Ford Global Technolgoies, LLC

Ford Motor Company Limited

Semipower Systems, Inc.

Other

Venkateswara Anand Sankaran

Chingchi Chen

Lawrence E Rinehart

John Michael Miller

Xingyi Xu

Chi Paik

Robert Taenaka

Yi-Hsin Pao

Joseph F Freiman

Wen-Je Jung

Walter Noll

Jacqueline Jammoul

A vehicle includes a thermal system for a battery; and a controller for the thermal system. The controller may be configured to, during vehicle motion, cool the battery when a temperature of the battery exceeds a lower threshold and inhibit transfer of power with the battery when the temperature exceeds an upper threshold, and while coupled with a charge station, heat the battery to a temperature between the lower threshold and the upper threshold.

Battery pre-heating prior to fast charge

A fault detection circuit and method for monitoring a power converter system to identify faults. The detection circuit includes two comparator circuits each having one input connected to the dc bus of the power converter system and responsive to the voltage spikes that occur as a result of faults. The other inputs of the comparator circuits are respectively connected to first and second sources of reference voltages having preset limits. The outputs of the two comparator circuits are combined on an output lead, and a fault signal will be produced on the output lead when the voltage spike on the dc bus exceeds the limits.

System and method for monitoring the operation of a power converter

A power switching module includes a substrate having at least one silicon die forming at least one power switching element and having leadframe terminal posts extending away therefrom. A planar negative rail layer providing a negative power supply and including a non-inductive current shunt resistor formed therein and a planar positive rail layer providing a positive power supply are positioned at the substrate so that the negative rail layer and the positive rail layer are coplanar with respect to each other. A phase output layer providing a phase output signal is also positioned at the substrate. Each of the layers are electrically isolated from each of the other layers and are electrically connected to the substrate.

High power switching module

A system and method for detecting various fault conditions in semiconductor devices. A variable voltage reference is compared to the voltage output of the device during device turn-on to detect circuit fault conditions. The fault condition is then communicated to a controller.

Semiconductor switch fault detection

A substrate assembly for use with a high power switching module includes at least one power block having a base plate for providing mechanical rigidity for the power block. The power block also includes at least one silicon die mounted onto the base plate and configured to form at least one high power switching transistor having leads extending away therefrom. The power blocks are then supportably mounted into corresponding apertures in a rigid frame which mounts the power switching module onto a heat dissipating surface and tested independently before mounting into the frame at full load current and power, which cannot be performed at the bare die level.

Power block assembly and method of making same

An isolated gate driver device for a power switching device having a plurality of transistors includes a primary circuit having a voltage source of a first voltage potential. The primary circuit constantly switches the voltage source to generate first and second load signals based on control signals received from a microcontroller. The first load signal is modulated at a first frequency for enabling the transistors, and the second load signal is modulated at a second frequency, different from the first frequency, for disabling the transistors. A plurality of high frequency transformers corresponding to each of the transistors is coupled to the primary circuit. The transformers have a primary side for receiving one of the first and second load signals and a secondary side for transforming the one of the first and second load signals into corresponding signals at a second voltage potential. A secondary circuit coupled between each of the transformers and each of the corresponding transistors provides a bias power supply to each of the transistors at the second voltage potential. The secondary circuit also enables and disables each of the transistors based on the first and second load signals.

Isolated gate driver for power switching device and method for carrying

A cost-effective conditioning circuit for extracting a weak, floating, wide-band signal with a low common-mode voltage from noisy environments is proposed that includes a high gain single ended operational amplifier to increase the amplitude of the signal. A simple, cost-effective approximately unity gain differential amplifier stage is used to level-shift the signal down to the desired reference potential. A typical application is a motor drive system, where the signals to be measured are bi-directional motor currents.

Signal conditioning circuit for low amplitude, high common mode voltage

A power module has a metallic base plate layer and a substrate layer that has a first metallic layer, a dielectric layer, and a second metallic layer. A solder layer thermally and electrically connects the second metallic layer to the base plate. A plurality of silicon dice are mounted to the first metallic layer of the substrate. The solder layer has a void development region which after a predetermined number of thermal cycles does not significantly increase. The silicon dice are oriented on the substrate layer so that the silicon dice are not aligned over the void development region corresponding to the useful life of the module. The metallic base plate may also be mounted to a heatsink through a thermal grease layer. The heatsink may comprise the outer covering of the power module.

Power module with silicon dice oriented for improved reliability

An integrated power module combining drivers and power devices includes a diagnosis module integrated with or connected to the integrated power module. That includes protectors. The protectors provides protection against power device failure, transistor stack failure, gate drive failure, power failure, and other conditions. In a first level of diagnosis and protection, a gate driver is responsive to hard faults, such as short circuit and under voltage conditions, to disenable the power devices, for example, switching transistors of an inverter. In addition, the first level of protection includes soft faults, such as detection of overcurrent and over temperature in the power device, conditions that are merely reported to the controller, whereby the number and frequency of the events can be monitored. The second level of protection also provided by the diagnostic module may include power interlock to ensure that full power is being delivered to the integrated power module. The system permits detection of a transistor stack failure by monitoring the thermal resistance of the stack layers or junctions to detect physical degradation of the junctions and determine when the level of deterioration exceeds a pre-determined level. In addition, a power cycling failure diagnosis determines the integrity of the wirebonds, for example, wirebonds joining a silicon die to appropriate metal land patterns, as well as the integrity of stack junctions.

Integrated power module diagnostic unit

An electrically powered active suspension system is disclosed having a suspension unit wherein the system controller and the power electronics module are integrated into a single housing with the motor mechanism of the suspension unit.

Growing community of inventors

Farmington Hills, MI, United States of America

Venkateswara Anand Sankaran