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: 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 unitary on-board charger and generator (OBCG) for an electric vehicle system and method is disclosed. The OBCG includes a charging circuit with a diode bridge rectifier connected to an AC power source, a power factor correction converter, and a bi-directional DC/DC converter. The OBCG also includes a generating circuit with a a three-phase inverting circuit, three inductive coils connected to each leg of the three-phase inverting circuit, and a plurality of output capacitors connected to the outputs of the three inductive coils. The OBCG also includes a bridge capacitor and a control switching element connected between the charging circuit and the generating circuit for changing between a charging and generating state.

Abstract: An inductor includes a pair of core portions having tapered legs and windings wound around the tapered legs. Each of the core portions are arranged adjacent to each other such that the tapered legs define a gap between the core portions that extends diagonally from one end of the inductor towards another end of the inductor relative to outer surfaces of the inductor.

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: 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: An inductor includes a pair of core portions having tapered legs and windings wound around the tapered legs. Each of the core portions are arranged adjacent to each other such that the tapered legs define a gap between the core portions that extends diagonally from one end of the inductor towards another end of the inductor relative to outer surfaces of the inductor.

Abstract: An automotive power converter includes a pair of series connected switches and an inductor including a core having a leg, a winding wound around the leg, and a terminal center tapping the switches. The leg includes a plurality of alternating frames and solid blocks arranged to define a continuous contact surface for the winding and to define internal cavities within the leg such that each of the frames surrounds one of the internal cavities.

Abstract: An automotive power module has a plurality of power cards stacked to form an inverter module, and a DC-link capacitor mounted against the inverter module. Each of the power cards includes a top cover having opposite sides. One of the sides has extended therefrom a first matrix of pins. Each of the power cards also includes a plurality of integrated circuits defining transistors of an inverter mounted on the other of the sides, terminals extending from a perimeter of the top cover and in electrical communication with the integrated circuits, and a bottom cover having extended therefrom a second matrix of pins.

Abstract: An automotive power converter includes a pair of series connected switches and an inductor including a core having a leg, a winding wound around the leg, and a terminal center tapping the switches. The leg includes a plurality of alternating frames and solid blocks arranged to define a continuous contact surface for the winding and to define internal cavities within the leg such that each of the frames surrounds one of the internal cavities.

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 unitary on-board charger and generator (OBCG) for an electric vehicle system and method is disclosed. The OBCG includes a charging circuit with a diode bridge rectifier connected to an AC power source, a power factor correction converter, and a bi-directional DC/DC converter. The OBCG also includes a generating circuit with a a three-phase inverting circuit, three inductive coils connected to each leg of the three-phase inverting circuit, and a plurality of output capacitors connected to the outputs of the three inductive coils. The OBCG also includes a bridge capacitor and a control switching element connected between the charging circuit and the generating circuit for changing between a charging and generating state.

Abstract: An automotive power module has a plurality of power cards stacked to form an inverter module, and a DC-link capacitor mounted against the inverter module. Each of the power cards includes a top cover having opposite sides. One of the sides has extended therefrom a first matrix of pins. Each of the power cards also includes a plurality of integrated circuits defining transistors of an inverter mounted on the other of the sides, terminals extending from a perimeter of the top cover and in electrical communication with the integrated circuits, and a bottom cover having extended therefrom a second matrix of pins.

Abstract: A vehicle includes an oil-cooling system arranged to circulate oil through an electric machine and an oil-to-coolant heat exchanger. A coolant system has conduit arranged to circulate coolant through an inverter, a heater core, and the heat exchanger. A climate control system is arranged to circulate an airstream through the heater core to heat a passenger cabin with waste heat from the electric machine and the inverter.

Abstract: A vehicle on-board charging assembly includes at least one power electronics module and a coolant channel in thermal contact with the at least one power electronics module. The charging assembly also includes a first reactive portion along a wall of the coolant channel defining a first reactive property and a second reactive portion along the wall of the coolant channel defining a second reactive property. The charging assembly further includes a plurality of emitters arranged to activate the first and second reactive portions. The charging assembly also further includes a controller programmed to sequentially activate the emitters to cause peristaltic pumping of coolant through the coolant channel.

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, 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 vehicle includes a passenger cabin, an inverter, and a coolant system having conduit arranged to circulate coolant through the inverter and an evaporator. A refrigerant system includes a condenser and conduit arranged to circulate refrigerant through the condenser and through the evaporator to absorb heat generated by the inverter. A climate control system is arranged to circulate an airstream through the condenser and into the cabin to heat the cabin.

Abstract: This disclosure relates to a coolant cap mix-up prevention system for a motor vehicle. In one example, a motor vehicle includes a first coolant bottle configured for use with a first cap and a second coolant bottle configured for use with a second cap. The second coolant bottle is configured prevent attachment of the first cap to the second coolant bottle. A method is also disclosed.

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.