Abstract: An apparatus includes a power converter having switches coupled to input voltage rails and to opposing terminals of a coil to be energized. The switches are configured to be turned ON or OFF to conduct or block current, respectively, responsive to switch control signals. The apparatus also includes a controller to generate the switch control signals to compel the power converter to selectively operate (i) in a normal mode in which the switches are periodically turned ON and OFF to supply current from the input voltage rails to the coil to energize the coil, and (ii) in a protection mode in which first switches are continuously turned ON, and second switches are continuously turned OFF, to interrupt the current, and to circulate an initial current, flowing in the coil when the protection mode is entered, through the power converter and the coil so that the initial current decays toward zero.

Abstract: A power inverter module includes a base module having a plurality of electrically conductive layers, including a first conductive layer, a second conductive layer and a third conductive layer. A first terminal is operatively connected to the first conductive layer at a first end and a second terminal is operatively connected to the second conductive layer at the first end. An isolation sheet is sandwiched between the first and second terminals. The first terminal and the second terminal include a respective proximal portion composed of a first material and a respective distal portion composed of a second material. At least one of the first terminal and the second terminal is bent to create an overlap zone such that a gap between the first terminal and the second terminal in the overlap zone is less than a threshold distance. The power inverter module is configured to reduce parasitic inductance.

Abstract: A power inverter module includes a base module having a plurality of electrically conductive layers, including a first conductive layer, a second conductive layer and a third conductive layer. A first terminal is operatively connected to the first conductive layer at a first end and a second terminal is operatively connected to the second conductive layer at the first end. An isolation sheet is sandwiched between the first and second terminals. The first terminal and the second terminal include a respective proximal portion composed of a first material and a respective distal portion composed of a second material. At least one of the first terminal and the second terminal is bent to create an overlap zone such that a gap between the first terminal and the second terminal in the overlap zone is less than a threshold distance. The power inverter module is configured to reduce parasitic inductance.

Abstract: An armature for use in an electric traction motor comprises a rotor having a central portion and a peripheral portion with the peripheral portion having a plurality of cavities. Permanent magnets solidified from liquid magnetic material are disposed in the cavities to form poles of the rotor with at least a portion of the cavities having directly abutting permanent magnets comprised of at least first and second magnetic materials of different properties injected in liquid or mobile form into single cavities. In interface regions between the at least first and second magnetic materials the first and second magnetic materials are intermingled to form a transition zone. A method of making the armature includes injecting the magnetic materials simultaneously as well as injecting a subsequent magnetic material when the initial magnetic material is still fluidly mobile.

Abstract: Methods for controlling a multiple DC-to-AC inverter system, which is suitable for an electric or hybrid vehicle application, are disclosed. In one embodiment, if an inverter fails or suffers from degraded performance (faulty inverter), the faulty inverter is disabled and drive signals to a healthy inverter that is coupled to the faulty inverter are updated such that the healthy inverter can remain active without being driven into an over-current condition.

Abstract: A multiple DC-to-AC inverter system, which is suitable for an electric or hybrid vehicle application, includes a plurality of inverters controlled by a single controller. One example embodiment includes four three-phase inverters driving one six-phase motor, where the output of the first inverter is coupled to the output of the fourth inverter and the output of the second inverter is coupled to the output of the third inverter. In response to the failure of an inverter, the drive signals to the inverter that is coupled to the faulty inverter are updated such that the partner inverter can remain active without being driven into an over-current condition.

Abstract: A filter assembly is provided which includes a Faraday cage interface. Electrical noise is filtered by the Faraday cage interface. The Faraday cage interface is configured to prevent passage of electromagnetic waves.

Abstract: A high current interconnection system is provided which can be configured to couple a motor to an inverter. A high current interconnection system comprises a bus bar, a motor winding coupled to the bus bar, and a thermal interface. The motor winding is configured to receive a current. The thermal interface can be coupled to at least one of the motor winding or the bus bar. The thermal interface is configured to reduce a temperature of the motor winding or bus bar which the thermal interface is coupled to.

Abstract: A low noise interconnection system is provided which is configured to couple a motor to an inverter. The system comprises a bus bar and a motor winding. The bus bar is configured to receive a current from the inverter. The motor winding is directly connected to the bus bar and configured to receive the current.

Abstract: A control system for a vehicle powered by a fuel cell includes a voltage conversion device that communicates with the fuel cell through a voltage bus and a propulsion system that is selectively powered by the fuel cell through the voltage bus and that selectively generates a ripple current in the voltage bus. The voltage conversion device is regulated to selectively generate a counter-ripple current that reduces the ripple current.

Abstract: The preferred embodiments of the present invention utilize the internal combustion engine of a hybrid vehicle, coupled with an energy storage device and series of inverters to provide electrical power generation capability for an electric power take-off (EPTO) system. Additional embodiments of the present invention utilize an existing on-board AC induction motor to provide filtering capability for the generated AC power.

Abstract: A method for decoupling a harmonic signal from an input signal wherein the harmonic signal is harmonic relative to a signal other than the input signal. An angular position of the other signal is multiplied by a value representing the harmonic to obtain an angular position multiple. A harmonic decoupling block uses the angular position multiple to obtain correction signals representing the harmonic signal, and subtracts the correction signals from the input current to decouple the harmonic signal from the input signal. This method is useful for decoupling unwanted harmonics from currents into which high-frequency signals have been injected for control of electric motors.

Abstract: Methods and apparatus are provided for controlling a stand-alone four-leg three-phase inverter. The inverter three-phase output is converted from AC domain elements to corresponding DC domain elements. The DC domain elements are processed into combined regulating and imbalance compensating signals, including over-current limiting. The compensating signals are restored to corresponding AC domain signals, and are processed into control inputs for the inverter, in order to stabilize the inverter output when connected to an unbalanced load. The inverter controller can be implemented entirely in software as a control algorithm.

Abstract: Methods and apparatus are provided for controlling an inverter with an under-damped L-C filter connected to a load. Samples of the inverter output are processed to generate voltage regulation signals and damping signals. The voltage regulation signals include both regulating and imbalance compensating elements, and are further modified by the damping signals. The modified voltage regulation signals control the switching circuits of the inverter to stabilize the inverter output to the load.

Abstract: A power supply generates alternating current and direct current from a constant-voltage source. A multi-phase pulse width modulation voltage source inverter is connected across the source to output multi-phase alternating current. At least one waveform generator is bridged in parallel with the inverter, with each waveform generator outputting zero-sequence waveform current compensated to maintain the multi-phase current within a predetermined tolerance from a desired set point. A rectifier receives the waveform current and generates direct current.

Abstract: A drive system that is suitable for high bandwidth current control of a three-phase voltage source inverter in the overmodulation region includes a feedback path that has a harmonic decoupling block that subtracts selected harmonic components from signals representative of a corresponding motor phase current signal. The harmonic decoupling block thereby generates corrected feedback signals. The drive system also includes subtractor blocks that subtract the corrected feedback signals from signals representative of open-loop magnetizing reference currents to generate difference signals. Also included is a modulation block that utilizes the difference signals to produce signals to drive a three-phase voltage source inverter in an overmodulated six-step mode.

Abstract: The present invention includes a method for thermal management in a voltage source inverter. The method includes sensing a low output frequency condition, determining a zero vector modulation responsive to the sensed low output frequency condition, and applying the determined zero vector modulation to reduce thermal stress in the voltage source inverter. The step of determining the zero vector modulation responsive to the sensed low output frequency condition includes mapping an output voltage requirement to a space vector structure and determining state switching space vectors based on the mapped output voltage requirement.

Abstract: A method for providing additional dc inputs or outputs (49, 59) from a dc-to-ac inverter (10) for controlling motor loads (60) comprises deriving zero-sequence components (Vao, Vbo, and Vco) from the inverter (10) through additional circuit branches with power switching devices (23, 44, 46), transforming the voltage between a high voltage and a low voltage using a transformer or motor (42, 50), converting the low voltage between ac and dc using a rectifier (41, 51) or an H-bridge (61), and providing at least one low voltage dc input or output (49, 59). The transformation of the ac voltage may be either single phase or three phase. Where less than a 100% duty cycle is acceptable, a two-phase modulation of the switching signals controlling the inverter (10) reduces switching losses in the inverter (10). A plurality of circuits for carrying out the invention are also disclosed.

Abstract: The preferred embodiments of the present invention utilize the internal combustion engine of a hybrid vehicle, coupled with an energy storage device and series of inverters to provide electrical power generation capability for an electric power take-off (EPTO) system. Additional embodiments of the present invention utilize an existing on-board AC induction motor to provide filtering capability for the generated AC power.

Abstract: A method for making a motor and auxiliary devices with a unified stator body comprises providing a piece of material (10) having an area larger than a cross section of the stator (11), removing material from the piece of material (10) to form a pattern for a cross section of a core (11) for the stator, and removing material from the piece of material (10) outside the cross section of the core of the stator (11) to allow positioning of cores (22, 23, 24) for supporting windings (25, 26, 27) of least one additional electromagnetic device, such as a transformer (62) in a dc-to-dc converter (61, 62) that provides a low. voltage dc output. An article of manufacture made according to the invention is also disclosed and apparatus made with the method and article of manufacture are also disclosed.