Abstract: An electrical energy management system includes a first battery having a nominal operating voltage, a second battery having a charging voltage sufficiently close to the nominal operating voltage of the first battery such that the first battery can charge the second battery when the first battery and the second battery are electrically connected in parallel, a generator that is controllable to provide a variable output voltage, a starter motor, an electrical load, a plurality of switches each controllable to be in an open state or a closed state, and a controller that is configured to control the output voltage of the generator and to control the open or closed state of each of the plurality of switches.

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 electric machine includes: a first stator winding including first and second stator winding portions; a second stator winding including third and fourth stator winding portions; a third stator winding including fifth and sixth stator winding portions, where inputs of the stator windings are configured to be connected to phases, respectively, of an inverter; and switches connected between the stator winding portions and outputs of a power source.

Abstract: A system for regulating voltage includes an electronic fuse including a switching component and an active control circuit connected to the switching component, the control circuit configured to open the switching component based on at least an overcurrent condition. The system also includes a voltage regulation component connected to the switching component, the voltage regulation component configured to regulate a voltage across the switching component by applying a voltage to the switching component based on a measured voltage drop across the switching component, and a desired load voltage.

Abstract: A charging system for an electric vehicle comprises a charger connector configured to connect to a charge port on the electric vehicle and includes a housing, a first conductor passing through the housing, a second conductor passing through the housing, and a current sensor configured to sense current flowing through at least one of the first conductor and the second conductor to a battery system of the electric vehicle. A charger-side controller includes an arc fault detection module configured to selectively identify a DC arc fault in response to measured current sensed by the current sensor and to stop charging the electric vehicle in response to detecting the DC arc fault.

Abstract: A power inverter includes first and second inputs and a plurality of power switches in communication with the first and second inputs. First, second and third outputs communicate with the plurality of power switches. First, second and third conductors are configured to connect the first, second and third outputs to an electric machine. Each of the first, second and third conductors comprise a plurality of twisted and segmented wires.

Abstract: A system in a vehicle includes a first fuse connected between a power source and a load. The first fuse is an electronic fuse (eFuse) to disconnect the load from the power source via the first fuse based on detecting a failure in the first fuse. The system also includes a second fuse connected between the power source and the load, the first fuse and the second fuse being part of a cluster of fuses. The second fuse is an eFuse and the first fuse signals the second fuse to disconnect the load from the power source via the second fuse based on the first fuse detecting the failure in the first fuse without the second fuse detecting a failure in the second fuse.

Abstract: A power control system for a battery system of a vehicle includes one or more supplemental protection devices that are connected to at least one of a first contactor, a second contactor, one of N fuses, and one of N vehicle loads. A battery management module is configured to measure and store a plurality of state of health parameters for the battery system and to selectively operate the one or more supplemental protection devices in a coverage gap between first and second coverage areas handled by the first contactor and the second contactor and the N fuses based on a calibration function and/or calibration parameters. A telematics system selectively sends the plurality of state of health parameters for the battery system to a remote server and to receive at least one of a new calibration function and new calibration parameters for the vehicle from the remote server.

Abstract: An electric machine disposed within a housing includes a stator, a rotor, and one or more point field detectors. The stator receives current from an inverter. The rotor is connected to and rotating a shaft based on a magnetic field generated by the stator. The one or more point field detectors are configured to detect leakage flux within the housing. The stator, the rotor and the one or more point field detectors are disposed within the housing.

Abstract: A protection system for a battery system includes a battery control module configured to selectively open at least one contactor to isolate the battery system from a load in response to a sensed current being greater than a first threshold and within a first current range, at least one fuse connected between first and second terminals of the battery system and configured to open to isolate the battery system from the load in response to the sensed current being greater than a second threshold and within a second current range that is greater than and offset from the first current range, and an auxiliary protection module configured to selectively form a short circuit between first and second terminals in response to the sensed current being greater than the first threshold, less than the second threshold, and within a coverage gap region between the first and second current ranges.

Abstract: A current source inverter includes a first phase leg including a plurality of switching devices, a second phase leg including a plurality of switching devices, and a third phase leg including a plurality of switching devices. The current source inverter also includes a zero-state phase leg including at least one switching device, wherein the zero-state phase leg is configured to transition from an open state to prevent current flow to a closed state to allow current flow between a positive and negative terminal during a dead-band time.

Abstract: A motor control system includes: a voltage command module configured to determine a target d-axis voltage for an electric motor and a target q-axis voltage for the electric motor; a target frequency module configured to: selectively set a target switching frequency to a first predetermined switching frequency; and selectively set the target switching frequency to a second predetermined switching frequency that is at least 2 kilohertz (kHz) greater than the first predetermined switching frequency; and a switching module configured to: based on the target d-axis voltage and the target q-axis voltage, determine target pulse width modulation (PWM) duty cycles for phases, respectively, of the electric motor; and switch switches of legs of an inverter module connected to the phases of the electric motor at the target PWM duty cycles, respectively, and the target switching frequency.

Abstract: A system in a vehicle includes a current regulator to obtain current commands from a controller based on a torque input and provide voltage commands and an inverter to use the voltage commands from the current regulator and direct current (DC) supplied by a battery to provide alternating current (AC). The system also includes an electric traction motor to provide drive power to a transmission of the vehicle based on injection of the AC from the inverter. The current regulator adjusts parameters of a transfer function implemented by the current regulator, based on feedback of an input to and an output from the electric traction motor to achieve the AC corresponding with the torque input in no more than two control cycles.

Abstract: A power control system for a battery system includes a resistor including a first terminal and a second terminal. A normally closed transistor includes a first terminal, a second terminal and a control terminal. The first terminal of the transistor is connected to a second terminal of the resistor and the second terminal of the transistor is connected to a second terminal of the battery system. A capacitor includes a first terminal connected to the first terminal of the resistor and a second terminal connected to the second terminal of the battery system. A power inverter includes a first terminal connected to the first terminal of the resistor, a second terminal connected to the second terminal of the battery system and an output connected to a load.

Abstract: A motor control system includes: a voltage command module configured to determine a target d-axis voltage for an electric motor and a target q-axis voltage for the electric motor; a target frequency module configured to: selectively set a target switching frequency to a first predetermined switching frequency; and selectively set the target switching frequency to a second predetermined switching frequency that is at least 2 kilohertz (kHz) greater than the first predetermined switching frequency; and a switching module configured to: based on the target d-axis voltage and the target q-axis voltage, determine target pulse width modulation (PWM) duty cycles for phases, respectively, of the electric motor; and switch switches of legs of an inverter module connected to the phases of the electric motor at the target PWM duty cycles, respectively, and the target switching frequency.

Abstract: A power control system for a propulsion system of a vehicle includes an energy storage system including a precharge circuit and one or more battery packs. A DC-DC converter is connected to the energy storage system and including a first capacitor, a first plurality of power switches and an inductor. A power inverter module is connected to the DC-DC converter and including a second capacitor and a second plurality of power switches. A controller is configured to pre-charge the first capacitor of the DC-DC converter and the second capacitor of the power inverter module and control operating modes of the DC-DC converter and the power inverter module.

Abstract: A power control system for a vehicle includes a charge port and a contactor connected to the charge port and including a first plurality of switches. An energy storage system includes a second plurality of switches and one or more battery packs. A bi-directional DC-DC converter is connected between the energy storage system and a plurality of vehicle loads. A controller is configured to control states of the first and second plurality of switches to configure in a plurality of modes including a range improvement mode, a first charging mode to perform charging at a first voltage level, a second charging mode to perform charging at a second voltage level, a battery preconditioning mode; and an accessory load support mode.

Abstract: A system in a vehicle includes a current regulator to obtain current commands from a controller based on a torque input and provide voltage commands and an inverter to use the voltage commands from the current regulator and direct current (DC) supplied by a battery to provide alternating current (AC). An electric traction motor provides drive power to a transmission of the vehicle based on injection of the AC from the inverter. A current observer obtains measured input current signals based on the AC for a current control cycle and provides predicted current signals for a next control cycle to the current regulator using a model. The current observer includes a controller to check output of the model against the measured input current signals. The current observer tunes parameters of the controller and the model used to generate the predicted current signals based on the measured input current signals.

Abstract: A battery system for a vehicle includes a battery tray having a base wall, a plurality of side walls, and a cover that collectively define a receiving zone. A vent includes an inlet and an outlet exposed to the battery receiving zone. A battery is supported by the base wall. A battery electronic controller (BEC) is arranged in the receiving zone and directly connected to the battery.

Abstract: A system for regulating voltage includes an electronic fuse including a switching component and an active control circuit connected to the switching component, the control circuit configured to open the switching component based on at least an overcurrent condition. The system also includes a voltage regulation component connected to the switching component, the voltage regulation component configured to regulate a voltage across the switching component by applying a voltage to the switching component based on a measured voltage drop across the switching component, and a desired load voltage.