Ford Global Technolgoies, LLC

Continental Automotive Systems Us, Inc.

Joseph Sherman Kimmel

Michael W Degner

Lihua Chen

Fan Wang

Jiyao Wang

Yang Xu

Silong Li

Monty J Anderson

Papiya Bagchi

William Robert Brown

Jogendra Singh Thongam

An electric drive system includes a power electronics module (PEM) having a DC-link capacitor and an inverter. A controller reduces power output of the inverter while a sensed temperature of an inverter power switch, a sensed current of the PEM, such as a sensed ripple current of the DC-link capacitor, and parameter values of the DC-link capacitor are indicative of a predicted temperature of the capacitor being greater than a threshold to maintain capacitor temperature lower than the threshold. The parameter values are obtainable from a thermal model of the DC-link capacitor. The thermal model may be derived from testing a test version of the PEM under different drive cycles in which for each drive cycle a set of information is recorded including a sensed temperature of the inverter power switch test version, a current of the PEM test version, and a sensed temperature of the DC-link capacitor test version.

Method and system for controlling electric drive system according to predicted temperature of DC-link capacitor to prevent overheating

A vehicle includes an electric machine, a battery, an inverter, and a controller. The controller switches the inverter at a switching frequency selected to generate an AC current to heat the battery, adjusts a d-axis current of the electric machine to increase a battery heating power, and adjusts a q-axis current of the electric machine according to the adjusted d-axis current.

System and method for resonant heating battery

An integrated capacitor and power module include a power module, an intermediate cold plate, and a capacitor module. The intermediate cold plate has a first side attached to the power module and a second side opposite the first side. The capacitor module is attached to a second side of the intermediate cold plate. The capacitor module includes a plurality of metalized film capacitor cells supported by a metal plate and a base cold plate with a layer of thermal interface material between the metal plate and the base cold plate. A fluid circulation system is operatively connected to the intermediate cold plate to circulate a fluid through the cold plate. The capacitor module includes a housing, a plurality of capacitor cells and first and second busbars. Alternating cell arrays have a P-end and an N-end that are inverted relative to each other.

Integrated power module and capacitor module thermal and packaging design

A bus bar assembly includes a first bus bar having at least first and second mounting arms and a second bus bar having at least third and fourth mounting arms. The first and third mounting arms are adapted to alternately interleave with one another such that the position of the first mounting arm relative to the third mounting arm is opposite as to the position of the second mounting arm relative to the fourth mounting arm.

Bus bar assembly

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Carleton, MI, United States of America

Joseph Sherman Kimmel