Abstract: This disclosure is directed to power systems for transferring power between electrical components. An exemplary power system includes a first electrical component (e.g., an electric motor), a second electrical component (e.g., an inverter system), and a terminal block assembly adapted to electrically couple the first and second electrical components. The terminal block assembly includes an internal cooling channel configured to receive coolant for providing direct liquid cooling of the bus bar.

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: A vehicle power system has a DC to AC converter, a pair of AC to DC converters, a transformer including a core, a primary winding wound about the core and electrically connected to an output of the DC to AC converter, and a pair of secondary windings wound about the core, a traction battery electrically connected to a collective output of the AC to DC converters, and a controller.

Abstract: A vehicle, an inductor assembly for power electronics in a vehicle, and a method of providing and cooling an inductor assembly are provided. According to one example, the vehicle is provided with an inductor assembly in a vehicle electrical system with a variable voltage converter (VVC). The inductor assembly includes a core formed from a plurality of core segments spaced apart from one another to define gaps therebetween, with each of the plurality of core segments forming an internal fluid passage extending therethrough. The inductor assembly has a winding surrounding at least one of the plurality of core segments. A fluid system is connected to the core to provide pressurized fluid to the fluid passages of the plurality of core segments to circulate fluid through the core of the inductor assembly.

Abstract: An inductor includes a bobbin defining a cavity, coils wound around the bobbin, and a plug inserted into the cavity. The plug and bobbin define a first fluid path between an inlet and the cavity. The plug is also arranged to choke flow of fluid through the first fluid path.

Abstract: A vehicle, an inductor assembly for power electronics in a vehicle, and a method of providing and cooling an inductor assembly are provided. According to one example, the vehicle is provided with an inductor assembly in a vehicle electrical system with a variable voltage converter (VVC). The inductor assembly includes a core formed from a plurality of core segments spaced apart from one another to define gaps therebetween, with each of the plurality of core segments forming an internal fluid passage extending therethrough. The inductor assembly has a winding surrounding at least one of the plurality of core segments. A fluid system is connected to the core to provide pressurized fluid to the fluid passages of the plurality of core segments to circulate fluid through the core of the inductor assembly.

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 unitary on-board charger and generator (OBCG) for an electric vehicle system and method is disclosed. The OBCG includes a charging circuit with a diode bridge rectifier connected to an AC power source, a power factor correction converter, and a bi-directional DC/DC converter. The OBCG also includes a generating circuit with a a three-phase inverting circuit, three inductive coils connected to each leg of the three-phase inverting circuit, and a plurality of output capacitors connected to the outputs of the three inductive coils. The OBCG also includes a bridge capacitor and a control switching element connected between the charging circuit and the generating circuit for changing between a charging and generating state.

Abstract: An inductor includes a pair of core portions having tapered legs and windings wound around the tapered legs. Each of the core portions are arranged adjacent to each other such that the tapered legs define a gap between the core portions that extends diagonally from one end of the inductor towards another end of the inductor relative to outer surfaces of the inductor.

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 vehicle power system includes a traction battery, an electric machine configured to receive power from the traction battery, switching circuitry connected between the traction battery and electric machine, and including pairs of switches connected in parallel, and a capacitor connected with and between the pairs such that the capacitor shares a common terminal with each of the switches of the pairs, and a controller configured to responsive to a temperature of the traction battery being less than a first threshold, activate the switches of each of the pairs in complementary fashion at a switching frequency corresponding to a resonant frequency defined by a capacitance of the capacitor and an inductance of the traction battery to cause AC current to circulate between the traction battery and switching circuitry to generate heat within the traction battery, and responsive to the temperature exceeding a second threshold, deactivate the switches.

Abstract: An electrified vehicle thermal management system includes, among other things, a transmission, an inverter, and a terminal block disposed between the transmission and the inverter. The terminal block includes a conduit configured to deliver transmission fluid from the transmission to the inverter. An electrified vehicle thermal management method includes circulating a transmission fluid between a transmission, a terminal block, and an inverter, and using the transmission fluid to manage thermal energy within the inverter.

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: This disclosure is directed to power systems for transferring power between electrical components. An exemplary power system includes a first electrical component (e.g., an electric motor), a second electrical component (e.g., an inverter system), and a terminal block assembly adapted to electrically couple the first and second electrical components. The terminal block assembly includes an internal cooling channel configured to receive coolant for providing direct liquid cooling of the bus bar.

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 vehicle electric drive includes a controller programmed to operate a power converter to boost voltage from a battery for a DC bus and to limit voltage output from the power converter to a predefined maximum voltage value that varies with temperature of coolant used to cool the power converter.

Abstract: An inductor includes a pair of core portions having tapered legs and windings wound around the tapered legs. Each of the core portions are arranged adjacent to each other such that the tapered legs define a gap between the core portions that extends diagonally from one end of the inductor towards another end of the inductor relative to outer surfaces of the inductor.

Abstract: An automotive power converter includes a pair of series connected switches and an inductor including a core having a leg, a winding wound around the leg, and a terminal center tapping the switches. The leg includes a plurality of alternating frames and solid blocks arranged to define a continuous contact surface for the winding and to define internal cavities within the leg such that each of the frames surrounds one of the internal cavities.

Abstract: An automotive power converter includes a pair of series connected switches and an inductor including a core having a leg, a winding wound around the leg, and a terminal center tapping the switches. The leg includes a plurality of alternating frames and solid blocks arranged to define a continuous contact surface for the winding and to define internal cavities within the leg such that each of the frames surrounds one of the internal cavities.

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.