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 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: 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 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 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: 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: 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: 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 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 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: A controller of a vehicle power system closes a pre-charge contactor and one of a pair of main contactors to electrically connect a battery and inverter such that current flows through a pre-charge resistor. The controller also opens the pair to electrically disconnect the battery and inverter, and closes a switch configured to complete a circuit such that charge acquired by a capacitor of the inverter is dissipated via the pre-charge resistor.

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: A shared resistor performs precharging and discharging functions of capacitors in an electric vehicle drive system. In a precharge state, the shared resistor is connected between the capacitors and a DC source via a precharge relay. In a discharge state, the resistor is connected across the capacitors via a discharge transistor. Otherwise, the resistor is disconnected. A bypass switch is connected between the resistor and an input capacitor. The bypass switch is rendered conductive during the precharge state and during the discharge state. The discharge transistor is activated only during the discharge state. As a result, the invention uses less components by virtue of eliminating separate resistance elements for pre-charging and discharging and by eliminating discharge switches dedicated to separate resistances. The circuit integration and the placement of components outside the inverter module improves overall system cost and packaging size.

Abstract: A controller of a vehicle power system closes a pre-charge contactor and one of a pair of main contactors to electrically connect a battery and inverter such that current flows through a pre-charge resistor. The controller also opens the pair to electrically disconnect the battery and inverter, and closes a switch configured to complete a circuit such that charge acquired by a capacitor of the inverter is dissipated via the pre-charge resistor.

Abstract: A traction inverter system includes a capacitor module, a power module, a cold plate between and in contact with the modules, and an end plate defining an inlet and outlet. The modules and plates define a bore spanning the modules and plates, and a passageway in fluid communication with the inlet and outlet. The traction inverter system also includes a mechanical fastener occupying the bore, spanning the modules and plates, and clamping the modules and plates together.

Abstract: A shared resistor performs precharging and discharging functions of capacitors in an electric vehicle drive system. In a precharge state, the shared resistor is connected between the capacitors and a DC source via a precharge relay. In a discharge state, the resistor is connected across the capacitors via a discharge transistor. Otherwise, the resistor is disconnected. A bypass switch is connected between the resistor and an input capacitor. The bypass switch is rendered conductive during the precharge state and during the discharge state. The discharge transistor is activated only during the discharge state. As a result, the invention uses less components by virtue of eliminating separate resistance elements for pre-charging and discharging and by eliminating discharge switches dedicated to separate resistances. The circuit integration and the placement of components outside the inverter module improves overall system cost and packaging size.

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.