method further includes selectively assigning control of the vehicle to a vehicle system or to a driver of the vehicle based on the driver requested torque value and the passive pedal torque value.

Abstract: An inverter including: a housing including a first surface and a second surface opposite to the first surface; a power module including a first surface and a second surface opposite to the first surface, wherein the first surface of the power module contacts the first surface of the housing; a heat sink including a first surface and a second surface opposite to the first surface, wherein the first surface of the heat sink is coupled to the second surface of the power module; a multi-functional structural element, the multi-functional structural element including a first surface and a second surface, wherein the first surface of the multi-functional structural element contacts the second surface of the heat sink; and a printed circuit board, the printed circuit board being coupled to the second surface of the multi-functional structural element; wherein the housing and heat sink define a cooling circuit.

Abstract: A system for an electric vehicle includes: a first heat sink including a cooling pipe extending in an axial direction; a housing including a port to receive the cooling pipe, the port including an alignment feature; and a second heat sink between the first heat sink and the housing, the second heat sink including an opening to cooperate with the alignment feature of the port to align the second heat sink with the housing.

Abstract: A system for an electric vehicle includes: a first heat sink including a first mounting hole extending through the first heat sink; a second heat sink positioned adjacent to the first heat sink in an axial direction; and a spacer between the first heat sink and the second heat sink to set a distance between the first heat sink and the second heat sink, the spacer including: a flange that is coupled to both the first heat sink and the second heat sink, the flange having a thickness in the axial direction, and a protrusion extending away from the flange, the protrusion received by the first mounting hole of the first heat sink.

Abstract: A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter) including a bulk capacitor, the AC-DC converter connectable to a line voltage; a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including: one or more transformers having a secondary side connectable to a battery, and a bridge rectifier connected to the secondary side of the one or more transformers, the bridge rectifier including a bridge rectifier switch; and one or more controllers configured to control an operation of the bridge rectifier switch to control a voltage of the bulk capacitor.

Abstract: A system includes: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a first power module including: a first connection; a second connection; a first power switch including a first gate terminal, the first power switch configured to control a first flow of current between the first connection and the second connection based on a first signal to the first gate terminal; and a first point-of-use controller configured to provide the first signal to the first gate terminal to control the first power switch.

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: A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter) including: a bulk capacitor, and an AC-DC converter switch connectable to a line voltage; a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including: one or more transformers having a secondary side connectable to a battery, and a bridge driver connected to a primary side of the one or more transformers, the bridge driver including a bridge driver switch; and one or more controllers configured to control an operation of the bridge driver switch to control a discharge of the bulk capacitor to the battery at an end of a grid-to-battery operation, the grid-to-battery operation to supply electric power from the line voltage to the battery.

Abstract: A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter) including a bulk capacitor, the AC-DC converter connectable to a line voltage; a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including: one or more transformers having a secondary side connectable to a battery, a bridge rectifier connected to the secondary side of the one or more transformers, the bridge rectifier including a bridge rectifier switch, and a filter capacitor; and one or more controllers configured to control an operation of the bridge rectifier switch to control a discharge of the filter capacitor to the bulk capacitor.

Abstract: A planar transformer includes: a first primary coil in a first layer of a printed circuit board (PCB); a first secondary coil in one or more second layers in the PCB; and a second secondary coil in the one or more second layers.

Abstract: An apparatus includes a first analog-to-digital converter configured to measure a first reference voltage and a third reference voltage. The apparatus also includes a second analog-to-digital converter configured to measure a second reference voltage and a fourth reference voltage. The apparatus also includes a controller configured to calculate a first resistance ratio, and determine a positive high voltage associated with the positive high voltage direct current input signal based, at least in part, on the first resistance ratio. The controller is further configured to calculate a second resistance ratio, and determine a negative high voltage associated with the negative high voltage direct current input signal based, at least in part, on the second resistance ratio.

Abstract: A method for controlling vehicle propulsion may include identifying at least one route characteristic of a portion of a route being traversed by a vehicle and determining a profile for a target vehicle speed based on the at least one route characteristic and a vehicle energy consumption profile. The method may also include, in response to detecting a lead vehicle, determining a vehicle speed of the lead vehicle and determining whether to avoid triggering initiation of the vehicle follow mode by the vehicle propulsion controller based on (i) a distance between the vehicle and a triggering threshold and (ii) the vehicle speed of the vehicle. The method may also include, in response to not triggering vehicle follow mode, determining, based on the vehicle speed of the lead vehicle and the profile for the target vehicle speed, a traveling distance between the vehicle and a trigger threshold.

Abstract: A system includes: a battery charger to convert AC power to DC power to charge a battery, wherein the battery charger includes: an upper switch to condition an input voltage and input current; a lower switch to condition the input voltage and the input current: an upper silicon controlled rectifier (SCR); a lower SCR; and a bulk capacitor.

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 system includes: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a first power module including: a first connection; a second connection; a first power switch including a first gate terminal, the first power switch configured to control a first flow of current between the first connection and the second connection based on a first signal to the first gate terminal; and a first point-of-use controller configured to provide the first signal to the first gate terminal to control the first power switch.

Abstract: A heat sink system includes: a container including a cavity; a housing connecting to the container to cover the cavity, wherein one or more of the container or the housing includes an inlet port, and one or more of the container or the housing includes an outlet port; and a cooling module in the cavity between the container and the housing, the cooling module in a flow of coolant from the inlet port to the outlet port, wherein the cooling module includes: first cooling fins with a first cooling fin geometry, and second cooling fins with a second cooling fin geometry, wherein the first cooling fins are upstream of the second cooling fins along the flow of coolant from the inlet port to the outlet port.

Abstract: A clutch arrangement for a hybrid vehicle powertrain including an input shaft to be connected to a crankshaft of an internal combustion engine, an output shaft for connection to a transmission, a one-way clutch comprising an inner race connected to rotate with the input shaft and an outer race, a coupling hub rotationally coupled with the output shaft, a synchronizer ring arranged between the coupling hub and the one-way clutch, the synchronizer ring cooperating with the outer race of the one-way clutch, and a coupling sleeve unit that is selectively and axially moveable across the coupling hub. The synchronizer ring and the outer race include three positions, a neutral position, a first position, and a second position.

Abstract: A power semiconductor package includes: a first power semiconductor; a cold plate including a floor and a first pedestal extending from the floor, wherein the first pedestal is configured to support the first power semiconductor; a thermal interface material configured to transfer heat from the first power semiconductor to the first pedestal of the cold plate; and a spacer including: a first frame configured to receive at least a portion of the first pedestal, and a second frame configured to receive the thermal interface material; wherein the spacer is configured to provide a uniform thickness of the thermal interface material between the first pedestal of the cold plate and the first power semiconductor.

Abstract: An automotive power package includes a heat sink layer fabricated onto at least one surface of the automotive power package. The heat sink layer includes a material having a thermal conductivity higher than 130 W/m-K and a coefficient of thermal expansion between 5 and 15 ppm/° C.