Abstract: A paving machine for laying a mat of paving material on a paving surface includes a generator, such as a switched reluctance generator, integrally installed with a pump drive and operatively connected to an output shaft of a power source of the paving machine. The generator outputs AC power to a power converter that in turn outputs DC power for a plurality of screed heating elements to produce heat to warm a screed. The paving machine may also include an insulation monitoring system for determining the occurrences of ground faults in the electrical components by comparing current levels in the components to a predetermined maximum current level. A controller of the paving machine may monitor the temperature of the generator and produce the speed of the power source to prevent overheating.

Abstract: A power electronics system configured to determine a condition of a winding insulation is disclosed. The system may include at least one capacitor, and a first resistance coupled to the at least one capacitor. The system may further include a plurality of electronic switching devices coupled to at least the first resistance and the at least one capacitor, wherein the plurality of electronic switching devices are configured to selectively couple the at least one capacitor to a power source to charge the at least one capacitor during a first time interval and selectively couple the at least one capacitor to a second resistance during a second time interval. The system may further include a voltage measuring device configured to detect a change in voltage at a terminal of the at least one capacitor in response to the selective coupling of the at least one capacitor to the second resistance.

Abstract: A high voltage wiring system for an electric powertrain is disclosed. The system includes a power conversion unit sealed in a first enclosure. The system also includes at least one second enclosure configured to be sealed and having at least one cable disposed therein. The disclosed system further includes a plurality of wiring termination compartments configured to provide a plurality of electrical termination points. The plurality of wiring termination compartments are separately encased in a material configured to provide a sealed barrier between an outside environment and the plurality of electrical termination points. The disclosed system further includes a source of at least one pressurized gas configured to substantially prevent the ingress of moisture into the first enclosure, the at least one second enclosure, and the plurality of wiring termination compartments.

Abstract: A power converter control system for electric powertrains is disclosed. The power converter control system may include at least one power producing device and at least one power consuming device. The power converter control system may further include at least one power electronics module configured to convert and condition a flow of electrical current between the at least one power producing device and the at least one power consuming device. The at least one power electronics module may further be configured to serialize a flow of a first set of signals between the at least one power electronics module and at least one controller. The first set of signals may correspond to at least one characteristic of the at least one power electronics module.

Abstract: A testing system for a ground fault detection system of an electrical system of a machine is disclosed. The testing system has a low voltage power source, the low voltage power source capable of operation that is independent from a high voltage power source of the machine. The testing system also has a variable current source that is permanently connected to a positive voltage bus or to a negative voltage bus of the electrical system of the machine, where the machine operates self-sufficiently. The testing system also has a controller connected to the variable current source. The testing system also has an input device, where the input device is connected to the controller.

Abstract: Systems and methods are disclosed for detecting a faulty ground strap connection for a machine hosting a high voltage system. In one embodiment, a fault detection and compensation system includes a ground strap, a DC power supply electrically referenced to a machine frame, a leakage detection switch connected to the machine frame, a current source controlled by the leakage detection switch, and a voltage measuring device that measures an offset voltage. The fault detection and compensation system further includes a leakage detection and compensation controller that compensates for the unbalanced fault condition by controlling the leakage detection switch and the current source, and determines whether the ground strap is properly connected to the machine frame.

Abstract: Systems and methods are disclosed for detecting high-voltage levels associated with a work machine. In one embodiment a high-voltage detection system is disclosed and includes a threshold detector configured to determine a voltage level associated with an element, determine whether the voltage level associated with the element is greater than a predetermined threshold value, and provide a threshold indicator if the voltage level associated with the element is greater than the predetermined threshold value. The system also includes a controller coupled to the threshold detector via an isolation device. The controller is configured to detect the threshold indicator and provide one or more warning signals in response to the threshold indicator.

Abstract: Systems and methods are disclosed for compensating electrical leakage and detecting balanced electrical leakage for a machine hosting an HV system. In one embodiment, a fault detection and compensation system includes a DC power supply electrically referenced to a machine frame, a leakage correction switch connected to the machine frame, a current source controlled by the leakage correction switch, and a voltage measuring device that measures an offset voltage reflecting whether the HV system is in an unbalanced fault condition. The fault detection and compensation system further includes a leakage detection and compensation controller that compensates for the unbalanced fault condition by controlling the leakage correction switch and the current source.

Abstract: A power electronics system configured to determine a condition of a winding insulation is disclosed. The system may include at least one capacitor, and a first resistance coupled to the at least one capacitor. The system may further include a plurality of electronic switching devices coupled to at least the first resistance and the at least one capacitor, wherein the plurality of electronic switching devices are configured to selectively couple the at least one capacitor to a power source to charge the at least one capacitor during a first time interval and selectively couple the at least one capacitor to a second resistance during a second time interval. The system may further include a voltage measuring device configured to detect a change in voltage at a terminal of the at least one capacitor in response to the selective coupling of the at least one capacitor to the second resistance.

Abstract: A power converter control system for electric powertrains is disclosed. The power converter control system may include at least one power producing device and at least one power consuming device. The power converter control system may further include at least one power electronics module configured to convert and condition a flow of electrical current between the at least one power producing device and the at least one power consuming device. The at least one power electronics module may further be configured to serialize a flow of a first set of signals between the at least one power electronics module and at least one controller. The first set of signals may correspond to at least one characteristic of the at least one power electronics module.

Abstract: A high voltage wiring system for an electric powertrain is disclosed. The system includes a power conversion unit sealed in a first enclosure. The system also includes at least one second enclosure configured to be sealed and having at least one cable disposed therein. The disclosed system further includes a plurality of wiring termination compartments configured to provide a plurality of electrical termination points. The plurality of wiring termination compartments are separately encased in a material configured to provide a sealed barrier between an outside environment and the plurality of electrical termination points. The disclosed system further includes a source of at least one pressurized gas configured to substantially prevent the ingress of moisture into the first enclosure, the at least one second enclosure, and the plurality of wiring termination compartments.

Abstract: A testing system for a ground fault detection system of an electrical system of a machine is disclosed. The testing system has a low voltage power source, the low voltage power source capable of operation that is independent from a high voltage power source of the machine. The testing system also has a variable current source that is permanently connected to a positive voltage bus or to a negative voltage bus of the electrical system of the machine, where the machine operates self-sufficiently. The testing system also has a controller connected to the variable current source. The testing system also has an input device, where the input device is connected to the controller.

Abstract: Systems and methods are disclosed for detecting a faulty ground strap connection for a machine hosting a high voltage system. In one embodiment, a fault detection and compensation system includes a ground strap, a DC power supply electrically referenced to a machine frame, a leakage detection switch connected to the machine frame, a current source controlled by the leakage detection switch, and a voltage measuring device that measures an offset voltage. The fault detection and compensation system further includes a leakage detection and compensation controller that compensates for the unbalanced fault condition by controlling the leakage detection switch and the current source, and determines whether the ground strap is properly connected to the machine frame.

Abstract: Systems and methods are disclosed for detecting balanced electrical leakage between a power source and a machine frame. In one embodiment, a balanced fault detection system for a machine includes a power source that is electrically insulated from a machine frame and a leakage detection switch that is connected to a ground. The balanced fault detection system also includes a leakage detection resistor that is interposed between a power source terminal and the switch having a leakage detection resistance. The balanced fault detection system further includes a voltage measuring device that measures voltages of the power source at positive and negative voltage sides of the ground and a leakage calculator that calculates a leakage resistance of the machine based on the measured voltages at the positive and negative voltage sides and the leakage detection resistance.

Abstract: Systems and methods are disclosed for compensating electrical leakage and detecting balanced electrical leakage for a machine hosting an HV system. In one embodiment, a fault detection and compensation system includes a DC power supply electrically referenced to a machine frame, a leakage correction switch connected to the machine frame, a current source controlled by the leakage correction switch, and a voltage measuring device that measures an offset voltage reflecting whether the HV system is in an unbalanced fault condition. The fault detection and compensation system further includes a leakage detection and compensation controller that compensates for the unbalanced fault condition by controlling the leakage correction switch and the current source.

Abstract: Systems and methods are disclosed for detecting balanced electrical leakage between a power source and a machine frame. In one embodiment, a balanced fault detection system for a machine includes a power source that is electrically insulated from a machine frame and a leakage detection switch that is connected to a ground. The balanced fault detection system also includes a leakage detection resistor that is interposed between a power source terminal and the switch having a leakage detection resistance. The balanced fault detection system further includes a voltage measuring device that measures voltages of the power source at positive and negative voltage sides of the ground and a leakage calculator that calculates a leakage resistance of the machine based on the measured voltages at the positive and negative voltage sides and the leakage detection resistance.

Abstract: An integrated motor monitoring system includes a housing and a motor disposed within the housing, the motor being configured to provide a power output. The integrated motor monitoring system also includes at least one monitoring device communicatively coupled to the motor and configured to monitor an operational aspect of the motor and generate a data signal associated with the operational aspect. The integrated motor monitoring system further includes a controller, disposed within the housing and in communication with the at least one monitoring device, and configured to energize a plurality of field conductors of the motor and receive the data signal from the at least one monitoring device over at least one of the plurality of field conductors.

Abstract: An electric motor control system includes a housing and a motor disposed within the housing. The electric motor control system also includes an actuator operatively coupled to the motor and configured to operate in response to an operation of the motor. The electric motor control system further includes a controller disposed within the housing and communicatively coupled to the motor. The electric motor control system also includes a first electric conductor communicatively coupling the motor to the controller, wherein the controller is configured to supply power to and communicate a data signal with the motor over the first electric conductor.

Abstract: An integrated cooling system includes a housing and a pumping device disposed within the housing, configured to pressurize a fluid. The cooling system also includes a motor disposed within the housing and operatively coupled to the pumping device. The cooling system further includes a first cooling circuit configured to receive the pressurized fluid and circulate the pressurized fluid through at least one component external to the housing. The cooling system also includes a second cooling circuit in fluid communication with the first cooling circuit, and configured to direct at least a portion of the pressurized fluid through the motor.