Abstract: A voltage converter includes a set of series connected capacitors collectively configured to provide voltage to an inverter. The voltage converter includes a switchgear including rails and switches configured to energize the capacitors with energy from the rails. The voltage converter includes interleaved inductors having respective half bridge switches configured to energize the rails. The voltage converter includes a controller configured to operate the switches of the switchgear to energize less than all of the set. The switch operation is responsive to a request to change the DC link voltage.

Abstract: A computer includes a processor; and a memory. The memory stores instructions executable by the processor to determine, based on a measurement performed in a vehicle, that a parameter of a power device is outside of a predetermined range; and actuate components in the vehicle to heat the power device.

Abstract: A vehicle powertrain has a power inverter that includes a load switch with a main emitter and a current mirror emitter, a variable resistor coupled between the current mirror emitter and the main emitter, and a controller. The controller may be configured to adjust a gate voltage based on a voltage across the variable resistor, and responsive to the gate voltage exceeding a Miller plateau gate voltage, increase a variable resistor resistance such that feedback increases as the load switch saturates.

Abstract: A vehicle powertrain includes a variable voltage converter, a bypass diode and a controller. The bypass diode may be coupled in parallel with the converter and configured to clamp an output of the converter to a battery voltage. The controller may be configured to, while in a boost mode and in response to a rate of change of a converter inductor current exceeding a boost threshold, open switches of the converter to divert propulsive energy through the bypass diode. The controller may also be configured to, while in buck mode and in response to a magnitude of a converter inductor current exceeding a buck threshold, open switches of the converter to divert regenerative energy through the bypass diode, while reversed biased, to the battery.

Abstract: A vehicle may include an electric drive system including switches having gates configured to control the switches. The vehicle may include a galvanic isolation coupling having a primary side electrically connected with an input power source and a secondary side electrically connected with a gate driver circuit. The gat driver circuit has a controller configured to actuate the gates and a power supply circuit electrically connected to the controller to provide backup power. The galvanic isolation coupling may be a flyback converter.

Abstract: A powertrain for a vehicle includes a Y-wound generator, a Y-wound motor, a generator inverter, a motor inverter, and a traction battery. The Y-wound generator and Y-wound motor are coupled via each respective neutral terminal. The generator inverter is coupled between the Y-wound generator and a generator bus and the motor inverter is coupled between the Y-wound motor and a motor bus. The traction battery has a first terminal coupled to each neutral terminal and a second terminal coupled to bus terminals of the generator and motor bus.

Abstract: A powertrain for a vehicle includes an electric machine and a controller. The electric machine has electrically isolated windings and is coupled with an inverter. The controller may be programmed to configure respective terminals of the windings to form a Y-connection, and responsive to an electrical connection between the vehicle and a 3-phase power grid, reconfigure the respective terminals such that each is coupled to a respective phase of the 3-phase power grid.

Abstract: A power system has a single-side-cooled power module including a contiguous five-layer substrate of two insulative layers interleaved with three conductive layers. A center one of the conductive layers is partitioned to define discrete spaced apart positive terminal and output terminal portions, and an outer of the conductive layers defines a negative terminal portion such that the positive terminal and negative terminal portions overlap. The power system also has semiconductors respectively in direct contact with the positive terminal and output terminal portions without directly contacting the other layers.

Abstract: A gate driver of a power device includes a power supply and a resonant circuit. The power supply may have a positive potential and a negative potential. The resonant circuit may include an inductor and be configured to recirculate charge during turn-off by inducing a first field based on a positive charge from a gate caused by the positive potential, and in response to reversal of a voltage across the inductor, collapsing the first field to draw charge from the gate.

Abstract: A power module includes power switching devices that are electrically coupled in parallel to increase current capacity. The paralleled power switching devices are triggered by a common gate signal. Each of the power switching devices include a gate terminal, a current-sense terminal, and a Kelvin source/emitter terminal. The power module includes a plurality of magnetically coupled windings coupling the gate terminal, the current-sense terminal and the Kelvin source/emitter terminal of each of the switching devices to a gate driver circuit.

Abstract: A vehicle includes an inverter having a supply bus including a contactor operable to conduct current through a resistive element connected to a capacitive element having a voltage supplied by a battery. The vehicle includes a controller configured to energize a first gate of the inverter. The energization is responsive to the voltage exceeding a threshold. The controller is configured to detect current flow between a first phase associated with the gate and the bus based on a voltage drop associated with the voltage.

Abstract: A vehicle includes an inverter connected to an energy store having a variable output voltage and including a first pair of battery partitions. The vehicle includes a controller configured to operate a first set of switches to arrange electrical connections between the first pair such that the variable output voltage is greater than battery voltage of a one of the battery partitions. The operation of switches is responsive to a parameter indicative of speed of an electric machine electrically coupled to the inverter exceeding a first predetermined threshold.

Abstract: A vehicle power system may include a gate driver configured to drive a traction gate and a generator gate corresponding to switches of a variable voltage controller such that the gates have alternating pulse width modulation ON periods. The gates may be driven in response to a throughput magnitude falling below a threshold. The gate driver may be further configured to drive the gates such that a duty cycle of one of the gates is zero in response to the throughput exceeding the threshold.

Abstract: A vehicle powertrain includes a power inverter and a controller. The power inverter includes a load switch monolithically integrated with a mirror switch, and a current sensor configured to measure current through the load switch to provide current feedback for vector control of a motor. The controller may be configured to, responsive to a difference between a mirror current of the mirror switch and an output of the current sensor resulting from temperature changes of the load switch, operate the power inverter to reduce a temperature of the load switch.

Abstract: A powertrain for a vehicle may include a variable voltage converter (VVC), and a controller. The VVC may include an inductor, a bus capacitor and a flying capacitor. The controller may be configured to, in response to a power demand signal exceeding a threshold, modulate switches of the VVC such that an inductor current created by a collapsing field of the inductor is directed into the flying capacitor or the bus capacitor such that a bus capacitor voltage exceeds a flying capacitor voltage, and in response to the power demand signal dropping below the threshold, modulate switches such that the flying capacitor and the bus capacitor are coupled in parallel.

Abstract: A vehicle powertrain includes a switch configured to provide a drive current to an electric machine and coupled with a diode array and a gate driver. The gate driver may be configured to, in response to a voltage across the array exceeding a threshold while providing the drive current in a presence of a turn-off request, confine operation of a resistive switch to a linear region to decrease a rate of change of the drive current proportional to the voltage.

Abstract: A power module provides one or more power transistors and support elements in a card shape. The pins/terminals for signal-level input/outputs (e.g., gate drive, current sensor, and temperature sensor signals) are arranged in two parallel layers. The power terminals (e.g., positive and negative bus, and output junction of a phase leg) are preferably arranged in just one of the layers. The signal pins are spaced both laterally across a long edge of the power module and transversely to the edge direction, so that the minimum spacings (i.e., clearances) can be achieved while shortening the lateral length of the edge(s) of the power module. Preferably, the signal pins belonging to an individual power transistor (e.g., an IGBT or MOSFET) are distributed between the two layers so that corresponding signal loops can be magnetically decoupled from the power terminal loop.

Abstract: A power device supply includes an inverter, a converter, and a cooling system. The inverter is configured to convert direct electrical current into alternating electrical current. The converter has an inductor and is configured to amplify voltage. The cooling system has top, bottom, and intermediate cooling plates. The cooling system is arranged such that the inverter and inductor are interleaved with the plates and such that the inverter and inductor are disposed on opposing sides of the intermediate cooling plate.

Abstract: A system of one or more computers can be configured to perform particular operations or actions by virtue of having software, firmware, hardware, or a combination of them installed on the system that in operation causes or cause the system to perform the actions. One or more computer programs can be configured to perform particular operations or actions by virtue of including instructions that, when executed by data processing apparatus, cause the apparatus to perform the actions. One general aspect includes a series-parallel electric vehicle drive system, including a controller commutatively coupled to at least one inverter circuit with a serial insulated gate bipolar transistor (IGBT) and a parallel IGBT. The system includes a dc power source connected to an inverter circuit and a winding of a motor connected to an output of the invert circuit, wherein the inverter circuit generates a motor control signal.

Abstract: A vehicle system in a hybrid vehicle comprises a controller configured to generate for output a modulated voltage to a direct current capacitor to prevent voltage spikes on the capacitor in response to receiving a reference current via a direct current voltage clamping control block that outputs a reference current in response to a difference between a feedback voltage and a reference voltage exceeding a threshold.