Abstract: An energy storage system includes a plurality of batteries coupled in series, a plurality of first isolated DC-DC power converters each having first and second sides, a DC bus coupled to the second sides of the plurality of first isolated DC-DC power converters, and a second isolated DC-DC power converter coupled in parallel with the plurality of first isolated DC-DC power converters. Each of the first sides of the plurality of first isolated DC-DC power converters is coupled to at least one of the batteries. The second isolated DC-DC power converter includes a first side coupled to the plurality of batteries and a second side coupled to the DC bus. The second isolated DC-DC power converter is configured to mitigate a transient load condition on the DC bus.

Abstract: A battery system for a vehicle includes multiple battery cells each configured to store charge for powering an electric vehicle, a high voltage bus electrically coupled with the multiple battery cells to provide power to an electric motor, and multiple cell monitoring modules each coupled with a corresponding one of the multiple battery cells, each cell monitoring module including a controller configured to monitor operation parameters of the corresponding one of the multiple battery cells. The system includes multiple DC-DC converters in a converter housing, each DC-DC converter electrically coupled with a corresponding one of the multiple battery cells outside of the converter housing, and a low voltage bus electrically connected between the multiple DC-DC converters in the converter housing and at least one vehicle electrical component outside of the converter housing. The low voltage bus is configured to provide low voltage power to at least one vehicle electrical component.

Abstract: A charging system includes a scalable power source for powering a motor of a vehicle and telematics and battery management modules. The scalable power source includes: N battery packs, where N is an integer greater than or equal to 3; and multiple switches connected to the N battery packs including N?1 switches for serially connecting the N battery packs between supply and return lines and a multiple of N switches for parallel connecting the N battery packs to the supply and return lines. The telematics module requests capability of a charging station and receives a response signal from a device indicating the capability of the charging station. The battery management module: based on the capability of the charging station, selects one of the available arrangements in which to connect the N battery packs, sets states of the multiple switches; and then charges the N battery packs based on the states.

Abstract: Aspects of the disclosure include a power module having enhanced thermal management. An exemplary power module can include a direct bond copper (DBC) substrate having a top copper layer, a bottom copper layer, and a dielectric layer between the top copper layer and the bottom copper layer. The power module includes a thin-film thermoelectric cooler (TFTEC) having a thermoelectric film positioned between a top insulator and a bottom insulator. One or more dies are positioned over the DBC substrate and the TFTEC and a controller is configured to adjust a thermoelectric device current of the TFTEC responsive to a temperature of the one or more dies.

Abstract: An electrified vehicle may include a plurality of electric drive units, a plurality of battery packs, a plurality of charge ports and a plurality of controllable switches. The switches may be controlled to flexibly configure power transfer into and out of the vehicle through one or more charge ports affecting one or more battery packs in parallel or individually passively or actively through inverter integrated converter charge transfer.

Abstract: A battery system for a vehicle includes multiple battery cells each configured to store charge for powering an electric vehicle, a high voltage bus electrically coupled with the multiple battery cells to provide power to an electric motor, and multiple cell monitoring modules each coupled with a corresponding one of the multiple battery cells, each cell monitoring module including a controller configured to monitor operation parameters of the corresponding one of the multiple battery cells. The system includes multiple DC-DC converters in a converter housing, each DC-DC converter electrically coupled with a corresponding one of the multiple battery cells outside of the converter housing, and a low voltage bus electrically connected between the multiple DC-DC converters in the converter housing and at least one vehicle electrical component outside of the converter housing. The low voltage bus is configured to provide low voltage power to at least one vehicle electrical component.

Abstract: A battery electric system for a motor vehicle or another electrified system includes a battery pack connected to a direct current voltage bus, and having positive and negative battery terminals, a main pyrotechnic fuse (“pyro fuse”), a high-voltage (HV) component connected to the bus via an HV channel, a current sensing element connected to the HV component on the HV channel, and a control system configured to selectively disconnect the battery pack from the bus by transmitting a voltage signal to the main pyro fuse when a measured current value from the current sensor is indicative of a short-circuit fault. A channel switch may be connected to or integral with the current sensing element, and configured to disconnect the HV component from the bus by opening in response to the measured current value.

Abstract: A method includes: selectively actuating switches of an inverter module and first, second, third, and fourth switches of a motor; and charging a battery with power from a charger using at least one of first, second, and third stator windings of the motor, the battery having a first voltage and being electrically connected in parallel with the inverter module, and the charger having a second voltage that is less than the first voltage.

Abstract: A charging system of a vehicle includes an inverter of a propulsion system, the inverter connected to an electric motor and a battery system of the vehicle, and a switching assembly including a plurality of switches. The charging system also includes a controller configured to control the switching assembly to connect the inverter and the electric motor to a charge port of the vehicle and define a conversion circuit including one or more inverter switches and the electric motor by selectively connecting the charge port to the inverter or the electric motor and selectively connecting the battery system to the electric motor by the switching assembly. The controller is configured to operate the conversion circuit to adjust at least one of an input voltage for charging the battery system from a power source, and an output voltage for discharging the battery system to charge an external energy storage system.

Abstract: An electric vehicle includes an electrical system and performs a method of charging the electric vehicle. The electrical system includes a first battery subpack, a second battery subpack, wherein the first battery subpack, the second battery subpack, and an electrical load of the electric vehicle are connected in parallel, and a processor. The processor is configured to control a first connection between the first battery subpack and a first charge port and a second connection between the second battery subpack and a second charge port to charge each of the first battery subpack and the second battery subpack while providing power to the electrical load.

Abstract: A battery system includes a plurality of battery modules electrically connected in series. Each of the battery modules includes: one or more battery cells; a first switch connected between a positive reference potential of the one or more battery cells and a first node; and a second switch connected between the first node and a second node, where a negative reference potential of the one or more battery cells is connected to the second node. A management module is configured to: selectively close the first switches of the battery modules while the second switches are open; and selectively close the second switch of one of the battery modules while the first switch of the one of the battery modules is open.

Abstract: A power control system comprises a battery system including N battery packs. A plurality of contactors selectively connects N battery packs of a battery system in a first configuration supplying a first voltage level, a second configuration supplying a second voltage level, and a disconnected configuration. M power inverters connect the battery system to M electric machines, respectively. A controller is configured to determine when to transition between the first configuration and the second configuration. The controller is configured to transition between the first configuration and the second configuration by causing one of a positive torque transient and a negative torque transient to be generated by at least one of the M electric machines, transitioning the battery system from one of the first configuration and the second configuration to the disconnected configuration, and transitioning from the disconnected configuration to the other one of the first configuration and the second configuration.

Abstract: An electrified vehicle may include a plurality of electric drive units, a plurality of battery packs, a plurality of charge ports and a plurality of controllable switches. The switches may be controlled to flexibly configure power transfer into and out of the vehicle through one or more charge ports affecting one or more battery packs in parallel or individually passively or actively through inverter integrated converter charge transfer.

Abstract: An example of a vehicle electrical system includes a rechargeable energy storage system (RESS) having a first voltage and a power inverter electrically connected to the RESS. The system further includes an electric motor having a plurality of machine windings with each of the machine windings including a polyphase terminal electrically connected to the power inverter. The electric motor further includes a neutral terminal separate from the polyphase terminals. The system further includes an accessory load electrically connected to the power inverter and the neutral terminal of the electric motor, with the accessory load requiring a second voltage that is below the first voltage. A current flows through the machine windings to step down the first voltage to the second voltage. The power inverter is configured to cycle between first and second operational states, such that the power inverter steps down the first voltage to the second voltage.

Abstract: A method for charging a battery pack via an offboard energy source uses an interleaved boost converter and closed-loop control. The energy source outputs a charging current via a DC charge port during a direct current fast-charging (DCFC) process. A controller detects a voltage disparity condition in which a voltage capability of the battery pack exceeds a voltage capability of the energy source. In response to this condition, a rise of the charging current over time is recorded as a current trajectory and an open-loop equivalent time constant is extracted from the current trajectory. A time constant of the PI control block is set substantially equal to the equivalent time constant. The PIM is controlled in closed-loop using proportional-integral control. The charging current is controlled in a continuous current conduction mode during the DCFC process.

Abstract: A system for use with a direct current fast-charging (DCFC) station includes a controller and battery system. The battery system includes first and second battery packs, and first, second, and third switches. The switches have ON/OFF conductive states commanded by the controller to connect the battery packs in a parallel-connected (P-connected) or series-connected (S-connected) configuration. An electric powertrain with one or more electric machines is powered via the battery system. First and second charge ports of the system are connectable to the station via a corresponding charging cable. The first charge port receives a low or high charging voltage from the station. The second charge port receives a low charging voltage. When the station can supply the high charging voltage to the first charge port, the controller establishes the S-connected configuration via the switches, and thereafter charges the battery system solely via the first charge port.

Abstract: A charging system of a vehicle includes a first conversion device of a first drive system of the vehicle, the first conversion device connected to a first electric motor. The system also includes a second conversion device of a second drive system of the vehicle, the second conversion device connected to a second electric motor. The first drive system and the second drive system are connected to a battery system of the vehicle. The system also includes a switching assembly including a plurality of switches configured to selectively connect the first electric motor and/or the second electric motor to a charge port of the vehicle, and a controller configured to control the switching assembly to define a conversion circuit that includes components of the first drive system and/or the second drive system, and control the conversion circuit to regulate an output voltage and supply power to an energy storage system.

Abstract: A battery charging system includes: an electric motor including stator coils; a battery; a charge port configured to receive power from charging stations by wire; first and second electrical conductors connected between the battery and the charge port; an inverter module including (a) inputs connected to receive power from the battery and (b) outputs connected to the electric motor; a third electrical conductor; and a switch configured to electrically connect and disconnect a first end of the third electrical conductor to and from the first electrical conductor, where the third electrical conductor includes a second end that is connected to at least one of the stator coils via one of the outputs of the inverter module.

Abstract: A system in a vehicle includes a first winding section including first two or more windings and a second winding section including second two or more windings. Each of the second two or more windings corresponds to one of the first two or more windings of the first winding section. The system also includes an inverter including a high side switch and a low side switch corresponding to each of the first two or more windings. The inverter is coupled to a battery of the vehicle and boosts a voltage of a direct current (DC) charger during charging of the battery with the DC charger, converts alternating current (AC) from an AC grid to DC during charging of the battery with the AC grid, and converts DC to AC during supply of the AC grid by the battery.

Abstract: A slew rate controllable system for powering an electric machine. The system may include a plurality of power transistors operable for converting a direct current (DC) input into an alternating current (AC) output suitable for electrically powering the electric machine. The system may further include a gate drive system operable for controlling a slew rate associated with transitioning the power transistors between the opened and closed states.