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.

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: A variable voltage converter includes a pair of series connected switches, a series connected switch and inductor, and a capacitor having a terminal sharing a node with adjacent terminals of the series connected switches and another terminal sharing a node with adjacent terminals of the series connected switch and inductor such that during operation, a voltage input to the variable voltage converter and a voltage across the capacitor are same and less than a voltage output by the variable voltage converter.

Abstract: An electrified vehicle includes an inductor having an associated arcuate deflector to redirect fluid toward inductor coils to facilitate heat transfer. The inductor may be disposed within a transmission proximate to at least one gear that distributes fluid during rotation to proximate components to provide splash lubrication. The arcuate deflector may redirect splashed fluid from between the inductor and the transmission housing toward the inductor coils. The deflector may be secured to the inductor via terminal connectors that electrically couple the inductor coils to a bus bar connected to a variable voltage converter.

Abstract: A power system includes an inverter, a pair of traction batteries electrically in series, and collectively in parallel with the inverter, a plurality of switches electrically in series, and collectively electrically in parallel with the traction batteries and inverter such that the switches are connected between the traction batteries and inverter, and one or more controllers programmed to operate the switches during charge of one of the traction batteries or operation of the inverter to balance states of charge of the traction batteries.

Abstract: A boost converter for a hybrid vehicle includes an inductor, a bus bar, an insulator, a temperature sensor, and a wire. The bus bar is configured to connect the inductor to a power source. The insulator is disposed over the bus bar and defines an array of orifices. The temperature sensor is configured to measure a temperature of the inductor. The wire is connected to the temperature sensor. The wire is weaved through the array of orifices such that the wire positionally alternates between opposing external sides of the insulator.

Abstract: An inverter is electrically connected between a traction battery and a switch bank. The inverter includes a plurality of pairs of series connected power semiconductor devices. Each of the pairs is electrically connected in parallel with the traction battery to define a phase leg, and each of the power semiconductor devices has a body diode in parallel therewith. The inverter also includes a plurality of diodes connected in parallel with the power semiconductor devices such that only one of the power semiconductor devices of each of the pairs has one of the diodes connected in parallel therewith.

Abstract: A thermal energy management system for an electrified vehicle component includes an electronic component, a heat sink, and at least one heat pipe configured to communicate thermal energy from the electronic component to the heat sink to cool the electronic component.

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 power converter has a pair of series connected switches defining a phase leg, a pair of gate driver circuits that respectively provide power to gates of the series connected switches, a positive rail electrically connected with the phase leg, and a clamping circuit including a clamping switch. The clamping circuit, responsive to one of the gate driver circuits being de-energized, activates the clamping switch with energy from the positive rail to clamp a gate of one of the series connected switches associated with the one of the gate driver circuits to another terminal of the one of the series connected switches.

Abstract: A power system for a vehicle includes a traction battery having an output voltage, a transformer including a coil, and a power converter including a plurality of capacitors and a plurality of switches arranged such that when a first subset of the switches are ON, two of the capacitors are in parallel, an AC voltage across the coil is in a positive half cycle, and a voltage across each of the two of the capacitors is half the output voltage.

Abstract: An automotive power converter may be controlled by detecting a magnitude of current output by a phase leg of the automotive power converter, selecting a mutual off time for switches of the phase leg according to the magnitude, and generating pulse width modulation signals for the switches having the mutual off time to operate the switches to transfer power between a traction battery and electric machine.

Abstract: A power converter includes a plurality of switches, a transformer electrically connected between some and other of the switches, and a plurality of series connected capacitors electrically connected between the switches and an output of the power converter. A controller operates the switches such that a voltage at an input of the power converter and across each of the capacitors is same and a voltage at the output is double the voltage at the input.

Abstract: An automotive vehicle includes an electric machine, a traction battery, and a power converter. The power converter transfers power between the electric machine and traction battery. The power convert includes a switch that defines a portion of a phase leg, a gate driver circuit that provides provide power to a gate of the switch, and a clamping circuit. The clamping circuit includes a clamping switch that, responsive to the gate driver circuit being de-energized and a voltage of the gate exceeding a predetermined threshold value, conducts current from the gate to dissipate the voltage and clamp the gate to an emitter of the switch.

Abstract: A power system includes a DC/AC converter, a traction battery, an AC/DC converter electrically connected between the DC/AC converter and traction battery, and a transformer electrically connected between the DC/AC converter and AC/DC converter. The AC/DC converter includes a plurality of semiconductor devices and a plurality of capacitors such that during power transfer from the DC/AC converter to the traction battery, a voltage across each of the capacitors is half of a battery voltage.

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 power converter includes a plurality of switches, a transformer electrically connected between some and other of the switches, and a plurality of series connected capacitors electrically connected between the switches and an output of the power converter. A controller operates the switches such that a voltage at an input of the power converter and across each of the capacitors is same and a voltage at the output is double the voltage at the input.

Abstract: A power inductor includes windings having a first coil defining an axially extending cavity and a core have at least first and second core segments extending axially through at least a portion of the cavity. The segments are radially spaced from each other to define a molding channel. Molding is disposed in the molding channel and configured to urge the first and second core segments radially apart such that outer surfaces of the core segments are in direct contact with inner surfaces of the coil.

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 power system for a vehicle includes a traction battery having an output voltage, a transformer including a coil, and a power converter including a plurality of capacitors and a plurality of switches arranged such that when a first subset of the switches are ON, two of the capacitors are in parallel, an AC voltage across the coil is in a positive half cycle, and a voltage across each of the two of the capacitors is half the output voltage.