Gm Global Technolgoy Operations, Inc.

Delco Electronics Corporation

Ronald W Young

David Yuang Tang

James E Tarchinski

Gery J Kissel

Silva Hiti

Brian A Welchko

Constantin C Stancu

Gregory S Smith

Terence G Ward

Seok-Joo Jang

Marko Jaksic

Jeffrey Johnson

William J Omell

Paul E Boskovitch

Sean S Clarke

Ronald J Wiegand

A power module includes a first circuit structure having a first bus substrate. The first bus structure has a first side on which is disposed a first circuit element. A second circuit structure has a second bus substrate and a second side on which is disposed a second circuit element. The first circuit structure and the second circuit structure are oriented in a stacked configuration such that the first side is disposed facing the second side, and the first circuit element partially overlaps the second circuit element. An output bus is disposed between the first circuit structure and the second circuit structure.

Power module

Methods and apparatus are provided for a functional high-voltage interlock system. The apparatus includes an enclosure, a high-voltage terminal, a low-voltage circuit, and a control circuit. The enclosure includes an access point that may be breached. The high-voltage terminal is disposed at least partially within the enclosure, is accessible by breaching the high-voltage access point, and is configured to be energized from a high-voltage electrical power source. The low-voltage circuit is disposed within the enclosure, and is coupled to selectively receive a low-voltage electrical signal. The control circuit is coupled to, and is configured to supply the low-voltage electrical signal to, the low-voltage circuit only when the high-voltage access point is not breached. The control circuit implements a first function and a disparate second function. The first function determines whether the access point is breached and, if so, prevents the high-voltage terminal from being energized from the high-voltage electrical source.

Functional high-voltage interlock system and method

Systems and methods are provided for monitoring current in an electric motor. An electrical system includes a (DC) interface, an electric motor, an inverter module coupled between the DC interface and the electric motor, a first current sensor between a first phase leg of the inverter module and a first phase of the electric motor to measure a first current flowing through the first phase of the electric motor, a second current sensor between the first phase leg and the DC interface to measure a second current flowing through the first phase leg, and a control module coupled to the first current sensor and the second current sensor. The control module is configured to initiate remedial action based at least in part on a difference between the first current measured by the first current sensor and the second current measured by the second current sensor.

Systems and methods for monitoring current in an electric motor

Systems and methods are provided for discharging a voltage bus. An electrical system comprises a first switch coupled to a first voltage rail, a second switch coupled between the first switch and a second voltage rail, and a control system coupled to the first switch and the second switch. The control system is configured to alternately activate the first switch and the second switch such that an energy potential between the first voltage rail and the second voltage rail is dissipated through the first switch and the second switch.

Systems and methods for discharging bus voltage using semiconductor devices

A connection monitoring system and method for a vehicle high voltage energy storage system is disclosed. The method performs a check, at initial connection of the high voltage energy storage system, to insure that the vehicle high voltage wiring system is fully connected and without short circuits prior to allowing full current to the vehicle and normal vehicle operation. The method switches in a resistor to limit current flow between the high voltage energy storage system and the vehicle high voltage wiring, and measures the voltage and a voltage rise time across the resistor. The voltage and the voltage rise time across the resistor are used to determine if a short circuit is present, and if so the high voltage energy storage system is disconnected to protect the vehicle and its users.

High voltage energy storage connection monitoring system and method

A system and method that may be implemented in a power inverter or controller, for example, that uses the speed of a rotor to control the torque output of a motor of an electric vehicle. A rotor encoder coupled to the rotor of the motor provides encoder signals that indicate the speed of the rotor and thus the speed of the vehicle. Alternatively, wheel speed sensors may be employed in lieu of the encoder to provide sensed signals that are processed to produce traction control of the vehicle. By monitoring the rate of change of the signals from the encoder or sensor, the controller determines if the drive wheels are spinning due to loss of traction. If this condition is detected, the controller reduces torque until traction has been regained.

Electric vehicle traction control system and method

A system and methods that provide for battery regeneration in electric vehicles without employing brake blending. Wheel speed sensors provide speed inputs to a controller, for example, that are processed to control the torque commands issued to a motor of the vehicle, which allows a higher level of battery regeneration without causing drive wheels to lock up. In the present invention, speed inputs derived from the wheel speed sensors are sampled. The absolute value of the difference between the input signals derived from the wheel speed sensors is compared to a predetermined difference threshold. If the absolute value of the difference between the input signals is less than the predetermined difference threshold, a regeneration torque command is generated to control the torque output of the motor that is equal to a current value of the regeneration torque command. If the absolute value of the difference between the input signals is greater than or equal to the predetermined difference threshold, a regeneration torque command is generated that is equal to the current value of the regeneration torque command times a reduction scale factor, to reduce the amount of battery regeneration to a level that does not lock up the wheels.

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Whittier, CA, United States of America

Ronald W Young