Abstract: After start of an electric drive system, a controller reduces power output of an inverter responsive to sensed temperature of a power switch of the inverter, sensed current of a power electronics module, sensed DC-link voltage, and thermal impedance parameters of a DC-link capacitor being indicative of an estimated temperature of the DC-link capacitor that is greater than a threshold to maintain DC-link capacitor temperature lower than the threshold.

Abstract: A variable voltage converter includes a pair of series connected switches, a series connected switch and inductor, and a capacitor having a terminal sharing a node with adjacent terminals of the series connected switches and another terminal sharing a node with adjacent terminals of the series connected switch and inductor such that during operation, a voltage input to the variable voltage converter and a voltage across the capacitor are same and less than a voltage output by the variable voltage converter.

Abstract: A vehicle power system includes an inverter electrically connected between a traction battery and electric machine, a three phase coupled inductor electrically connected between the traction battery and inverter, and one or more controllers that operate the inverter while a common mode voltage at a neutral point of the electric machine is constant.

Abstract: A power converter includes a pair of series connected switches and circuitry. The circuitry includes another switch and an optocoupler that activates responsive to changes in current through one of the series connected switches exceeding a predefined threshold. Activation of the optocoupler causes the another switch to conduct and reduce a gate voltage of the one of the series connected switches to reduce the changes in current through the one of the series connected switches.

Abstract: A power converter has a pair of series connected switches defining a phase leg, a pair of gate driver circuits that respectively provide power to gates of the series connected switches, a positive rail electrically connected with the phase leg, and a clamping circuit including a clamping switch. The clamping circuit, responsive to one of the gate driver circuits being de-energized, activates the clamping switch with energy from the positive rail to clamp a gate of one of the series connected switches associated with the one of the gate driver circuits to another terminal of the one of the series connected switches.

Abstract: A power system for a vehicle includes a traction battery having an output voltage, a transformer including a coil, and a power converter including a plurality of capacitors and a plurality of switches arranged such that when a first subset of the switches are ON, two of the capacitors are in parallel, an AC voltage across the coil is in a positive half cycle, and a voltage across each of the two of the capacitors is half the output voltage.

Abstract: This disclosure is directed to power systems for transferring power between electrical components. An exemplary power system includes a first electrical component (e.g., an inverter system) having a current sensor assembly for detecting current flowing between the first electrical component and a second electrical component (e.g., an electric motor) in order to more reliably manage and control operation of the second electrical component. The current sensor assembly may include an integrated cooler that includes an internal cooling circuit configured to circulate coolant for cooling one or more bus bars of the current sensor assembly.

Abstract: A power inductor includes a magnetic core, a conductor coiled around the core; an end cover secured to the core, a tube configured to convey fluid, and a fluid flow guide supported on the end cover. The flow guide has a receiving portion disposed under an end of the tube to receive the fluid and a distribution portion in fluid communication with the receiving portion. The distribution portion is configured to supply the fluid onto the conductor and the core and includes a plurality of guide walls.

Abstract: A power converter includes a plurality of switches, a transformer electrically connected between some and other of the switches, and a plurality of series connected capacitors electrically connected between the switches and an output of the power converter. A controller operates the switches such that a voltage at an input of the power converter and across each of the capacitors is same and a voltage at the output is double the voltage at the input.

Abstract: An automotive vehicle includes an electric machine, a traction battery, and a power converter. The power converter transfers power between the electric machine and traction battery. The power convert includes a switch that defines a portion of a phase leg, a gate driver circuit that provides provide power to a gate of the switch, and a clamping circuit. The clamping circuit includes a clamping switch that, responsive to the gate driver circuit being de-energized and a voltage of the gate exceeding a predetermined threshold value, conducts current from the gate to dissipate the voltage and clamp the gate to an emitter of the switch.

Abstract: A power system includes a DC/AC converter, a traction battery, an AC/DC converter electrically connected between the DC/AC converter and traction battery, and a transformer electrically connected between the DC/AC converter and AC/DC converter. The AC/DC converter includes a plurality of semiconductor devices and a plurality of capacitors such that during power transfer from the DC/AC converter to the traction battery, a voltage across each of the capacitors is half of a battery voltage.

Abstract: A power system, responsive to a detected change in an onboard charger or a generator, switches a converter from a first conversion setting, in which a first low voltage value of a medium-voltage bus port is converted to a first high voltage value of a high-voltage bus port, to a second conversion setting, in which a second low voltage value of the medium-voltage bus port is converted to the first high voltage value of the high-voltage bus port.

Abstract: A power converter includes a plurality of switches, a transformer electrically connected between some and other of the switches, and a plurality of series connected capacitors electrically connected between the switches and an output of the power converter. A controller operates the switches such that a voltage at an input of the power converter and across each of the capacitors is same and a voltage at the output is double the voltage at the input.

Abstract: A vehicle, a vehicle power electronics assembly, and a method of packaging and cooling an inductor assembly are provided. The vehicle has a vehicle electrical system with a variable voltage converter (VVC) and an inductor assembly. The inductor assembly has a core and a winding. A bobbin is connected to and surrounds an outer perimeter of the inductor assembly. The bobbin defines an inlet, an internal fluid passage, and a series of nozzles. The nozzles in the series of nozzles are spaced apart from one another about the bobbin and are positioned to spray fluid directly onto the winding. A fluid system is connected to the inlet to provide pressurized fluid to the inlet.

Abstract: A power system for a vehicle includes a traction battery having an output voltage, a transformer including a coil, and a power converter including a plurality of capacitors and a plurality of switches arranged such that when a first subset of the switches are ON, two of the capacitors are in parallel, an AC voltage across the coil is in a positive half cycle, and a voltage across each of the two of the capacitors is half the output voltage.

Abstract: A power inductor includes a magnetic core, a conductor coiled around the core; an end cover secured to the core, a tube configured to convey fluid, and a fluid flow guide supported on the end cover. The flow guide has a receiving portion disposed under an end of the tube to receive the fluid and a distribution portion in fluid communication with the receiving portion. The distribution portion is configured to supply the fluid onto the conductor and the core and includes a plurality of guide walls.

Abstract: This disclosure is directed to power systems for transferring power between electrical components. An exemplary power system includes a first electrical component (e.g., an electric motor), a second electrical component (e.g., an inverter system), and a terminal block assembly adapted to electrically couple the first and second electrical components. The terminal block assembly includes an internal cooling channel configured to receive coolant for providing direct liquid cooling of the bus bar.

Abstract: A vehicle power system has a DC to AC converter, a pair of AC to DC converters, a transformer including a core, a primary winding wound about the core and electrically connected to an output of the DC to AC converter, and a pair of secondary windings wound about the core, a traction battery electrically connected to a collective output of the AC to DC converters, and a controller.

Abstract: A vehicle, an inductor assembly for power electronics in a vehicle, and a method of providing and cooling an inductor assembly are provided. According to one example, the vehicle is provided with an inductor assembly in a vehicle electrical system with a variable voltage converter (VVC). The inductor assembly includes a core formed from a plurality of core segments spaced apart from one another to define gaps therebetween, with each of the plurality of core segments forming an internal fluid passage extending therethrough. The inductor assembly has a winding surrounding at least one of the plurality of core segments. A fluid system is connected to the core to provide pressurized fluid to the fluid passages of the plurality of core segments to circulate fluid through the core of the inductor assembly.

Abstract: A vehicle, an inductor assembly for power electronics in a vehicle, and a method of providing and cooling an inductor assembly are provided. According to one example, the vehicle is provided with an inductor assembly in a vehicle electrical system with a variable voltage converter (VVC). The inductor assembly includes a core formed from a plurality of core segments spaced apart from one another to define gaps therebetween, with each of the plurality of core segments forming an internal fluid passage extending therethrough. The inductor assembly has a winding surrounding at least one of the plurality of core segments. A fluid system is connected to the core to provide pressurized fluid to the fluid passages of the plurality of core segments to circulate fluid through the core of the inductor assembly.