Abstract: Systems and methods for operating a vehicle power system are described. The vehicle power system includes an inverter and an electric machine. Switches and a diode are arranged in a way that allows a traction battery to be charged by either a lower voltage charger or a higher voltage charger. Additionally, the switches and diode allow the vehicle power system to heat the traction battery so that the traction battery may operate in a desired temperature range.

Abstract: A discharge system for a drive system includes a discharge circuit, a sensor, and a control system. The discharge circuit is connected in parallel to the drive system, and is operable in an ON-position to be electrically coupled to the drive system or an OFF-position to be electrically decoupled from the drive system. The sensor is arranged in series with the discharge circuit to detect an electrical characteristic of the discharge circuit. The control system is configured to, for a diagnostic check, operate the discharge circuit in the ON-position, and provide a notification in response to the electric characteristic detected being unresponsive to the discharge circuit being in the ON-position.

Abstract: Systems and methods for constructing a traction inverter of a vehicle are described. The traction inverter includes a positive bus bar and a negative bus bar that couple a capacitor and to a plurality of switches. The capacitor is formed from a plurality of individual capacitors that are stacked together.

Abstract: A power system, responsive to a detected change in an onboard charger or a generator, switches a converter from a first conversion setting, in which a first low voltage value of a medium-voltage bus port is converted to a first high voltage value of a high-voltage bus port, to a second conversion setting, in which a second low voltage value of the medium-voltage bus port is converted to the first high voltage value of the high-voltage bus port.

Abstract: A vehicle power system includes an inverter electrically connected between a traction battery and electric machine, a three phase coupled inductor electrically connected between the traction battery and inverter, and one or more controllers that operate the inverter while a common mode voltage at a neutral point of the electric machine is constant.

Abstract: An automotive propulsion system has a transmission including an output shaft, a variable voltage converter including an inductor disposed within a housing of the transmission such that transmission fluid within the housing contacts the inductor to cool the inductor, and a controller that maintains a magnitude of current through the inductor to less than a limit value that is defined by a speed associated with the output shaft and a switching frequency of the variable voltage converter.

Abstract: While a voltage at a gate of one of a pair of series connected switches of a phase leg is greater than a threshold value, circuitry generates a signal with a logical value that precludes a gate driver corresponding to a gate of the other of the pair of series connected switches from driving the gate of the other of the pair of series connected switches.

Abstract: An automotive on-board charger topology includes an inverter, an electric machine, and a rectifier that together perform functions such as power factor correction usually performed by a collection of multiple components. This topology also includes a set of contactors that isolate a battery from other components of the charger based on the contactors' configuration.

Abstract: A system for an electrified vehicle, such as a battery electric vehicle (BEV), includes an inverter connected between a battery and a motor having windings. A center-tap of the battery and a neutral-point of the windings are connected whereby the battery, the inverter, and the motor are connected in a closed circuit. The system further includes a controller configured to control the inverter to cause a circulating current from the battery through the closed circuit to thereby achieve a target temperature of the battery.

Abstract: A power inductor such as a variable voltage converter power inductor having a temperature sensor embedded therein is disclosed. In one or more embodiments, the sensor may be disposed between the core and the coil or winding. The sensor may be positioned in the cavity of a bobbin or the core itself.

Abstract: A traction powertrain system of an electrified vehicle includes a power electronics module and a controller. The power electronics module, such as in the form of an inverter, is configured to drive a traction motor with power from a traction battery via a DC-link capacitor. The controller has an on-board power source, such as in the form of a super capacitor. The controller is configured to, in response to detecting an event in which the DC-link capacitor is to be discharged, use power from the on-board power source for controlling the power electronics module and control the power electronics module to operate in a manner causing the DC-link capacitor to be discharged.

Abstract: A closed ferromagnetic housing has a pair of access ports and a center ferromagnetic post extending from and between opposite ends thereof. At least one conductor, contained within and completely surrounded by the closed ferromagnetic housing, is wound around the center ferromagnetic post such that the closed ferromagnetic housing, center ferromagnetic post, and at least one conductor form an inductor in which the ferromagnetic housing and the center ferromagnetic post define a core of the inductor and the at least one conductor defines a coil of the inductor. The access ports are configured to permit flow of coolant into the closed ferromagnetic housing and around the center ferromagnetic post to cool the at least one conductor.

Abstract: A system for an electrified vehicle, such as a battery electric vehicle (BEV), includes an inverter configured to drive a motor having motor windings with electrical power from a battery according to a configuration of a power switch of the inverter. The system further includes a capacitor connected between a center-tap of the battery and a neutral-point of the motor winding whereby the capacitor and the motor windings form an LC circuit. The system further includes a controller configured to operate the power switch in a zero-current-switching mode with a switching frequency dependent on a resonant frequency of the LC circuit to thereby cause electrical current to circulate between the battery, the inverter, and the motor which heats the battery and the motor windings.

Abstract: An electric drive system includes a power electronics module with a prefabricated DC bus bar assembly. The prefabricated DC bus bar assembly includes a molded bleed resistor which serves two different functions. First, it dissipates energy from a capacitor when the battery is disconnected. Secondly, it physically supports the positive bus bar and the negative bar with respect to one another.

Abstract: An electric drive system includes an actively cooled inductor. The inductor is formed by winding C-shaped wire around a bobbin such that channels are defined between the bobbin and the wire. After the bobbin is installed over the core, a plastic layer is injected between the core and the bobbin. This expands the bobbin against the wire to seal the channels and also to fasten the bobbin in place. A variety of porting arrangements are proposed to route cooling fluid through the channels to cool the windings and the core.

Abstract: Responsive to a voltage across a capacitor being greater than a voltage across a traction battery, a controller may open switches such that charge current from a DC charger flows through a diode to the traction battery without following through coils of an electric machine and without flowing through an inverter.

Abstract: A traction powertrain system of an electrified vehicle includes a power electronics module and a controller. The power electronics module, such as in the form of an inverter, is configured to drive a traction motor with power from a traction battery via a DC-link capacitor. The controller has an on-board power source, such as in the form of a super capacitor. The controller is configured to, in response to detecting an event in which the DC-link capacitor is to be discharged, use power from the on-board power source for controlling the power electronics module and control the power electronics module to operate in a manner causing the DC-link capacitor to be discharged.

Abstract: A power converter includes a pair of series connected switches and circuitry. The circuitry includes another switch and an optocoupler that activates responsive to changes in current through one of the series connected switches exceeding a predefined threshold. Activation of the optocoupler causes the another switch to conduct and reduce a gate voltage of the one of the series connected switches to reduce the changes in current through the one of the series connected switches.

Abstract: A hybrid transmission has a housing with two chambers. One chamber contains electric motors and other transmission components that require a liquid lubricant and coolant such as automatic transmission fluid. The other chamber contains power electronics that must be isolated from the liquid lubricant/coolant. To reduce the number of breather tubes required, it is beneficial if air can move between the chambers. A terminal block cooperates with a separating wall between the two chambers to create a labyrinth seal between the chambers.

Abstract: An inductor for a converter of an electric machine includes a core defining a channel configured to receive transmission fluid on an outer surface of the core. Coils made of windings are wrapped on the core. The windings enclose an open side of the channel to define an oil flow passage, wherein oil flowing through the oil flow passage is in direct contact with both the windings and the core to absorb heat from the windings and the core.