Gm Global Technolgoy Operations, Inc.

Konking Wang

Kris Sevel

Brendan M Conlon

Yue Fan

Emil Francu

Steven V Wybo

Aniket P Kothari

Alexander M Bilinski

Leo Francis Schwab

Li-Pen J Ho

Stephen G Heien

Daniel R Brouns

Charles J Swan

Cotrina C Connolly

Kevin J Robinet

A protection system for a high-voltage component includes a switching circuit and a protection controller. The switching circuit changes a variable arrangement of multiple battery packs between a parallel arrangement and a series arrangement. The protection controller commands the switching circuit into the series arrangement in response to a recharging session, commands a current flow in the recharging session, measures a measured voltage between an input node and a floating chassis ground of the high-voltage component, advances a timer while the measured voltage indicates a presence of an improper voltage, and cancels the recharging session in response to the presence of the improper voltage for greater than an exposure time. The recharging session provides a direct-current fast-charging voltage to battery packs in the series arrangement, and is greater than the battery voltage.

High-voltage component protection during vehicle recharging

Dynamically monitoring of an electrically-isolated power bus for a DC power system is described, and includes dynamically monitoring voltage and current on the power bus to determine a variation in the voltage on the power bus. When the variation in the voltage on the power bus is less than a threshold, an active positive isolation resistance term and an active negative isolation resistance term are determined. A first voltage balance term is determined based upon a ratio of the active positive isolation resistance term and the active negative isolation resistance term. A dynamic positive isolation resistance term and a dynamic negative isolation resistance term are determined based upon the active negative isolation resistance term. A fault associated with the power bus is determined based upon the dynamic positive isolation resistance term and the dynamic negative isolation resistance term.

Method and apparatus for monitoring isolation of an electric power bus

An electrical system includes a high-voltage bus connected to a rechargeable energy storage system (RESS) and a high-voltage component connected to the RESS via the voltage bus. The component defines a service opening spanned by a removable cover. The electrical system may include a fastener connecting the cover to the component, as well as a battery disconnect unit (BDU) having a high-voltage switch device connecting the RESS to the high-voltage bus. The switch device closes responsive to a low-voltage drive current to connect the RESS to the high-voltage bus. A drive circuit conducts the current to the switch device. An electrical connector has multiple connector pieces collectively forming a switch in the drive circuit. Disconnection of the pieces from each other opens the switch to interrupt the drive current and cause the high-voltage switch device to open, which disconnects the RESS from the high-voltage bus.

Connector-based high-voltage lockout function

A discharge control system of a vehicle includes a traction power inverter module (TPIM) configured to convert a first direct current (DC) voltage output by a first battery to alternating current (AC) power and apply the AC power to an electric motor. An accessory power module (APM) is configured to convert the first DC voltage into a second DC voltage of a second battery. A voltage calculation module is configured to, when the first DC voltage is less than an operation threshold voltage of the APM, determine the second DC voltage based on a function of the first DC voltage and the operation threshold voltage. A diagnostic module is configured to indicate whether a discharge fault is present. A discharge control module is configured to, when the discharge fault is present, based the first DC voltage and the second DC voltage, selectively control operation of the TPIM and the APM.

Active discharging high voltage direct current bus system and method for a vehicle

A topology for electric power distribution in a vehicle includes a high-voltage bus connected to a DC-DC electric power converter that is connected to a low-voltage DC load. The DC-DC electric power converter includes a high-voltage switching circuit, a transformer, and a low-voltage rectifier. The high-voltage switching circuit includes first and second switches arranged in series between positive and negative legs of the high-voltage electric power bus at a first node that connects to a leg of an inductor of the transformer. A controller receives a command to discharge the high-voltage electric power bus, and in response, controls a first gate circuit to operate a first switch in a linear mode, and controls a second gate circuit to operate a second switch in a pulsewidth-modulated mode. A duty cycle for the pulsewidth-modulated operation of the second switch is determined based upon the magnitude of electric current.

Electric power distribution system and topology

A system includes a rechargeable energy storage system (RESS) having an enclosure, battery cells, contactors, a first pair of high-voltage interlock (HVIL) ports, and female blind-mate electrical sockets selectively connected to the battery cells via the contactors. The battery cells and contactors are within the RESS enclosure. The system includes a high-power distribution module (HPDM) having another enclosure, male blind-mate electrical pins, a second pair of HVIL ports engagable with the first pair, ring-terminal connections connected to the blind-mate electrical pins and connectable to high-current components, and HV280 electrical connectors electrically connected to one or more of the male blind-mate electrical pins. The male blind-mate electrical pins insert directly into and engage with the female blind-mate electrical sockets of the RESS enclosure. A vehicle includes the system, a transmission, and an electric machine.

Powertrain with high-power distribution module and high-current ring terminal connection for the same

An inverter power module: selectively applies power from a battery to a permanent magnet (PM) electric motor; and selectively provides power output by the PM electric motor for the battery. A switch, when open, prevents power flow the inverter power module from the battery, and, when closed, enables power flow between the inverter power module and the battery. An adjustment module determines an SOC adjustment based on at least one of a vehicle speed and a temperature of the battery. A maximum module receives a first maximum SOC of the battery and that determines a second maximum SOC of the battery based on the first maximum SOC and the SOC adjustment. A clutch control module disengages a clutch, decoupling the PM electric motor from a transmission, when the switch is stuck closed and an SOC of the battery is greater than the second maximum SOC.

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Canton, MI, United States of America

Konking Wang