Abstract: An electric motor circuit includes a motor controller having a plurality of gate drivers and an inverter configured to receive direct current (DC) power from a source and output alternating current (AC) power to an electric motor. The inverter includes a plurality of transistor elements. Each transistor element includes multiple transistors arranged on a transistor board. Multiple temperature sensors are configured to monitor a plurality of temperatures on each transistor element. The motor controller is configured to alter a pulse width modulation (PWM) control of a first subset of transistors on a first transistor element in response to a first subset of temperature sensors detecting a temperature exceeding a threshold temperature and a second subset of temperature sensors not detecting a temperature exceeding the threshold.

Abstract: A multi-level inverter control system includes a power storage system having a high voltage terminal, a low voltage terminal, and an intermediate voltage terminal. The intermediate voltage terminal is at a voltage between the high voltage terminal and the low voltage terminal. A multi-level inverter includes a plurality of switches, a high voltage input connected to the high voltage terminal, a low voltage input connected to the low voltage terminal, and an intermediate voltage input connected to the intermediate voltage terminal. A controller is controllably coupled to the multi-level inverter. The controller includes at least a processor and a memory. The memory stores instructions configured to cause the controller to operate the multi-level inverter in a three-level inverter mode, a full power two-level inverter mode, a first partial power two-level inverter mode and a second partial power two-level inverter mode.

Abstract: A current sensing apparatus may include a common mode core surrounding two or more current conductors and a current sensing element proximate the common mode core.

Abstract: A power supply system for a vehicle is provided. The power supply system includes a high-voltage battery pack having a plurality of batteries, a primary isolated converter connected to the high-voltage battery pack, and a plurality of distributed isolated converters, each of the plurality of distributed isolated converters being connected to one of the plurality of batteries. Each of the distributed isolated converters includes a primary stage configured to receive power from one of the plurality of batteries and an isolated stage configured to provide power to a low-voltage bus. The bias signals configured to control the operation of each of the plurality of distributed isolated converters are powered by the connected one of the plurality of batteries and activated based on an enable signal provided by the primary isolated converter.

Abstract: A vehicle, slew rate control circuit and method of operating an electric motor of a vehicle. The slew rate control circuit is between a gate driver of the vehicle and an inverter of the vehicle. The slew rate control circuit includes a first branch between the gate driver and the inverter, wherein the inverter provides an electrical signal output to an electric motor of the vehicle, and a second branch between the gate driver and the inverter in parallel with the first branch, wherein current flows through the first branch during a first time period and through the second branch during a second time period, wherein the flow of the current controls a slew rate of the electrical signal output by the inverter to the electric motor.

Abstract: A vehicle includes a system for controller the vehicle. The vehicle includes a motor. The system includes an inverter, and a gate controller. The inverter has a switch for controlling current to the motor. The gate controller is configured to apply a gate current to the switch at a first on-current control level during a first switch-on stage of a turn-on operation of the switch, lower the gate current to a second on-current control level less than the first on-current control level during a second switch-on stage of the turn-on operation, and raise the gate current to a third on-current control level during a third switch-on stage of the turn-on operation, wherein the third on-current control level is greater than the second on-current control level.

Abstract: A vehicle includes two or more battery packs configured to power a motor. A controller is configured to dynamically activate an operational mode during operation. The operational mode is one of multiple possible operational modes including a first operational mode defining a series connection between the two or more battery packs and second operational mode defining a parallel connection between the two or more battery packs. The connection between the battery packs is controlled by a first plurality of switches. A plurality of low voltage loads are connected to a subset of the battery packs in the battery packs such that a power output of the subset of the battery packs provides full power to the plurality of low voltage loads. The plurality of low voltage loads are connected to only the subset of the battery packs in both the first operational mode and the second operational mode.

Abstract: A vehicle includes a system for charging a battery of the vehicle. An electric motor couples to a charging station. A T-bridge multi-level inverter couples the electric motor to the battery. The inverter includes a first leg having a first set of switches and a first AC terminal coupled to the electric motor, a second leg having a second set of switches and a second AC terminal coupled to the electric motor and a third leg having a third set of switches and a third AC terminal coupled to the electric motor. A processor connects the third AC terminal to the charging station and controls at least one of the first set of switches to control a first current through the first AC terminal of the first leg and the second set of switches to control a second current through second AC terminal of the second leg.

Abstract: A vehicle includes a system for charging a battery of the vehicle. An electric motor couples to a charging station. a diode-clamped multi-level inverter and a processor. A diode-clamped multi-level inverter couples the electric motor to the battery and includes a first leg having a first set of switches and a first AC terminal coupled to the electric motor, a second leg having a second set of switches and a second AC terminal coupled to the electric motor and a third leg having a third set of switches and a third AC terminal coupled to the electric motor. The processor connects the third AC terminal to the charging station and control at least one of the first set of switches to control a first current through the first AC terminal and the second set of switches to control a second current through the second AC terminal to charge the battery.

Abstract: A vehicle includes an inverter having a power module. The power module includes a high side bus, a low side bus and an alternating current (AC) output bus. The high side bus includes a first switch, wherein a high side current is configured to flow through the first switch in a first direction. The high side bus is disposed in a plane. The low side bus includes a second switch, wherein a low side current is configured to flow through the second switch in the first direction. The low side bus is parallel to the high side bus. The alternating current (AC) output bus is parallel to the high side bus and the low side bus, wherein an output current flows through the AC output bus in a second direction opposite to the first direction.

Abstract: A vehicle includes a system for charging a battery of the vehicle. The system includes an electric motor couplable to a charging station, a capacitor-clamped multi-level inverter, and a processor. The capacitor-clamped multi-level inverter is couples the electric motor to the battery and includes a first leg having a first set of switches and a first AC terminal coupled to the electric motor, a second leg having a second set of switches and a second AC terminal coupled to the electric motor and a third leg having a third set of switches and a third AC terminal coupled to the electric motor. The processor connects one of the third AC terminal and a neutral point of the electric motor to the charging station and control at least one of the first set of switches and the second set of switches to charge the battery through the electric motor.

Abstract: A power control system for an electric vehicle includes a power inverter comprising a switch module including a plurality of power switches, a controller board, and a gate driver board in communication with the controller board and configured to drive gates of the plurality of switches. A first housing is made of polymer composite, encloses the power inverter, defines a first cooling cavity in thermal communication with a first surface of the switch module, and encapsulates a portion of at least one of the switch module, the controller board and the gate driver board.

Abstract: A conversion system includes a conversion device including a multilevel inverter configured to generate two alternating current (AC) output currents, a current sensor configured to sample a current through the multilevel inverter, or from the multilevel inverter, during a switching cycle, and a processor configure to estimate both of the two AC output currents based on the sampled current from the current sensor.

Abstract: Multi-switch module packaging for a multilevel inverter is provided. A multilevel inverter is connected to the battery. The multilevel inverter includes three levels, each of the three levels having a first module and a second module. The first module is formed on a first insulating substrate material, and the second module is formed on a second insulating substrate material separate from the first insulating substrate material. The first module includes a first switch coupled to the battery via a positive power rail, a second switch coupled to the battery via a negative power rail, and a third switch coupled to the second module. The second module includes another first switch coupled to the battery, another second switch coupled to the battery, and another third switch coupled to the first module. The first module includes four terminals and the second module includes another four terminals.

Abstract: A multi-level inverter control system includes a power storage system having a high voltage terminal, a low voltage terminal, and an intermediate voltage terminal. The intermediate voltage terminal is at a voltage between the high voltage terminal and the low voltage terminal. A multi-level inverter includes a plurality of switches, a high voltage input connected to the high voltage terminal, a low voltage input connected to the low voltage terminal, and an intermediate voltage input connected to the intermediate voltage terminal. A controller is controllably coupled to the multi-level inverter. The controller includes at least a processor and a memory. The memory stores instructions configured to cause the controller to operate the multi-level inverter in a three-level inverter mode, a full power two-level inverter mode, a first partial power two-level inverter mode and a second partial power two-level inverter mode.

Abstract: A system includes an inverter configured to output multiphase alternating current (AC) currents to an electric motor, the multiphase AC currents including a first phase current and a second phase current, the inverter including a set of switches for each phase current. The system also includes a switching controller operably connected to each set of switches, the switching controller configured to control a gate driver connected to a switch of the set of switches, the switching controller configured to determine a time difference between a first switching event of a first phase and a second switching event of a second phase during a switching cycle, and control a switching speed of the switch based on the time difference.

Abstract: A cooling system for a drivetrain of an electric vehicle includes a coolant circuit directing a flow of coolant through a first inverter and a second inverter of the drivetrain, and an adjustable flow valve positioned along the coolant circuit to selectably alter proportions of the flow of coolant directed through each of the first inverter and the second inverter. A method of operating a cooling system for a first inverter and a second inverter of a vehicle drivetrain includes commanding a speed and torque of each of the first and second inverter, and estimating losses and temperature of each of the first inverter and the second inverter as a result of the commanded speed and torque. A valve position of an adjustable flow valve operably connected to the first inverter and the second inverter is selected, and a change of the valve position is commanded.

Abstract: A system includes an electronic device including a circuit having a semiconductor switch, and a switching control system operably connected to the semiconductor switch. The switching control system is configured to control a switching speed of the semiconductor switch based on a received voltage by altering at least one of a gate resistance and a gate capacitance of the semiconductor switch.

Abstract: An electric motor circuit includes a motor controller having a plurality of gate drivers and an inverter configured to receive direct current (DC) power from a source and output alternating current (AC) power to an electric motor. The inverter includes a plurality of transistor elements. Each transistor element includes multiple transistors arranged on a transistor board. Multiple temperature sensors are configured to monitor a plurality of temperatures on each transistor element. The motor controller is configured to alter a pulse width modulation (PWM) control of a first subset of transistors on a first transistor element in response to a first subset of temperature sensors detecting a temperature exceeding a threshold temperature and a second subset of temperature sensors not detecting a temperature exceeding the threshold.

Abstract: A vehicle includes two or more battery packs configured to power a motor. A controller is configured to dynamically activate an operational mode during operation. The operational mode is one of multiple possible operational modes including a first operational mode defining a series connection between the two or more battery packs and second operational mode defining a parallel connection between the two or more battery packs. The connection between the battery packs is controlled by a first plurality of switches. A plurality of low voltage loads are connected to a subset of the battery packs in the battery packs such that a power output of the subset of the battery packs provides full power to the plurality of low voltage loads. The plurality of low voltage loads are connected to only the subset of the battery packs in both the first operational mode and the second operational mode.