Abstract: An electrical architecture that allows power to be transferred to a battery powered machine while the machine is moving and that allows the machine to be charged while stationary.

Abstract: The present disclosure is directed to systems and methods for charging a battery array in a work machine. A system includes a battery array, a first power interface for receiving electrical energy at a first supply voltage, and a second power interface for receiving electrical energy at a second, lower supply voltage. An accessory power converter of the system selectively converts power from the battery array to an accessory or converts the lower voltage energy to charge the battery array. A controller assembly of the system detects power interface connections and controls battery charging through the detected connection, enabling flexible charging options for work machines.

Abstract: An electrical transformer core assembly may include a magnetic core, a set of coils, including a primary coil surrounding a first portion of the magnetic core, and a secondary coil surrounding the primary coil, and a heat exchanger located between the magnetic core and the primary coil. The heat exchanger may also include a heat exchanger body including an outer surface and an inner surface, wherein the outer surface is substantially non-linear as viewed in a cross-sectional plane normal to a longitudinal axis of the body, and the inner surface substantially conforms to an outer surface of the magnetic core.

Abstract: A diagnostic and testing module for an electrically powered vehicle integrates multiple high-voltage buses for assessment while protecting personnel from accessing equipment energized at hazardous voltages. The consolidated module contains circuitry for assessing each high-voltage bus, including checking for ground faults, generating and distributing a priming voltage before energization of the buses, and identifying a bus voltage exceeding a predetermined hazardous level. A protective wall separates the high-voltage buses and circuitry at a rear of the module from a probing block at a front of the module. Lamps within the protective wall warn of energized bus voltages above the hazardous level. If the lamps are not illuminated, personnel can verify de-energized bus voltages using test points within the probing block and then install a grounding bar across all test points to ensure de-energization and prevent inadvertent re-energization.

Abstract: A power electronics module (PEM) is constructed to convert electricity from an input form to an output form. Electrical power conversion subcircuits having input and output ports are positioned proximal to a front mounting plate. Rigid conductor elements having respective preformed shapes are constructed to electrically interconnect the subcircuits at input and output ports thereof to form a power conversion circuit selected from among multiple power conversion circuits configurable solely by selection of the conductor elements. Other preformed conductor shapes are constructed to interconnect input and output ports of the selected power conversion circuit to ports disposed on a rear mounting plate. A controller is mechanically coupled to the front mounting plate and constructed to operate the semiconductor switches in a prescribed timing that converts the electricity of the input form to the electricity of the output form by the selected power conversion circuit.

Abstract: A system and method of swapping a primary battery of an electric machine may include storing, by the primary battery, a first amount of energy. A secondary battery may store a second amount of energy that is less than the first amount of energy. First electrical power may be supplied from the primary battery to at least one motor. A second voltage level of the secondary battery may be managed (e.g., boosted) to match a first voltage level of the primary battery in response to receiving a battery swap initiation signal during which the primary battery is to be electrically disconnected from the electric machine to enable second electrical power from the secondary battery to be supplied to the motor(s) therefrom.

Abstract: A packaged power inverter including a cylindrical outer housing having a central longitudinal axis, a heatsink core located within the housing and having a longitudinal axis aligned with the longitudinal axis of the outer housing and a plurality of outer planar surface portions. The packaged power inverter further includes a plurality of electronic modules each being coupled to one of the plurality of planar surface portions. A plurality of AC bus bars are coupled to one of the plurality of planar surface portions. A plurality of capacitors and DC bus bars located within the outer housing.

Abstract: An electrical architecture that allows power to be transferred to a battery powered machine while the machine is moving and that allows the machine to be charged while stationary.

Abstract: An example converter for a switched reluctance (SR) generator includes one or more gate driver circuits that are not only used to synchronously control switches, such as insulated gate bipolar transistors (IGBTs) of the converter, but also used to provide priming function during start-up of the generator. Since, an SR generator does not have to ability to self provide magnetic flux, priming current is provided to coils of the SR generator to initiate a magnetic flux. By using the gate drive circuit to provide the priming current, an additional priming circuit is not required. As a result, the converter design is more streamlined, with reduced complexity, cost, and size. When a bus voltage of the converter is below a threshold level, the one or more gate drive circuits can provide the priming current on the bus to initiate the SR generator.

Abstract: A power electronics module (PEM) is constructed to convert electricity from an input form to an output form. Electrical power conversion subcircuits having input and output ports are positioned proximal to a front mounting plate. Rigid conductor elements having respective preformed shapes are constructed to electrically interconnect the subcircuits at input and output ports thereof to form a power conversion circuit selected from among multiple power conversion circuits configurable solely by selection of the conductor elements. Other preformed conductor shapes are constructed to interconnect input and output ports of the selected power conversion circuit to ports disposed on a rear mounting plate. A controller is mechanically coupled to the front mounting plate and constructed to operate the semiconductor switches in a prescribed timing that converts the electricity of the input form to the electricity of the output form by the selected power conversion circuit.

Abstract: An electrical architecture that allows power to be transferred to a battery powered machine while the machine is moving and that allows the machine to be charged while stationary.

Abstract: An example converter for a switched reluctance (SR) generator includes one or more gate driver circuits that are not only used to synchronously control switches, such as insulated gate bipolar transistors (IGBTs) of the converter, but also used to provide priming function during start-up of the generator. Since, an SR generator does not have to ability to self provide magnetic flux, priming current is provided to coils of the SR generator to initiate a magnetic flux. By using the gate drive circuit to provide the priming current, an additional priming circuit is not required. As a result, the converter design is more streamlined, with reduced complexity, cost, and size. When a bus voltage of the converter is below a threshold level, the one or more gate drive circuits can provide the priming current on the bus to initiate the SR generator.

Abstract: A power inverter has an inverter unit with a housing defining a main compartment and a first lateral compartment adjacent the main compartment. The main compartment contains an inverter power module configured to convert direct current (DC) power into alternating current (AC) power output, an inverter driver module configured to provide driving signals to drive the inverter power module, an inverter control module configured to provide control signals to the inverter driver module to control the AC power output, and a capacitor for coupling to the DC power. The capacitor is arranged on or over at least one of the inverter power module, the inverter driver module, or the inverter control module. Additionally, the power inverter has a base on which the housing sits, the base comprising a heat sink configured to draw heat away from one or more of the inverter power module, the inverter driver module, or the inverter control module.

Abstract: A power inverter has an inverter unit with a housing defining a main compartment and a first lateral compartment adjacent the main compartment. The main compartment contains an inverter power module configured to convert direct current (DC) power into alternating current (AC) power output, an inverter driver module configured to provide driving signals to drive the inverter power module, an inverter control module configured to provide control signals to the inverter driver module to control the AC power output, and a capacitor for coupling to the DC power. The capacitor is arranged on or over at least one of the inverter power module, the inverter driver module, or the inverter control module. Additionally, the power inverter has a base on which the housing sits, the base comprising a heat sink configured to draw heat away from one or more of the inverter power module, the inverter driver module, or the inverter control module.

Abstract: An electrical power supply system for a machine is provided. The electrical power supply system includes a generator, a primary power converter unit and an auxiliary power converter unit. The primary power converter unit is electrically coupled to the generator. The primary power converter unit includes a rectifier connected to the generator and an inverter electrically connected to the rectifier by a Direct current (DC) link. Further, the auxiliary power converter unit is electrically connected to the DC bus within the primary power converter unit.

Abstract: A motor driver for driving a motor is disclosed. The motor driver has a first power bus, a first switching device coupled between the first power bus and a first terminal of the motor, a second power bus, a second switching device coupled between the second power bus and a second terminal of the motor, and an integrated braking chopper coupled between the first and second power buses. The integrated braking chopper is configured to dissipate an extra power generated by the motor.

Abstract: A modular inverter unit for an inverter for generating an alternating current (AC) output based on a direct current (DC) input is disclosed. The modular inverter unit includes an input terminal configured to receive the DC input. The modular inverter unit further includes a power semiconductor device communicably coupled to the input terminal and encapsulated within a potting material. The power semiconductor device is configured to generate the AC output. The modular inverter unit further includes an output terminal communicably coupled to the power semiconductor device and configured to supply the AC output.

Abstract: A motor driver for driving a motor is disclosed. The motor driver has a first power bus, a first switching device coupled between the first power bus and a first terminal of the motor, a second power bus, a second switching device coupled between the second power bus and a second terminal of the motor, and an integrated braking chopper coupled between the first and second power buses. The integrated braking chopper is configured to dissipate an extra power generated by the motor.

Abstract: An electrical power supply system for a machine is provided. The electrical power supply system includes a generator, a primary power converter unit and an auxiliary power converter unit. The primary power converter unit is electrically coupled to the generator. The primary power converter unit includes a rectifier connected to the generator and an inverter electrically connected to the rectifier by a Direct current (DC) link. Further, the auxiliary power converter unit is electrically connected to the DC bus within the primary power converter unit.

Abstract: A power system includes a prime mover drivingly connected to an electric motor/generator. The power system may also include a first electrical energy storage device and a second electrical energy storage device. The power system may further include power-system controls configured to selectively start the prime mover by selectively charging the first electrical energy storage device with electricity from the second electrical energy storage device and transmitting electricity from the first electrical energy storage device to the electric motor/generator to operate the electric motor/generator as an electric motor to start the prime mover.