Abstract: An onboard charging system for charging from a power source may include an energy storage system. A connector may be configured to couple the onboard charging system with the power source. A charging circuit may be electrically connected between the connector and the energy storage system. A converter may be electrically connected in the charging circuit between the connector and the energy storage system. A rectifier may be electrically connected in the charging circuit between the connector and the converter. Output of an inductive receiver may be electrically connected with the charging circuit between the connector and the converter. The converter may control the delivery of voltage and current to the energy storage system from the power source and from the inductive receiver.

Abstract: A disconnect architecture for use with a system having a battery pack and positive and negative bus rails includes a mid-pack low-power (LP) relay, a fuse, semiconductor switches, and a sequencer circuit. The mid-pack LP relay is positioned between the rails at a mid-stack point of the battery pack, and divides a voltage across the battery pack when commanded open. The fuse is positioned between the mid-pack LP relay and the positive bus rail, and opens in response to a dead short condition of the system. The semiconductor switches are positioned in electrical parallel with the mid-pack LP relay. The sequencer circuit selectively turns on the semiconductor switches and thereby coordinates a flow of electrical current through the semiconductor switches and the mid-pack LP relay in response to a detected partial short condition of the system. A system includes the battery pack, bus rails, and disconnect architecture.

Abstract: A power system is configured to deliver direct current (DC) electric power to an energy storage system (ESS) at a first voltage and to deliver DC electric power from the ESS at a second voltage. A converter is coupled to an electric power source at the second voltage. The converter includes a boost converter and a buck converter. The boost converter and the buck converter are configurable in a first interleaved arrangement and in a second interleaved arrangement, different than the first interleaved arrangement. In the first interleaved arrangement the converter provides DC electric power from the power source to the ESS at the first voltage, and in the second interleaved arrangement the converter provides DC electric power from the ESS to the power source at the second voltage.

Abstract: A high voltage bus system for electrified vehicles may include a direct current (DC) bus. A rectifier may be electrically coupled to the DC bus. The rectifier may be configured to receive an alternating current (AC) input and to provide a first DC electric power output to the DC bus. An energy storage system (ESS) may be electrically coupled to the DC bus. A converter may be electrically coupled to the ESS. The converter may be configured to provide a second DC electric power output to the DC bus. A load may be electrically coupled to the DC bus to receive the second DC electric power output.

Abstract: An onboard charging system for charging from a power source may include an energy storage system. A connector may be configured to couple the onboard charging system with the power source. A charging circuit may be electrically connected between the connector and the energy storage system. A converter may be electrically connected in the charging circuit between the connector and the energy storage system. A rectifier may be electrically connected in the charging circuit between the connector and the converter. Output of an inductive receiver may be electrically connected with the charging circuit between the connector and the converter. The converter may control the delivery of voltage and current to the energy storage system from the power source and from the inductive receiver.

Abstract: A power inverter includes a multi-phase inverter circuit electrically connected to positive and negative conductors of the high-voltage bus. A bi-stable switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus, and a capacitor is electrically connected between the positive and negative conductors of the high-voltage bus. First and second trigger circuits are in communication with a gate of the bi-stable switch, and first and second contactors are controllable to electrically connect a respective one of the positive and negative conductors of the high-voltage bus to the high-voltage DC power source. The bi-stable switch is controllable to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal from one of the first and second high-voltage DC contactor circuits.

Abstract: An electrical system includes a voltage bus, battery pack, power inverter module (PIM), electric machine, first contactor, and controller. The PIM is connected to the battery pack and has a capacitor, voltage sensor, and semiconductor switches. The electric machine having phase legs with a corresponding phase winding and resistive path. The first contactor connects the PIM to a positive rail of the bus. The controller opens the first contactor in response to a power-off event, commands a discharge of the capacitor through the resistive paths, diagnoses a state of health (SOH) of the first contactor using a first threshold decay rate of the capacitor output voltage upon opening the first contactor, and executes a control action with respect to the electrical system using the diagnosed SOH. The three possible SOH are unhealthy/hard-welded contactor, unhealthy/soft-welded contactor, and healthy/normally-functioning contactor condition. A vehicle and method are also disclosed.

Abstract: A power inverter including a multi-phase inverter circuit is electrically connected to a high-voltage DC power source, and includes a capacitor electrically connected between positive and negative conductors of a high-voltage bus. A normally-ON discharge switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus. The discharge switch includes a control gate, wherein the control gate of the discharge switch is in communication with an ignition switch. The discharge switch is controllable to an open state between the positive and negative conductors of the high-voltage bus when the ignition switch is in an ON state. The discharge switch achieves a closed state to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus when the ignition switch is in an OFF state.

Abstract: A discharge circuit for a high-voltage bus that is electrically connected to a high-voltage DC power source is described. The discharge circuit includes a discharge switch electrically connected in series with a discharge resistor between positive and negative conductors of the high-voltage bus, and the discharge switch includes a gate. A bi-stable switch includes a control gate, an input line that is electrically connected to the high-voltage bus and an output line that is electrically connected to the gate of the discharge switch. A trigger device is in communication with the control gate of the bi-stable switch. The input line of the bi-stable switch is electrically connected to the high-voltage bus, and the discharge switch is controllable to a closed state to provide an electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal.

Abstract: An electrical system includes a voltage bus, battery pack, power inverter module (PIM), electric machine, first contactor, and controller. The PIM is connected to the battery pack and has a capacitor, voltage sensor, and semiconductor switches. The electric machine having phase legs with a corresponding phase winding and resistive path. The first contactor connects the PIM to a positive rail of the bus. The controller opens the first contactor in response to a power-off event, commands a discharge of the capacitor through the resistive paths, diagnoses a state of health (SOH) of the first contactor using a first threshold decay rate of the capacitor output voltage upon opening the first contactor, and executes a control action with respect to the electrical system using the diagnosed SOH. The three possible SOH are unhealthy/hard-welded contactor, unhealthy/soft-welded contactor, and healthy/normally-functioning contactor condition. A vehicle and method are also disclosed.

Abstract: An onboard charging module (OBCM), e.g., for a vehicle, is characterized by an absence of a transformer and includes an AC-to-DC voltage rectifier, DC-DC buck converter, DC-DC boost converter, DC link capacitor between the buck converter and boost converter, and solid-state devices. The devices include a diode and first and second switches having opposite open/closed switching states. The first and second switches are connected to a common rail of a DC bus, the first switch and diode are between the voltage rectifier and boost converter, and the second switch is between the link capacitor and buck converter. Third and fourth switches may be used on the opposite rail as the first and second switches. The OBCM is operable, via operation of the solid-state devices, to charge the HV-ESS via an AC power supply while maintaining current isolation. An electrical system includes the OBCM, DC bus, and HV-ESS.

Abstract: A power inverter includes a multi-phase inverter circuit electrically connected to positive and negative conductors of the high-voltage bus. A bi-stable switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus, and a capacitor is electrically connected between the positive and negative conductors of the high-voltage bus. First and second trigger circuits are in communication with a gate of the bi-stable switch, and first and second contactors are controllable to electrically connect a respective one of the positive and negative conductors of the high-voltage bus to the high-voltage DC power source. The bi-stable switch is controllable to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal from one of the first and second high-voltage DC contactor circuits.

Abstract: A power inverter including a multi-phase inverter circuit is electrically connected to a high-voltage DC power source, and includes a capacitor electrically connected between positive and negative conductors of a high-voltage bus. A normally-ON discharge switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus. The discharge switch includes a control gate, wherein the control gate of the discharge switch is in communication with an ignition switch. The discharge switch is controllable to an open state between the positive and negative conductors of the high-voltage bus when the ignition switch is in an ON state. The discharge switch achieves a closed state to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus when the ignition switch is in an OFF state.

Abstract: A discharge circuit for a high-voltage bus that is electrically connected to a high-voltage DC power source is described. The discharge circuit includes a discharge switch electrically connected in series with a discharge resistor between positive and negative conductors of the high-voltage bus, and the discharge switch includes a gate. A bi-stable switch includes a control gate, an input line that is electrically connected to the high-voltage bus and an output line that is electrically connected to the gate of the discharge switch. A trigger device is in communication with the control gate of the bi-stable switch. The input line of the bi-stable switch is electrically connected to the high-voltage bus, and the discharge switch is controllable to a closed state to provide an electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal.

Abstract: A disconnect architecture for use with a system having a battery pack and positive and negative bus rails includes a mid-pack low-power (LP) relay, a fuse, semiconductor switches, and a sequencer circuit. The mid-pack LP relay is positioned between the rails at a mid-stack point of the battery pack, and divides a voltage across the battery pack when commanded open. The fuse is positioned between the mid-pack LP relay and the positive bus rail, and opens in response to a dead short condition of the system. The semiconductor switches are positioned in electrical parallel with the mid-pack LP relay. The sequencer circuit selectively turns on the semiconductor switches and thereby coordinates a flow of electrical current through the semiconductor switches and the mid-pack LP relay in response to a detected partial short condition of the system. A system includes the battery pack, bus rails, and disconnect architecture.

Abstract: An onboard charging module (OBCM), e.g., for a vehicle, is characterized by an absence of a transformer and includes an AC-to-DC voltage rectifier, DC-DC buck converter, DC-DC boost converter, DC link capacitor between the buck converter and boost converter, and solid-state devices. The devices include a diode and first and second switches having opposite open/closed switching states. The first and second switches are connected to a common rail of a DC bus, the first switch and diode are between the voltage rectifier and boost converter, and the second switch is between the link capacitor and buck converter. Third and fourth switches may be used on the opposite rail as the first and second switches. The OBCM is operable, via operation of the solid-state devices, to charge the HV-ESS via an AC power supply while maintaining current isolation. An electrical system includes the OBCM, DC bus, and HV-ESS.