Abstract: Embodiments of the present disclosure are directed to power module cooling systems. In particular, some embodiments of the present disclosure relate to power module cooling systems with structures to generate three-dimensional swirling and tumbling in liquid coolant flowing within a chamber of the cooling system. Other embodiments may be disclosed or claimed.

Abstract: A vehicle, slew rate control circuit and method of operating an electric motor of a vehicle. The slew rate control circuit is between a gate driver of the vehicle and an inverter of the vehicle. The slew rate control circuit includes a first branch between the gate driver and the inverter, wherein the inverter provides an electrical signal output to an electric motor of the vehicle, and a second branch between the gate driver and the inverter in parallel with the first branch, wherein current flows through the first branch during a first time period and through the second branch during a second time period, wherein the flow of the current controls a slew rate of the electrical signal output by the inverter to the electric motor.

Abstract: A vehicle, suspension system and method of dampening a force on the suspension system is disclosed. The suspension system includes a damper having a first damping element and a second damping element configured to rotate relative to each other in response to a force received at the suspension system. The second damping element induces an eddy current in the first damping element during relative rotation. A feature of one at least one of the first damping element and the second damping element provides a first electrical resistance to the eddy current during relative rotation in a first direction and a second electrical resistance to the eddy current during relative rotation in a second direction. The first electrical resistance generates a first damping force and the second electrical resistance generates a second damping force.

Abstract: A vehicle includes a system for controller the vehicle. The vehicle includes a motor. The system includes an inverter, and a gate controller. The inverter has a switch for controlling current to the motor. The gate controller is configured to apply a gate current to the switch at a first on-current control level during a first switch-on stage of a turn-on operation of the switch, lower the gate current to a second on-current control level less than the first on-current control level during a second switch-on stage of the turn-on operation, and raise the gate current to a third on-current control level during a third switch-on stage of the turn-on operation, wherein the third on-current control level is greater than the second on-current control level.

Abstract: A battery system for an electric vehicle includes at least one battery cell configured to store charge for powering an electric vehicle, a high voltage bus electrically coupled with the at least one battery, a DC-DC converter electrically coupled with the battery cell, a low voltage bus electrically connected between the DC-DC converter and at least one vehicle electrical component, and a cell monitor electrically coupled with the at least one battery cell and the DC-DC converter, wherein the cell monitor includes a current sensor configured to detect a current from the at least one battery cell to the DC-DC converter. The cell monitor includes a controller configured to estimate a state of charge of the at least one battery cell according to the current detected by the current sensor, and adjust switching operation of the DC-DC converter according to the current detected by the current sensor.

Abstract: A power control system for a vehicle includes a charge port and a contactor connected to the charge port and including a first plurality of switches. An energy storage system includes a second plurality of switches and one or more battery packs. A bi-directional DC-DC converter is connected between the energy storage system and a plurality of vehicle loads. A controller is configured to control states of the first and second plurality of switches to configure in a plurality of modes including a range improvement mode, a first charging mode to perform charging at a first voltage level, a second charging mode to perform charging at a second voltage level, a battery preconditioning mode; and an accessory load support mode.

Abstract: A low voltage (LV) charging system for charging a high voltage (HV) rechargeable energy storage system (RESS), such as a HV RESS operable for electrically powering a traction motor of an electric vehicle. The LV charging system may include an input configured for receiving LV electrical power from a LV source and a distributed converter system configured for charging a plurality of modules of the HV RESS via a plurality of charging circuits. The charging circuits may be configured for separately charging one of the modules with a charging electrical power derived from converting the LV electrical power. The LV charging system may further include a controller configured for individually controlling the charging electrical power provided via each of the charging circuits.

Abstract: A vehicle includes a system for charging a battery of the vehicle. An electric motor couples to a charging station. a diode-clamped multi-level inverter and a processor. A diode-clamped multi-level inverter couples the electric motor to the battery and includes a first leg having a first set of switches and a first AC terminal coupled to the electric motor, a second leg having a second set of switches and a second AC terminal coupled to the electric motor and a third leg having a third set of switches and a third AC terminal coupled to the electric motor. The processor connects the third AC terminal to the charging station and control at least one of the first set of switches to control a first current through the first AC terminal and the second set of switches to control a second current through the second AC terminal to charge the battery.

Abstract: A vehicle includes a system for charging a battery of the vehicle. An electric motor couples to a charging station. A T-bridge multi-level inverter couples the electric motor to the battery. The inverter includes a first leg having a first set of switches and a first AC terminal coupled to the electric motor, a second leg having a second set of switches and a second AC terminal coupled to the electric motor and a third leg having a third set of switches and a third AC terminal coupled to the electric motor. A processor connects the third AC terminal to the charging station and controls at least one of the first set of switches to control a first current through the first AC terminal of the first leg and the second set of switches to control a second current through second AC terminal of the second leg.

Abstract: A vehicle includes an inverter having a power module. The power module includes a high side bus, a low side bus and an alternating current (AC) output bus. The high side bus includes a first switch, wherein a high side current is configured to flow through the first switch in a first direction. The high side bus is disposed in a plane. The low side bus includes a second switch, wherein a low side current is configured to flow through the second switch in the first direction. The low side bus is parallel to the high side bus. The alternating current (AC) output bus is parallel to the high side bus and the low side bus, wherein an output current flows through the AC output bus in a second direction opposite to the first direction.

Abstract: A vehicle includes a system for charging a battery of the vehicle. The system includes an electric motor couplable to a charging station, a capacitor-clamped multi-level inverter, and a processor. The capacitor-clamped multi-level inverter is couples the electric motor to the battery and includes a first leg having a first set of switches and a first AC terminal coupled to the electric motor, a second leg having a second set of switches and a second AC terminal coupled to the electric motor and a third leg having a third set of switches and a third AC terminal coupled to the electric motor. The processor connects one of the third AC terminal and a neutral point of the electric motor to the charging station and control at least one of the first set of switches and the second set of switches to charge the battery through the electric motor.

Abstract: A charging box performs a direct current fast charging (DCFC) session of a recipient by a donor, e.g., during a vehicle-to-vehicle (V2V) charging session, and includes a portable housing, disconnect devices connected to a high-voltage (HV) bus to connect/disconnect respective inlet and outlet charging ports to/from the bus, and multiple direct current-to-direct current (DC-DC) converters. A high-voltage-to-high-voltage (HV-HV) converter is connected to the bus. An optional high-voltage-to-low-voltage (HV-LV) converter may be connected to the HV-HV converter. An optional low-voltage (LV) energy storage device is connected to the housing and HV-LV converter. A communication processing unit (CPU) establishes two-way communication between the donor and recipient. A system controller selectively pre-charges the bus, recharge the energy storage device, and selectively command offloading of a DC charging current from the donor, through the HV-HV converter, and to the recipient.

Abstract: Embodiments include an electric vehicle having a charging port configured to receive an alternating current (AC) power, a direct current (DC) battery, and a bidirectional inverter configured to convert AC power to DC power and to convert DC power to AC power, the bidirectional inverter is selectively connected to the DC battery by propulsion switches. The electric vehicle also includes an AC motor connected to the bidirectional inverter and selectively connected to the charging port by a first charging switch, an isolated DC/DC converter motor selectively connected to the DC battery via a second charging switch and a third charging switch, and a processor configured to control the operation of the propulsion switches, the first charging switch, the second charging switch, and the third charging switch based on an operational mode of the electric vehicle.

Abstract: A conversion system includes a conversion device including a multilevel inverter configured to generate two alternating current (AC) output currents, a current sensor configured to sample a current through the multilevel inverter, or from the multilevel inverter, during a switching cycle, and a processor configure to estimate both of the two AC output currents based on the sampled current from the current sensor.

Abstract: A multi-level inverter control system includes a power storage system having a high voltage terminal, a low voltage terminal, and an intermediate voltage terminal. The intermediate voltage terminal is at a voltage between the high voltage terminal and the low voltage terminal. A multi-level inverter includes a plurality of switches, a high voltage input connected to the high voltage terminal, a low voltage input connected to the low voltage terminal, and an intermediate voltage input connected to the intermediate voltage terminal. A controller is controllably coupled to the multi-level inverter. The controller includes at least a processor and a memory. The memory stores instructions configured to cause the controller to operate the multi-level inverter in a three-level inverter mode, a full power two-level inverter mode, a first partial power two-level inverter mode and a second partial power two-level inverter mode.

Abstract: Multi-switch module packaging for a multilevel inverter is provided. A multilevel inverter is connected to the battery. The multilevel inverter includes three levels, each of the three levels having a first module and a second module. The first module is formed on a first insulating substrate material, and the second module is formed on a second insulating substrate material separate from the first insulating substrate material. The first module includes a first switch coupled to the battery via a positive power rail, a second switch coupled to the battery via a negative power rail, and a third switch coupled to the second module. The second module includes another first switch coupled to the battery, another second switch coupled to the battery, and another third switch coupled to the first module. The first module includes four terminals and the second module includes another four terminals.

Abstract: A system for modular dynamically adjustable capacity storage for a vehicle is provided. The system includes a battery pack including a plurality of battery cells, a negative terminal including a chassis ground connection, and a plurality of positive battery pack terminals. The negative terminal and the plurality of positive battery pack terminals are useful for connecting at least one electrical circuit through the battery pack. The system further includes a battery cell switching system, including a plurality of solid-state switches connected to each of the battery cells. The plurality of solid-state switches is operable to selectively connect a portion of the battery cells in parallel, selectively connect the portion of the battery cells in series, and selectively connect one of the plurality of battery cells to one of the plurality of positive battery pack terminals.

Abstract: A system for controlling a propulsion system of a vehicle includes a switching system including a first switching device connecting a battery system to a first set of windings of an electric motor, and a second switching device connecting the battery system to a second set of windings. The system also includes a controller configured to transition the propulsion system from an initial propulsion mode in which an initial voltage is applied to the electric motor, to a target mode in which a target voltage is applied. The transitioning includes controlling the first switching device to provide current to the first set of windings at the initial voltage to produce torque, and subsequently controlling the second switching device to cause the battery system to apply the target voltage to the second set of windings while the current is provided to the first set of windings at the initial voltage.

Abstract: A system for providing updates in a vehicle includes a server device configured for providing an OTA campaign update and the vehicle. The vehicle includes a device including software to be upgraded by the over-the-air campaign update and a low voltage battery providing low voltage power. The system further includes a battery providing high voltage power and an accessory power module configured to transform the high voltage power into low voltage power and including programming to estimate an available power of the low voltage battery. The system further includes a controller monitoring the available power, comparing the available power to a threshold, and, when the available power is less than the threshold, commanding the accessory power module to transform the high voltage power to provide the low voltage electrical power. The controller further schedules receiving the update based upon the available power and updates the device with the update.

Abstract: A cooling system for a drivetrain of an electric vehicle includes a coolant circuit directing a flow of coolant through a first inverter and a second inverter of the drivetrain, and an adjustable flow valve positioned along the coolant circuit to selectably alter proportions of the flow of coolant directed through each of the first inverter and the second inverter. A method of operating a cooling system for a first inverter and a second inverter of a vehicle drivetrain includes commanding a speed and torque of each of the first and second inverter, and estimating losses and temperature of each of the first inverter and the second inverter as a result of the commanded speed and torque. A valve position of an adjustable flow valve operably connected to the first inverter and the second inverter is selected, and a change of the valve position is commanded.