Gm Global Technolgoy Operations, Inc.

Mark L Selogie

Mark D Korich

Constantin C Stancu

David Yuang Tang

Young Mok Doo

Konstantinos Triantos

Silva Hiti

Brian A Welchko

Keming Chen

Daniel L Kowalewski

Michael R Grimes

Robert T Dawsey

Erik Christopher Hatch

Alex Thompson

Gholamreza Esmaili

Ted D Peterson

Larry A Hagerty

A busbar assembly for an inverter module has a power module, a capacitor module with at least one capacitor, and a battery all interconnected by a busbar. The busbar includes a base busbar portion that is electrically coupled to the battery and a branch busbar portion that extends from the base busbar to the power module and that electrically connects to the capacitor module at points located between the base node and the power module.

Low inductance busbar

A connector assembly is provided for coupling an electric motor to a power source, wherein the power source comprises a first conductive member. The connector assembly comprises a non-conductive member having an inner channel configured to receive at least a portion of the first conductive member, a second conductive member slidably disposed within the inner channel, coupled to the electric motor, and configured to be coupled to, and to receive a force having a first direction from, the first conductive member, and a spring member, retained between the non-conductive member and the second conductive member and configured to resist movement of the second conductive member in the first direction.

Connector assembly for coupling an electric motor to a power source

Systems and apparatus are provided for a control module for operating an inverter in a vehicle. A control module comprises a first circuit card assembly and a microprocessor mounted on the first circuit card assembly. The microprocessor is configured to determine a phase modulation command for a first motor phase and determine a modulation criterion for the inverter. An integrated circuit is communicatively coupled to the microprocessor. The integrated circuit is configured to generate a first modulation signal based on the phase modulation command and the modulation criterion and generate a second modulation signal based on the phase modulation command and the modulation criterion.

Control module for dynamic operation of a power inverter using an application specific integrated circuit

An embodiment of a system for multiple source power conversion is implemented in a vehicle that includes an alternating current (AC) power source and first and second direct current (DC) power sources. The system includes an inverter, a DC-to-DC converter, and a controller. The controller receives external commands, inverter feedback signals, and DC-to-DC converter feedback signals, and executes and inverter control algorithm and DC-to-DC converter control algorithm. An embodiment of a method for multiple source power conversion between an AC power source, and first and second DC power sources includes receiving external commands from a remote source, inverter feedback signals from an inverter, and DC-to-DC converter feedback signals from a DC-to-DC converter. The method also includes executing an inverter control algorithm and a DC-to-DC converter control algorithm to generate drive signals for the inverter and DC-to-DC converter, respectively, based on the received commands and feedback signals.

Systems and methods for multiple source power conversion

Systems and apparatus are provided for capacitor segments for use in a vehicle. A capacitor segment comprises an inner conductor configured to receive a first potential and having a generally L-shaped longitudinal cross-section. An outer conductor is configured to receive a second potential, and is electrically insulated from the inner conductor. The outer conductor comprises a first section having a generally L-shaped longitudinal cross-section aligned with the inner conductor, and a second section coupled to the first section and having a generally L-shaped lateral cross-section. The second section and the inner conductor define an inner region. A capacitor is located in the inner region and coupled to the inner conductor and the second section. The capacitor segment is configured such that current flows through the capacitor in a first direction, and current flows through the second section in a second direction that generally opposes the first direction.

Low inductance interconnect device for a power capacitor component

A vehicular power inverter connector assembly is provided. The assembly includes a housing, a plurality of first engagement formations on the housing shaped to mate with a plurality of inverter engagement formations on a vehicular power inverter, a plurality of second engagement formations on the housing shaped to mate with a plurality motor engagement formations on a vehicular motor, and a plurality of current sensors connected to the housing and configured to detect current flowing between the vehicular power inverter and the vehicular motor.

Power inverter connector having integrated current sensors

An inverter assembly for a vehicle includes a housing, a first inverter, and a second inverter. The housing comprises a plurality of walls. The plurality of walls form an inlet for cooling fluid to enter the housing, an outlet for the cooling fluid to exit the housing, and a channel, and a channel for the cooling fluid to flow therebetween. The first inverter is disposed within the housing proximate the channel, and is configured to be cooled by the cooling fluid flowing through the channel. The second inverter is also disposed within the housing proximate the channel, and is also configured to be cooled by the cooling fluid flowing through the channel.

Vehicle inverter assembly with cooling channels

Methods and apparatus are provided for protecting a motor control circuit in a permanent magnet electric motor system. The permanent magnet electric motor system includes a permanent magnet electric motor having a predetermined number of windings corresponding to the phases of the permanent magnet electric motor and a direct current (DC) bus coupled to a power source for providing operational power for the electric motor system. A motor control circuit is connected to the DC bus for receiving the operational power therefrom and is connected to the windings of the permanent magnet electric motor for controlling the permanent magnet electric motor. A protection circuit is connected to the DC bus for receiving the voltage therefrom for operation of the protection circuit and for detecting predetermined motor control circuit fault conditions from voltage sensed on the DC bus and in response thereto providing protection for the motor control circuit.

Protection for permanent magnet motor control circuits

An interface assembly for an inverter of a vehicle includes an interface, a plurality of busbars, a communication medium, and a clip. The interface is for communicating with one or more vehicle systems outside of the interface assembly. The plurality of busbars are configured to receive and transport electric current. The communication medium is electrically coupled between the plurality of busbars and the interface. The communication medium is configured to provide information to the interface based at least in part on the electric current transported by the plurality of busbars. The clip assembly is electrically coupled between the plurality of busbars and the communication medium.

Interface assemblies for use with inverters of vehicles

An assembly for transporting electric current in a vehicle includes a connector and a sensor package. The connector comprises a plurality of prongs. The plurality of prongs are configured to receive and transport electric current. The sensor package is electrically coupled to the connector, and comprises a plurality of sensors. Each of the plurality of sensors is electrically coupled to a different one of the plurality of prongs, and is configured to determine a measure of electric current thereof.

Vehicle electric current connector assembly with electric current sensors

A filter assembly is provided which includes a Faraday cage interface. Electrical noise is filtered by the Faraday cage interface. The Faraday cage interface is configured to prevent passage of electromagnetic waves.

Snap in high power, high current connector with integrated EMI filtering

A high current interconnection system is provided which can be configured to couple a motor to an inverter. A high current interconnection system comprises a bus bar, a motor winding coupled to the bus bar, and a thermal interface. The motor winding is configured to receive a current. The thermal interface can be coupled to at least one of the motor winding or the bus bar. The thermal interface is configured to reduce a temperature of the motor winding or bus bar which the thermal interface is coupled to.

High power, low noise interconnection for an integrated dual wound motor to a dual inverter

An electrical system as described herein is suitable for use in an electric or hybrid vehicle. The electrical system includes electrical devices, such as power transistors, coupled to an electrically and thermally conductive bus bar. The respective nodes of the electrical devices are coupled to the bus bar such that the bus bar carries a combined signal generated by the electrical devices. The bus bar is also thermally coupled to a conduction heat transfer system, such as a liquid cooled cold plate. Thus, the bus bar functions as both an electrical conduit and a conduction-based heat sink for the electrical system.

Integrated thermal and electrical connection system for power devices

Methods for controlling a multiple DC-to-AC inverter system, which is suitable for an electric or hybrid vehicle application, are disclosed. In one embodiment, if an inverter fails or suffers from degraded performance (faulty inverter), the faulty inverter is disabled and drive signals to a healthy inverter that is coupled to the faulty inverter are updated such that the healthy inverter can remain active without being driven into an over-current condition.

Multiple inverter system with single controller and related operating method

A multiple DC-to-AC inverter system, which is suitable for an electric or hybrid vehicle application, includes a plurality of inverters controlled by a single controller. One example embodiment includes four three-phase inverters driving one six-phase motor, where the output of the first inverter is coupled to the output of the fourth inverter and the output of the second inverter is coupled to the output of the third inverter. In response to the failure of an inverter, the drive signals to the inverter that is coupled to the faulty inverter are updated such that the partner inverter can remain active without being driven into an over-current condition.

Growing community of inventors

Manhattan Beach, CA, United States of America

Mark L Selogie