Abstract: An electrified vehicle propulsion system uses current feedback to modify gate drive signals to suppress voltage spikes and increase switching efficiency. A DC link having a link capacitor and a link inductance is connected to first and second converters. A first converter bridge has a first phase leg with first upper and lower switching devices, each switching device having a respective gate loop. A second converter bridge has a second phase leg with second upper and lower switching devices, each switching device having a respective gate loop. A plurality of gate drivers provide gate drive signals to respective gate loops for turning the respective switching devices on and off. A plurality of gate coils are provided, wherein each gate coil is connected in series between a respective gate driver and a respective gate loop. Each gate coil is respectively inductively coupled to the link inductance.

Abstract: A shunt includes a power terminal having a planar first potential region (FPR) connected to a second potential region (SPR) through a resistive element, the SPR being offset from and parallel to the FPR. The shunt includes a sensor terminal having a first potential lead (FPL) connected to the FPR, and a second potential lead (SPL) connected to the SPR and separated from the FPL by an insulation sheet. The SPL and sheet cover the resistive element.

Abstract: A selectable increase in the common source inductance is obtained by a layout for a power module used for a half-bridge phase leg in an inverter for an electrically-driven vehicle. The power module comprises a pair of transistor dies connected to positive, negative, and AC conductive tracks for carrying bridge currents. The module includes a pair of gate drive pins and a pair of gate drive coils connecting a respective pin and die. The gate drive coils are disposed in a region between the positive and negative tracks containing a flux generated by the currents having a locally greatest rate of change. The coils may preferably be comprised of traces on an auxiliary printed circuit board incorporated in the module. The gate drive pins can be on the gate side or the emitter side of the transistor dies.

Abstract: An electrified vehicle charger includes a diode bridge, contactors, and a controller. The diode bridge may be configured to rectify an alternating current (AC) source. The contactors may couple the AC source with a traction battery. The controller may be configured to, responsive to a magnitude of a potential across a diode of the bridge, corresponding to a neutral crossing of a potential of the AC source, exceeding a threshold, open the contactors.

Abstract: A power converter receives a DC supply voltage across a phase leg. The phase leg comprises an upper switching device and a lower switching device coupled across the DC link, wherein a junction between the upper and lower switching devices is configured to be coupled to a load. A gate driver is coupled to the phase leg activating the respective upper switching device according to an upper gate signal and activating the respective lower switching device according to a lower gate signal in response to a pulse-width modulation (PWM) control signal at a PWM frequency. The gate driver shuffles among a plurality of alternate paired sets of dead-time inserted signals. Each paired set of dead-time inserted signals corresponds to a different distortion of a current flowing in the load, so that overall distortion is dispersed.

Abstract: A phase leg in an inverter bridge has an upper transistor with upper gate, collector, and emitter terminals, wherein the upper gate and emitter terminals are arranged to create an upper common source inductance. A lower transistor has lower gate, collector, and emitter terminals, wherein the lower gate and emitter terminals are arranged to create a lower common source inductance. An upper diode is coupled across the upper collector and emitter terminals and substantially in parallel with the upper common source inductance. A lower diode is coupled across the lower collector and emitter terminals and substantially in parallel with the lower common source inductance. Thus, the diodes substantially bypass the common source inductances when carrying commutation current when one of the transistors is switching off. This allows the phase leg to possess significant common source inductance at the gate terminals while avoiding “shoot-through” issues.

Abstract: Embodiments include a power conversion circuit comprising first and second semiconductor switches, and a drive circuit configured to create a period of operational overlap for the first and second switches by setting a gate voltage of the first switch to an intermediate value above a threshold voltage of the first switch, during turn-on and turn-off operations of the second switch. Embodiments also include a method of operating first and second semiconductor devices, comprising: reducing a gate voltage of the first device to an intermediate value above a threshold voltage while the second device is off; turning off the first device after the second device is on; increasing the gate voltage of the first device to the intermediate value while the second device is on; and fully turning on the first device after the second device is off.

Abstract: A powertrain for a vehicle includes a DC/DC converter and a controller. The DC/DC converter includes an inductor and output capacitor and is coupled between a traction battery and an electric drive unit. The controller may be configured to, in response to an electrical connection between the vehicle and an AC grid, couple the output capacitor and inductor in series and across terminals of the traction battery to absorb reactive power from the AC grid.

Abstract: The methods and systems for correcting for an inductive load when testing high voltages devices are described. A high voltages device is a device under test (DUT) in a double-pulse test, which may require the inductive load. The method can include in a low current, high voltage time period, estimating an inductor current contribution range after a turn on of the device-under-test connected to an inductive load with an air core inductor. The method subtracts the estimated inductor current contribution from a device-under-test collector current to output a corrected collector current. This allows the double pulse test to be conducted with an air-core inductor. Vehicles can use the DUT in traction power applications.

Abstract: A vehicle power module assembly is provided. The assembly many include an array of stacked frames, a power stage housed within each of the frames, and busbars. Each of the power stages may include a pair of opposite polarity terminals extending therefrom. The busbars may be dispersed along the array to electrically connect like polarity terminals. The power stages may be arranged with one another such that like polarity terminals are adjacent one another and the busbars define an alternating sequence corresponding to the polarity of the terminals. The terminals may be located on the respective power stages such that the busbars are alternately dispersed in a linear sequence along a side face defined by portions of the frames.

Abstract: A direct bonded copper (DBC) power module with elevated common source inductance is adapted for use as a half bridge in an electric drive for an electric vehicle. Etching patterns on the DBC substrates provide indented notches for concentrating magnetic flux in the power loops. Etched gate traces form gate loops with coil windings disposed within or overlapping the notches in order to enhanced the common source inductance for each switching transistor (such as an IGBT). Switching loss is reduced and fuel economy is improved for the electric vehicle with minimal impact on packaging size and at no additional cost.

Abstract: A powertrain for a vehicle includes a DC/DC converter and a controller. The DC/DC converter includes an inductor and output capacitor and is coupled between a traction battery and an electric drive unit. The controller may be configured to, in response to an electrical connection between the vehicle and an AC grid, couple the output capacitor and inductor in series and across terminals of the traction battery to absorb reactive power from the AC grid.

Abstract: An inverter for an electric vehicle drive has a bridge including a plurality of power switching devices having respective insulated gate terminals and emitter terminals. A PWM circuit determines switching commands for controlling the bridge. A plurality of gate drivers receive the switching commands and provide gate drive signals to respective gate terminals. A plurality of gate capacitors are each thermally coupled to a respective switching device and are electrically connected between the respective gate and emitter terminals. Each gate capacitor has a negative temperature coefficient adapted to counter changes in a switching speed of the switching devices over a predetermined range of temperature. As a result, a consistent switching speed is maintained so that power loss and switching device reliability are optimal across the full temperature range.

Abstract: An inverter phase leg has upper and lower gate drive circuits supplying gate drive signals to upper and lower transistors. Each gate drive circuit includes an active clamp for selectively deactivating the upper and lower transistors. The transistors are comprised of semiconductor devices, each having respective gate, source, and emitter terminals. Each emitter terminal is connected to a respective output electrode structured to enhance a common source inductance between the respective gate and emitter terminals. Each emitter terminal is further connected to a respective Kelvin emitter electrode substantially bypassing the respective output electrode. Each respective active clamp is connected between the respective gate terminal and Kelvin emitter electrode so that the active clamping function remains effective in the presence of the enhanced common source inductance.

Abstract: A powertrain for a vehicle includes a wye wound electric machine and a controller. The electric machine is coupled with an inverter. The controller is configured to, in response to an electrical connection between the vehicle and an AC grid, couple a capacitor between a neutral terminal of the electric machine and a negative terminal of the inverter to absorb reactive power from the AC grid.

Abstract: A voltage probe holster includes a support member disposed on a base. The support member defines a plurality of apertures sized to receive a plurality of single-ended probes having coaxial leads. Each of the apertures have a conductive periphery configured to conduct electricity from one of the coaxial leads such that a common ground loop through the support member and the base is formed and that differences in ground potential are reduced.

Abstract: Embodiments include a power conversion circuit comprising first and second semiconductor switches, and a drive circuit configured to create a period of operational overlap for the first and second switches by setting a gate voltage of the first switch to an intermediate value above a threshold voltage of the first switch, during turn-on and turn-off operations of the second switch. Embodiments also include a method of operating first and second semiconductor devices, comprising: reducing a gate voltage of the first device to an intermediate value above a threshold voltage while the second device is off; turning off the first device after the second device is on; increasing the gate voltage of the first device to the intermediate value while the second device is on; and fully turning on the first device after the second device is off.

Abstract: A vehicle power stage assembly is disclosed which may include a power stage housing, a power stage supported by the housing, and a pair of stacked DC leadframes. The pair of stacked DC leadframes are of opposite polarity and spaced apart from one another. Each of the DC leadframes may extend from the power stage and each has distal and proximal ends. The spacing between the leadframes may be such that parasitic inductances associated with current flowing through each of the leadframes at least partially cancel one another. Each of the leadframes may define a first and second side surface opposite one another. The first side surfaces may be coplanar and the second side surfaces may be coplanar. A distance between the spaced apart pair of DC leadframes may be based on a preselected amount of current and a material of the DC leadframes.

Abstract: A vehicle includes a traction battery, an on-board charging system (OBCS), and a wireless power transfer system (WPTS). Each of the OBCS and WPTS is configured to selectively use a same rectifier such that the rectifier rectifies output of the OBCS and rectifies output of the WPTS to provide power to the traction battery.

Abstract: A shunt includes a power terminal having a planar first potential region (FPR) connected to a second potential region (SPR) through a resistive element, the SPR being offset from and parallel to the FPR. The shunt includes a sensor terminal having a first potential lead (FPL) connected to the FPR, and a second potential lead (SPL) connected to the SPR and separated from the FPL by an insulation sheet. The SPL and sheet cover the resistive element.