Abstract: An inverter includes an N-channel IGBT, with a freewheeling diode, coupled to a phase of an electric machine, and has a MOSFET coupling a local voltage with a gate of the IGBT and configured to transition from saturation to linear operation as a current flow direction through the diode switches from positive to negative while the IGBT initiates a current through the electric machine.

Abstract: An energy conversion system transfers energy between an energy source, or storage unit, and an electric device via a first port and a second port and at least one of receives and provides energy via a third port.

Abstract: A differential voltage probe for providing accurate measurement of differential voltage with high frequency components is disclosed that is further configured to accurately identify noise sources in EMI/EMC applications. The differential voltage probe is configured to provide the benefits of adequate differential voltage measurement bandwidth, galvanic isolation capability, high CMRR, flexible design to accommodate various requirements on voltage rating, loading effect, and frequency range of interest; and/or easy implementation and low cost. The differential voltage probe is able to achieve these optimized capabilities by implementing unique winding designs for transformer(s) used in the differential voltage probe circuit design.

Abstract: A power electronics assembly includes a case and an array of power stages disposed within the case. Each of the power stages includes a transistor-based switching arrangement configured to change direct current from a traction battery to alternating current for an electric machine. The power stages are bonded together via a resin to form a monolithic power module adhered to a wall of the case. This disclosure also discloses methods for forming power electronic assemblies.

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 method according to an exemplary aspect of the present disclosure includes, among other things, controlling a vehicle using switching loss information of a semiconductor switching device, the switching loss information derived from a conduction loss and a combined conduction and switching loss.

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: An electronic device for an electric powertrain of a vehicle is disclosed. The device includes a power module assembly having a housing that defines a first side, and an array of power modules disposed within the housing. Each of the power modules includes first electrical contact patches at least partially embedded in the first side and having an attachment surface substantially parallel to the first side. A capacitor assembly includes a housing defining a second side that is substantially coplanar with the first side, and an array of second electrical contact patches at least partially embedded in the second side. The second electrical contact patches have an attachment surface substantially parallel to the second side. A busbar mechanically and electrically couples at least one of the first contact patches to at least one of the second contact patches.

Abstract: A power converter has a phase leg with upper and lower switching devices coupled across a DC link. A junction between the devices is coupled to a load. A current sensor detects direction of current flow from the junction to the load. A gate driver activates the devices according to upper and lower gate signals in response to pulse-width modulation (PWM) to generate nominal gate signals from a variable duty cycle. When the positive current direction is detected then the upper gate signal has turn-on and turn-off times shifted by a predetermined offset with respect to the nominal signals, and dead-times are added to the lower gate signals. When the negative direction is detected then the lower gate signal has turn-on and turn-off times shifted by the predetermined offset with respect to the nominal signals, and dead-times are added to the upper gate signals.

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: In order to detect deterioration of a DC link capacitor between a DC source and an inverter load in an electric propulsion vehicle, capacitance of the link capacitor must be accurately measured during in-service use. A charge is established on the link capacitor. The capacitor is isolated from the source and the inverter load. A constant current circuit is activated to discharge the capacitor. A first voltage is measured across the capacitor at a first time during the discharging. A second voltage is measured across the capacitor at a second time during the discharging. A discharge current flowing from the capacitor is measured during the discharging. The capacitance is calculated in response to the discharge current multiplied by a ratio of a difference between the second and first times to a difference between the first and second voltages. The calculated capacitance is monitored for a decline indicative of a failure.

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 method according to an exemplary aspect of the present disclosure includes, among other things, controlling a vehicle using switching loss information of a semiconductor switching device, the switching loss information derived from a conduction loss and a combined conduction and switching loss.

Abstract: A DC to DC power converter includes switching circuitry and an LC filter. The LC filter includes a capacitor electrically connected between an inductor and coil. The inductor and coil are wound in a same direction. The coil is positioned and oriented relative to the inductor so that current from the switching circuitry flowing through the inductor and coil results in inductive coupling between the inductor and coil. This coupling increases a frequency at which a parasitic inductance and capacitance of the capacitor resonate.

Abstract: An improved capacitor packaging solution is presented that incorporates both thermal and electrical considerations. A package can include capacitor elements electrically coupled to a bus bar, and a thermally enhanced isolation layer between the bus bar and a case. The isolation layer can be provided adjacent a case base and sidewall portions. The bus bar can be disposed adjacent the isolation layer and be configured to extend along the package side and along the package length below the capacitor elements to provide an extended path for heat dissipation from the bus bar prior to its contact with capacitor elements. The enhanced isolation layer is configured to conduct heat away from the bus bar to the case to avoid the hotspot temperature of the capacitor. Reduced capacitor temperature allows use of smaller, cheaper capacitors, reducing inverter costs without compromising performance.

Abstract: A power converter has a phase leg with upper and lower switching devices coupled across a DC link. A junction between the devices is coupled to a load. A current sensor detects direction of current flow from the junction to the load. A gate driver activates the devices according to upper and lower gate signals in response to pulse-width modulation (PWM) to generate nominal gate signals from a variable duty cycle. When the positive current direction is detected then the upper gate signal has turn-on and turn-off times shifted by a predetermined offset with respect to the nominal signals, and dead-times are added to the lower gate signals. When the negative direction is detected then the lower gate signal has turn-on and turn-off times shifted by the predetermined offset with respect to the nominal signals, and dead-times are added to the upper gate signals.

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 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 PWM strategy can be implemented to reduce device power losses and hotspot temperature in an inverter circuit that drives a synchronous motor. A method includes migrating a phase current from a power device with higher losses to a power device with lower losses. A PWM modulation signal can be modified to alter the inverter duty cycle and migrate phase current in the direction of lower losses. As an example, a PWM reference signal can be shifted to a lower value. A PWM loss reduction strategy can be performed while a motor is in a rotor-lock state to reduce device hotspot temperature. The PWM loss reduction strategy can also be performed when a motor is operating in a normal state, pushing PWM to DPWM, reducing switching and overall losses. The strategy can be practiced while a PMSM is operating as a motor, and can also be practiced during regenerative braking.

Abstract: An energy conversion system transfers energy between an energy source, or storage unit, and an electric device via a first port and a second port and at least one of receives and provides energy via a third port.