Abstract: Systems are provided for a cooling system for an electric vehicle. In one example, a system includes a plate arranged between separate circuit boards. The plate directly cools one of the circuit boards and block thermal communication between the circuit boards.

Abstract: Methods and systems for a dielectric material coated busbar are provided. In one example, a conductive material may be formed into a shape of a busbar and portions of the busbar may be selectively coated with a dielectric material which may be both electrically insulating and thermally conductive. The dielectric coated portions of the busbar may dissipate heat to a heat sink via a thermal interface material compressed on the busbar.

Abstract: Methods and systems for a dielectric material coated busbar are provided. In one example, a conductive material may be formed into a shape of a busbar and portions of the busbar may be selectively coated with a dielectric material which may be both electrically insulating and thermally conductive. The dielectric coated portions of the busbar may dissipate heat to a heat sink via a thermal interface material compressed on the busbar.

Abstract: A system is shown for cooling components of an inverter. In one example, an inverter comprises a first compartment including a direct current (DC) link capacitor that is electrically coupled to a discharge resistor; and a thermal pad in contact with the DC link capacitor; a cooling system configured to circulate coolant through a housing adjacent to the thermal pad; and a noise filtering ferrite element coupled to a DC bus bar. A cooling plate may be further included between the DC link capacitor and the thermal pad and during a during a first condition when the inverter is operating, heat is transferred from the DC link capacitor to the cooling system; and during a second condition when the inverter is not operating, heat is reduced in the DC link capacitor by discharging electricity stored in the DC link capacitor via the discharge resistor.

Abstract: Systems are provided for a cooling system for an electric vehicle. In one example, a system includes a plate arranged between separate circuit boards. The plate directly cools one of the circuit boards and block thermal communication between the circuit boards.

Abstract: An inverter assembly including a phase-control chamber and a direct current (DC) chamber. The phase-control chamber includes a direct current (DC) link capacitor electrically connected a control circuit board via multiple connectors. The DC chamber includes a ferrite filter fixed to a DC bus bar via a support component.

Abstract: The present disclosure is concerned with bus bars that are provided with protrusions that allow them to be brought directly or indirectly in contact with a cooling system to remove heat generated in the bus bars themselves. The disclosure further provides a method of cooling a bus bar. The method includes providing at least one bus bar with at least one protrusion, and connecting the at least one protrusion to a cooling element.

Abstract: An inverter is provided that includes a direct current (DC) bus bar assembly positioned within a DC chamber in the housing is provided herein. The inverter further includes a gate-driver circuit board included in a phase-control chamber in the housing, and an external communication interface in electronic communication with a power control circuit board and positioned in an external communication chamber in the housing. The DC chamber, the phase-control chamber, and the external communication chamber have varying levels of electromagnetic interference (EMI).

Abstract: An inverter is provided herein. The inverter includes, in one example, a direct current (DC) bus bar assembly electrically connected to a capacitor and a current sensor and an electromagnetic interference (EMI) filtering capacitor on a circuit board. The inverter further includes a power module electrically coupled to a capacitor and an alternating current (AC) bus bar assembly, where the AC bus bar assembly includes multiple phase bus bars.

Abstract: Methods and systems are provided for a power module. In one example, the power module may have a half-bridge configuration with electrical terminals arranged at opposite side of the power module, semiconductor chips arranged in a printed circuit board (PCB), a capacitor electrically coupled to the electrical terminals and arranged above and in contact with a top plate of the power module, and one or more connectors coupled to the PCB to couple the power module to external circuits. The power module may be directly cooled by flowing a coolant over the semiconductor chips.

Abstract: Methods and systems are provided for an electric heavy-duty vehicle. In one example, the vehicle includes a battery pack for supplying current to an electric motor of the vehicle, the battery pack arranged in a chassis of the vehicle and configured to form part of a floor of the vehicle. The vehicle also includes a motor coupled to front wheels of the vehicle, the front wheels having hub assemblies housing drive shaft adapters configured to permanently couple the hub assemblies to drive shafts of the front wheels, and a cradle configured to be mounted with electrical sub-systems of the vehicle.

Abstract: Methods and systems are provided for an electric heavy-duty vehicle. In one example, the vehicle includes a battery pack for supplying current to an electric motor of the vehicle, the battery pack arranged in a chassis of the vehicle and configured to form part of a floor of the vehicle. The vehicle also includes a motor coupled to front wheels of the vehicle, the front wheels having hub assemblies housing drive shaft adapters configured to permanently couple the hub assemblies to drive shafts of the front wheels, and a cradle configured to be mounted with electrical sub-systems of the vehicle.

Abstract: Methods and systems are provided for a power module. In one example, the power module may have a half-bridge configuration with electrical terminals arranged at opposite side of the power module, semiconductor chips arranged in a printed circuit board (PCB), a capacitor electrically coupled to the electrical terminals and arranged above and in contact with a top plate of the power module, and one or more connectors coupled to the PCB to couple the power module to external circuits. The power module may be directly cooled by flowing a coolant over the semiconductor chips.

Abstract: Methods and systems are provided for an electric heavy-duty vehicle. In one example, the vehicle includes a battery pack for supplying current to an electric motor of the vehicle, the battery pack arranged in a chassis of the vehicle and configured to form part of a floor of the vehicle. The vehicle also includes a motor coupled to front wheels of the vehicle, the front wheels having hub assemblies housing drive shaft adapters configured to permanently couple the hub assemblies to drive shafts of the front wheels, and a cradle configured to be mounted with electrical sub-systems of the vehicle.

Abstract: An electric machine is described herein. The electric machine includes a casing, a stator, a rotor generally coaxial with the stator, an enclosed cooling assembly circulating a first cooling fluid within the casing, and an open cooling assembly through which a second cooling assembly can flow; the open cooling assembly cooling both the stator and the first cooling fluid.

Abstract: A multiphase connector for electric powertrain systems includes a terminal block and a plug member that are, at least in part, made from electrically conductive metal. The terminal block has at least one socket surrounding a retaining spring and the plug member has at least one contact pin configured to be inserted in to the at least one socket. The plug member can be engaged with the terminal block without use of installation tools and includes one or more cable gland assembly in contact with a shield of a shielded cable.

Abstract: Methods and systems for a dielectric material coated busbar are provided. In one example, a conductive material may be formed into a shape of a busbar and portions of the busbar may be selectively coated with a dielectric material which may be both electrically insulating and thermally conductive. The dielectric coated portions of the busbar may dissipate heat to a heat sink via a thermal interface material compressed on the busbar.

Abstract: The present disclosure is concerned with bus bars that are provided with protrusions that allow them to be brought directly or indirectly in contact with a cooling system to remove heat generated in the bus bars themselves. The disclosure further provides a method of cooling a bus bar. The method includes providing at least one bus bar with at least one protrusion, and connecting the at least one protrusion to a cooling element.

Abstract: A multiphase connector for electric powertrain systems includes a terminal block and a plug member that are, at least in part, made from electrically conductive metal. The terminal block has at least one socket surrounding a retaining spring and the plug member has at least one contact pin configured to be inserted in to the at least one socket. The plug member can be engaged with the terminal block without use of installation tools and includes one or more cable gland assembly in contact with a shield of a shielded cable.

Abstract: An electric machine is described herein. The electric machine includes a casing, a stator, a rotor generally coaxial with the stator, an enclosed cooling assembly circulating a first cooling fluid within the casing, and an open cooling assembly through which a second cooling assembly can flow; the open cooling assembly cooling both the stator and the first cooling fluid.