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: An electric drive system of an electrified vehicle has a power converter with phase leg switching devices controlled by pulse-width modulation to supply multi-phase AC to an electric traction motor. Dead-time intervals are inserted into gate drive signals for the switching devices without introducing any significant distortion in the output of the converter. A direction of current flow between a phase leg and the motor is detected. When the current direction is positive, lower gate signals for a lower switching device in the phase leg have a delayed rising edge and an advanced falling edge while upper gate signals are unmodified. When the current direction is negative, upper gate signals for an upper switching device in the phase leg have a delayed rising edge and an advanced falling edge while lower gate signals are unmodified.

Abstract: A power supply is provided. The power supply device includes a power module and a capacitor. The power module includes inverting circuitry and is configured to deliver electrical power to an electric machine. The capacitor is disposed adjacent to the power module and is arranged to limit voltage variation at the inverting circuitry input due to ripple current. The inverting circuitry and the capacitor are surrounded by a monolithic non-metal casing that provides voltage isolation between the power module and the capacitor.

Abstract: A power switching circuit provides temperature compensation for an insulated gate power switching device. A timing circuit determines a switch timing signal comprising desired on and off switching times of the switching device. A temperature monitor quantifies a device temperature. A gate drive profile generator generates a switching device drive signal according to the switch timing signal and having a dv/dt phase and a di/dt phase. The drive signal has a profile during the di/dt phase that is adjusted in response to the device temperature, and the drive signal has a profile during the dv/dt phase that is not adjusted in response to the device temperature.

Abstract: A power switching circuit provides temperature compensation for an insulated gate power switching device. A timing circuit determines a switch timing signal comprising desired on and off switching times of the switching device. A temperature monitor quantifies a device temperature. A gate drive profile generator generates a switching device drive signal according to the switch timing signal and having a dv/dt phase and a di/dt phase. The drive signal has a profile during the di/dt phase that is adjusted in response to the device temperature, and the drive signal has a profile during the dv/dt phase that is not adjusted in response to the device temperature.

Abstract: A vehicle includes an electric machine that provides propulsive force to the vehicle, and a power inverter that supplies power from a traction battery to the electric machine using a first and second switch configured as a half-bridge. The first switch has a first gate, a first gate lead coupled with the first gate and having a first inductance, and a second gate lead coupled with the first gate and having a second inductance greater than the first inductance.

Abstract: A power converter has one or more phase legs, each with upper and lower switching devices. A current sensor detects a magnitude of a current flow from a respective leg. A gate driver activates the upper and lower devices according to gate signals determined in response to a PWM control signal. When the detected current magnitude is greater than a positive threshold then the lower gate signal includes a dead-time insertion and the upper gate signal does not include a dead-time insertion. When the detected current magnitude is less than a negative threshold then the upper gate signal includes a dead-time insertion and the lower gate signal does not include a dead-time insertion. When the detected current magnitude is between the positive threshold and the negative threshold then the upper gate signal and the lower gate signal both include a dead-time insertion. Output distortion and control delay are greatly reduced.

Abstract: A vehicle power module assembly includes a modular manifold, an upper frame, and a plurality of power stages. The modular manifold includes a first base unit defining an inlet chamber, a second base unit defining an outlet chamber, a mid-unit defining one or more ports open to the chambers, and an upper unit defining a first set of slots and a second set of slots in fluid communication with the chambers via the ports. The plurality of power stages is housed within the frame and each of the power stages are spaced from one another to define inner channels therebetween. The chambers, channels, and ports are arranged with one another such that coolant flowing through the inner channels is in thermal communication with the power stages. The mid-unit may further include flow guides each sized to partially extend into one of the inner channels.

Abstract: A power inverter includes a plurality of power modules each having a power stage encased in a frame that defines an opening. The power modules are stacked in an array with the power stages being spaced apart to define coolant chambers interleaved with the power stages. The openings cooperate to form a manifold cavity extending along a length of the stack and in fluid communication with the chambers. A manifold insert is disposed in the cavity and extends through the openings.

Abstract: Routing of a gate signal for controlling a discrete power switching device (such as in an inverter for an electric vehicle drive) is configured to compensate for the common source inductance inherent in the switching device as a result of its integrated circuit packaging. The power device has a gate signal path via a gate pin and a power signal path via first and second power pins, wherein the gate signal path and the power signal path have a first mutual inductance. A circuit board apparatus provides a gate wiring loop juxtaposed with the power signal path, wherein the gate wiring loop and the power signal path have a second mutual inductance substantially canceling the first mutual inductance. The resulting reduction in common source inductance avoids the reductions in switching speed and the increased switching losses otherwise introduced by the common source inductance.

Abstract: A vehicle powertrain includes an IGBT and a gate driver. The IGBT is configured to energize an electric machine. The gate driver is configured to apply an off voltage less than a threshold voltage onto a gate of the IGBT while the IGBT is operating in a saturation mode, and in response to expiration of a delay from a transition from saturation to linear mode, apply a voltage pulse above the off voltage to reduce flyback from the electric machine. The gate driver may be configured to, in response to expiration of a delay from a transition from saturation to linear mode, apply a voltage pulse above the off voltage and below the threshold to reduce flyback from the electric machine.

Abstract: A vehicle power module assembly includes a modular manifold, an upper frame, and a plurality of power stages. The modular manifold includes a first base unit defining an inlet chamber, a second base unit defining an outlet chamber, a mid-unit defining one or more ports open to the chambers, and an upper unit defining a first set of slots and a second set of slots in fluid communication with the chambers via the ports. The plurality of power stages is housed within the frame and each of the power stages are spaced from one another to define inner channels therebetween. The chambers, channels, and ports are arranged with one another such that coolant flowing through the inner channels is in thermal communication with the power stages. The mid-unit may further include flow guides each sized to partially extend into one of the inner channels.

Abstract: A power inverter includes a plurality of power modules each having a power stage encased in a frame that defines an opening. The power modules are stacked in an array with the power stages being spaced apart to define coolant chambers interleaved with the power stages. The openings cooperate to form a manifold cavity extending along a length of the stack and in fluid communication with the chambers. A manifold insert is disposed in the cavity and extends through the openings.

Abstract: A capacitor comprising first and second end sprays respectively located at distal ends of a capacitor cell, a positive polarity bus bar extending from a first wound conductive layer of the capacitor cell adjacent to the first end spray, a negative polarity bus bar extending from a second wound conductive layer of the capacitor cell adjacent to the second end spray, and a capacitor film wrapped around an area between the first and second conductive layers.

Abstract: A DC to DC power converter includes a switching circuit and an LC filter configured to reduce parasitic inductance. The LC filter includes an inductor, capacitor, and a coil positioned and oriented relative to and electrically connected with the capacitor. The coil positioned with the capacitor provides the ripple current caused by operation of the switching circuitry to flow through the capacitor and coil with opposite direction. The ripple current flowing through the coil attenuates a magnetic field generated by the capacitor while reducing parasitic inductance of the capacitor.

Abstract: A vehicle powertrain includes an electric machine, an inverter including an IGBT having a gate configured to flow current through a phase of the electric machine, and a gate driver. The gate driver is configured to supply power onto the gate via a voltage regulated source, and in response to a collector current of the IGBT exceeding a previous steady state current through the phase, transition to a current regulated source to drive the gate. The gate driver may be configured to delay the transition by a predetermined time that is based on a difference between the previous steady state current and a reverse recovery peak current.

Abstract: An inverter for an electric vehicle comprises a phase leg having series-connected upper and lower transistors between a positive bus and a ground bus. Upper and lower gate drive circuits supply gate drive signals to the upper and lower transistors. Each gate drive circuit includes an active clamp for deactivating the upper and lower transistors. The transistors are comprised of semiconductor devices, each having respective gate, collector, and emitter terminals. Each pair of gate and emitter terminals is adapted to provide an enhanced common source inductance therebetween. Each gate terminal is adapted to be tied to a ground voltage of the drive circuits. Each respective active clamp is comprised of a p-channel MOSFET having a source terminal connected to the gate terminal of a respective transistor and having a drain terminal connected to the emitter terminal of the respective transistor bypassing the respective enhanced common source inductance.

Abstract: A vehicle powertrain includes an IGBT and a gate driver. The IGBT is configured to energize an electric machine. The gate driver is configured to apply an off voltage less than a threshold voltage onto a gate of the IGBT while the IGBT is operating in a saturation mode, and in response to expiration of a delay from a transition from saturation to linear mode, apply a voltage pulse above the off voltage to reduce flyback from the electric machine. The gate driver may be configured to, in response to expiration of a delay from a transition from saturation to linear mode, apply a voltage pulse above the off voltage and below the threshold to reduce flyback from the electric machine.

Abstract: A vehicle powertrain includes an IGBT that conducts current between a supply and load. The vehicle powertrain also includes a controller that applies voltage to a gate of the IGBT at a first level for a first duration that depends on a capacitance of the gate, and increases the voltage over a second duration based on a rate of change of the current falling below a threshold defined by a supply voltage for the load.

Abstract: A vehicle includes an electric machine, an IGBT, and a gate driver. The IGBT has a gate, an emitter, and a collector and is configured to flow an electric charge through a phase of the electric machine. The gate driver is configured to flow current onto the gate at a first level, and in response to a time integral of a voltage across the phase exceeding a predetermined level, transition from the first level to a second level less than the first level.