Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Circuits and methods for driving a load are disclosed. An exemplary driving circuit may include first and second switching devices electrically connected with each other in parallel. The driving circuit may also include a current sensing circuit configured to generate a current sensing signal indicating a value of a current flowing through the first switching device. The current sensing signal may include an offset caused by parasitic inductance imbalance in electrical connections connecting the first and second switching devices. The driving circuit may further include a driver circuit configured to control switching operations of the first and second switching devices. The driver circuit may include an overcurrent protection circuit electrically connected to the current sensing circuit.

Abstract: A three-phase current sensor for measuring currents running in three conductors of a three-phase conductor system includes at least a first magnetic measuring device. The magnetic measuring device includes a magnetic circuit provided with at least two gaps and a magnetic field sensor arranged in each gap of the magnetic circuit. The magnetic field sensors are positioned on both sides of a cavity sized to receive one of the three conductors. The gaps and thus the magnetic field sensors are positioned such that stray magnetic flux from an adjacent conductor has substantially equal amplitude passing through each of the sensors.

Abstract: A three-phase current sensor for measuring currents running in three conductors of a three-phase conductor system includes at least a first magnetic measuring device. The magnetic measuring device includes a magnetic circuit provided with at least two gaps and a magnetic field sensor arranged in each gap of the magnetic circuit. The magnetic field sensors are positioned on both sides of a cavity sized to receive one of the three conductors. The gaps and thus the magnetic field sensors are positioned such that stray magnetic flux from an adjacent conductor has substantially equal amplitude passing through each of the sensors.

Abstract: A system for interconnecting parallel insulated gate bipolar transistor (IGBT) modules is provided. A pair of switches selected from a plurality of the IGBT modules are assigned to a driver integrated circuit (IC). In the pair of switches, a master IGBT switch is selected, the other switch being a slave IGBT switch. A command signal from the driver IC is electrically coupled to both the master and slave IGBT switches. The master and slave IGBT switches both have protective circuits; however, the driver IC is electrically coupled to the protective circuits of the selected master IGBT switch only. The protective circuits include temperature and current sense circuits. The plurality of the IGBT modules may be formed by two hexpack power modules. The modules are configured such that only a single driver IC is needed for each pair of parallel IGBT switches, with equal current sharing of the paralleled modules.

Abstract: Systems and methods are disclosed for improving acceleration performance of an electric vehicle that includes an electric motor for propulsion. An exemplary system may include an inverter configured to drive the electric motor. The inverter may include at least one power electronic device. The system may also include a torque capability controller. The torque capability controller may be configured to receive information indicative of a selection between a first mode and a second mode. The second mode may correspond to a higher torque to be output by the electric motor than the first mode. The torque capability controller may also be configured to apply a switching frequency to the at least one power electronic device. The switching frequency may have a lower value when the received information indicates the selection of the second mode than when the received information indicates the selection of the first mode.

Abstract: Systems and methods are disclosed for improving acceleration performance of an electric vehicle that includes an electric motor for propulsion. An exemplary system may include an inverter configured to drive the electric motor. The inverter may include at least one power electronic device. The system may also include a torque capability controller. The torque capability controller may be configured to receive information indicative of a selection between a first mode and a second mode. The second mode may correspond to a higher torque to be output by the electric motor than the first mode. The torque capability controller may also be configured to apply a switching frequency to the at least one power electronic device. The switching frequency may have a lower value when the received information indicates the selection of the second mode than when the received information indicates the selection of the first mode.

Abstract: A system for interconnecting parallel insulated gate bipolar transistor (IGBT) modules is provided. A pair of switches selected from a plurality of the IGBT modules are assigned to a driver integrated circuit (IC). In the pair of switches, a master IGBT switch is selected, the other switch being a slave IGBT switch. A command signal from the driver IC is electrically coupled to both the master and slave IGBT switches. The master and slave IGBT switches both have protective circuits; however, the driver IC is electrically coupled to the protective circuits of the selected master IGBT switch only. The protective circuits include temperature and current sense circuits. The plurality of the IGBT modules may be formed by two hexpack power modules. The modules are configured such that only a single driver IC is needed for each pair of parallel IGBT switches, with equal current sharing of the paralleled modules.

Abstract: Circuits and methods for driving a load are disclosed. An exemplary driving circuit may include first and second switching devices electrically connected with each other in parallel. The driving circuit may also include a current sensing circuit configured to generate a current sensing signal indicating a value of a current flowing through the first switching device. The current sensing signal may include an offset caused by parasitic inductance imbalance in electrical connections connecting the first and second switching devices. The driving circuit may further include a driver circuit configured to control switching operations of the first and second switching devices. The driver circuit may include an overcurrent protection circuit electrically connected to the current sensing circuit.

Abstract: Methods and systems are provided for controlling an electrical system of a vehicle. Sensors are used to obtain first data for a first path of calculations and second data for a second path of calculations. The first path comprises a first plurality of calculations of generating a value of a parameter pertaining to the electrical system, and the second path comprises a second plurality of calculations of monitoring the electrical system with respect to the first path. A processor is coupled to the plurality of sensors, and is configured to determine whether a data frozen flag is active, perform the first plurality of calculations of the first path using the first data if the first data flag is inactive, and perform the second plurality of calculations of the second path if the first data flag is active.

Abstract: Circuits and methods for driving a load are disclosed. An exemplary driving circuit may include a plurality of switching devices and a controller electrically connected to the plurality of switching devices. The controller may be configured to provide a switching signal for controlling switching operations of the switching devices. The controller may also be configured to determine whether the switching signal falls within a predetermined dead zone. When it is determined that the switching signal falls within the predetermined dead zone, the controller may be configured to modify the switching signal by moving a space vector corresponding to the switching signal to a boundary of the predetermined dead zone. In addition, the controller may be configured to provide the modified switching signal to the switching devices.

Abstract: A three-phase current sensor for measuring currents running in three conductors of a three-phase conductor system includes at least a first magnetic measuring device. The magnetic measuring device includes a magnetic circuit provided with at least two gaps and a magnetic field sensor arranged in each gap of the magnetic circuit. The magnetic field sensors are positioned on both sides of a cavity sized to receive one of the three conductors. The gaps and thus the magnetic field sensors are positioned such that stray magnetic flux from an adjacent conductor has substantially equal amplitude passing through each of the sensors.

Abstract: A three-phase current sensor for measuring currents running in three conductors of a three-phase conductor system includes at least a first magnetic measuring device. The magnetic measuring device includes a magnetic circuit provided with at least two gaps and a magnetic field sensor arranged in each gap of the magnetic circuit. The magnetic field sensors are positioned on both sides of a cavity sized to receive one of the three conductors. The gaps and thus the magnetic field sensors are positioned such that stray magnetic flux from an adjacent conductor has substantially equal amplitude passing through each of the sensors.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Abstract: Systems and methods are disclosed for improving acceleration performance of an electric vehicle that includes an electric motor for propulsion. An exemplary system may include an inverter configured to drive the electric motor. The inverter may include at least one power electronic device. The system may also include a torque capability controller. The torque capability controller may be configured to receive information indicative of a selection between a first mode and a second mode. The second mode may correspond to a higher torque to be output by the electric motor than the first mode. The torque capability controller may also be configured to apply a switching frequency to the at least one power electronic device. The switching frequency may have a lower value when the received information indicates the selection of the second mode than when the received information indicates the selection of the first mode.

Abstract: An electric machine electrically connects to an inverter via a multi-phase power circuit. A method for monitoring the multi-phase power circuit includes non-intrusively adjusting a commanded AC electric current from the inverter after a prescribed time period and comparing a measured magnitude of AC electric current in the multi-phase power circuit with a minimum threshold. Presence of an open circuit fault in the multi-phase power circuit can be detected based upon the comparison.

Abstract: A powertrain system includes a torque machine rotatably coupled to an internal combustion engine via a pulley mechanism. The torque machine and the internal combustion engine are configured to transfer torque to a driveline and include a first sensor configured to monitor rotation of the engine and a second sensor configured to monitor rotation of the torque machine. The first sensor signally connects to a controller configured to control operation of the torque machine. A method for operating the powertrain system includes employing a signal output from the first sensor to monitor rotation of the torque machine to control operation thereof, said signal output from the first sensor adjusted for a pulley ratio of the pulley mechanism upon detecting a fault associated with the second sensor.