Gm Global Technolgoy Operations, Inc.

William T Ivan

Chandra S Namuduri

Alireza Fatemi

Yue Fan

Brendan M Conlon

Shifang Li

David J Trzcinski

Suresh Gopalakrishnan

Edward L Kaiser

Muhammad Hussain Alvi

Anthony M Coppola

Mohammad N Anwar

Yilun Luo

Aniket P Kothari

Mark Wisnewski

Song He

Timothy J Reinhart

Rajeev Vyas

Konstantinos Triantos

Kon-King Mike Wang

Kris Sevel

Bryan M Ludwig

Yew Sum Leong

Ahmad Albanna

Jeremy B Campbell

Grantland I Kingman

Mehrdad Teimorzadeh

Steven V Wybo

Konking (Michael) Wang

Md Nayeem Arafat

Azadeh Narimissa

Xiaoling Jin

Saranraj Karuppuswami

Ying Tan

Michael M Gandham

A choke device for an electric machine system is provided. The choke device includes a common-mode choke including a magnetic core configured in cross-section as a geometric shape including a hollow center. The choke device further includes a plurality of electric transmission lines configured for transmitting electrical energy in alternating current, wherein the plurality of electric transmission lines is routed through the hollow center. The geometric shape includes a number of sides based upon a number of the electric transmission lines present and is configured for minimizing or reducing an overall flux length of the magnetic core.

Choke device for an electric machine system

An electric machine including a stator, a rotor within the stator, and a shaft to which the rotor is mounted. The shaft extends through the stator. A first bearing and a second bearing support the shaft within the stator to allow the shaft and the rotor to rotate within the stator. The rotor is between the first bearing and the second bearing. A first magnetic core is at the shaft between the rotor and the first bearing. The first magnetic core is configured to suppress a bearing current flowing across the shaft, the first bearing, and the second bearing.

System for reducing bearing currents in an electric machine

Induced currents in a multi-phase AC motor may be attenuated by operating the multi-phase AC motor with an AC choke surrounding an AC bus providing multi-phase AC voltage to multi-phase AC stator windings in a stator, wherein the AC choke may include an effective bandwidth at least covering resonant frequencies of a capacitance between the multi-phase AC stator windings and the stator or a frame of the AC motor.

Attenuation of induced motor currents

An electric motor assembly includes a housing having a generally cylindrical inner surface defining a generally cylindrical cavity within the housing, a stator operatively disposed within the generally cylindrical cavity, the stator including a plurality of stacked laminations wherein each lamination has an outer circumferential edge and a plurality of finger elements extending inward, and a layer of polymer disposed between a generally cylindrical outer surface of the stator and the generally cylindrical inner surface of the housing, such that the stator is fastened to the housing by the polymer. A method of manufacturing the electric motor assembly includes disposing a stator within a housing such that a gap is defined between the stator and the housing and the stator is not directly connected to the housing, and substantially filling the gap with a polymer capable of fastening the stator to the housing by only the polymer.

Electric motor assembly using polymer-only fastening and methods of manufacturing the same

A multi-pack battery system having at least first and second battery packs each with positive and negative terminals, and each with upper and lower switches respectively connected to the positive and negative terminals. The battery packs have a first voltage level, and are connectable in either series or parallel. A controller controls an ON/OFF state of the switches in response to input signals to select between two series charging modes, three parallel charging modes, and one or more propulsion modes. Some embodiments have a series propulsion mode. An electric powertrain system includes first and second power inverter modules ('PIMs'), an electrical load, front and rear electric machines connected to a respective one of the first and second PIMs, and the battery system. The powertrain system may selectively provide all-wheel, front-wheel, or rear-wheel drive capabilities in each of the various propulsion modes.

Electric powertrain with multi-pack battery system

An electric propulsion system for a mobile platform includes a battery system connected to positive and negative bus rails, an accessory load having a rotary electric machine, a traction power inverter module ('TPIM'), and an accessory load, switches configured to transition the battery modules to a series-connected ('S-connected') configuration during a direct current fast-charging (&#x201c;DCFC&#x201d;) operation of the battery system, and a controller. When battery modules of the battery system are connected in series during a direct current fast-charging (&#x201c;DCFC&#x201d;) operation, the controller executes a diagnostic method to determine bus rail voltages on the positive and negative bus rails and a mid-bus voltage, identifies a diagnosed electrical condition of the electric propulsion system by comparing the voltages to expected values or ranges, and executes a control action in response to the diagnosed electrical condition.

Diagnostic method for electric propulsion system with reconfigurable battery system

An onboard charging module (OBCM), e.g., for a vehicle, is characterized by an absence of a transformer and includes an AC-to-DC voltage rectifier, DC-DC buck converter, DC-DC boost converter, DC link capacitor between the buck converter and boost converter, and solid-state devices. The devices include a diode and first and second switches having opposite open/closed switching states. The first and second switches are connected to a common rail of a DC bus, the first switch and diode are between the voltage rectifier and boost converter, and the second switch is between the link capacitor and buck converter. Third and fourth switches may be used on the opposite rail as the first and second switches. The OBCM is operable, via operation of the solid-state devices, to charge the HV-ESS via an AC power supply while maintaining current isolation. An electrical system includes the OBCM, DC bus, and HV-ESS.

Transformerless, current-isolated onboard charger with solid-state switching controls

An electrified powertrain system for a vehicle includes an electric machine coupled to a driveline. An inverter controller communicates directly with an auxiliary power module. An ignition module indicates either a key-on state or a key-off state. When the ignition module is in a key-off state, a low-power DC/DC converter generates an output voltage originating on the high-voltage DC bus having a magnitude sufficient to activate the inverter controller. The inverter controller detects a key-off uncontrolled generator (UCG) mode. The inverter controller directly communicates detection of the key-off UCG mode to the auxiliary power module. The inverter controller controls the inverter. The auxiliary power module supplies electric power to operate low-voltage electrically-powered powertrain actuators.

Method and apparatus for controlling an electrified powertrain system of a vehicle

A stator for an electric motor includes a plurality of pole pieces and a plurality of electrical windings associated with the pole pieces. Each winding includes a cable having an electrically conductive element. A lossy insulative material is located between the electrical windings and the associated pole pieces.

Stator for an electric motor

An electrical connector assembly for an electronic module includes a plug element having a body including at least one terminal receiving section. The at least one terminal receiving section includes at least one locking tab element. At least one rigid bus bar terminal is mounted in the at least one terminal receiving section. The at least one bus bar terminal extends from a first end to a second end through a substantially rigid intermediate portion. The first end includes a locking tab member inter-engaging with the locking tab element and the second end includes a module connector member.

Electrical connector assembly for an electronic module

An electromagnetic interference reduction assembly for a transmission is disclosed. A transmission casing includes a base and walls extending outwardly away from the base to a distal edge. The transmission casing defines a first cavity between the walls and includes a platform disposed between the walls. A power inverter module is disposed in the first cavity and supported by the platform when in the first cavity. The power inverter module generates electrical noise during operation which produces electromagnetic interference. A lid is attached to the distal edge of the walls to contain the power inverter module inside the first cavity. A grounding member engages the power inverter module and the lid when the lid is attached to the transmission casing to electrically connect the power inverter module to the lid to reduce the electrical noise exiting the first cavity which reduces the electromagnetic interference exiting the first cavity.

Electromagnetic interference reduction assembly for a transmission of a vehicle

Systems and methods for a fault protection are provided that can be implemented in a hybrid electric vehicle (HEV) to limit the magnitude of a current that flows when an AC-to-chassis fault (ACF) occurs between an AC connection and the chassis of the HEV. An electric machine having a winding, an inverter sub-module (ISM) having a first switch and a second switch, and fault protection elements (FPEs), coupled to the ISM, are provided. The winding is coupled to the ISM coupled via the AC connection. The FPEs can include, for example, first and second inductances. To limit the magnitude of the current, the current can be passed along a first current path that includes the second inductance when the first switch is closed, and can be passed along a second current path that includes the first inductance when the second switch is closed.

Method and system for fault protection

A seal for a vehicle having a transmission output shaft and a transmission output shaft housing is provided. The seal comprises a contact member at least partially surrounding and contacting the transmission output shaft, a support member coupled to the contact member, the support member at least partially surrounding the transmission output shaft and extending along the transmission output shaft, the support member coupled to the transmission output shaft housing, and an electrically-conductive surface overlying at least a portion of the contact member and at least a portion of the support member, the electrically-conductive surface contacting the transmission output shaft and the transmission output shaft housing.

Electrically-conductive seal assembly

Methods for AC fault (ACF) detection are provided. In addition, methods for AC fault (ACF) detection and verification are provided. In addition, methods for identification of a module which is the cause of an AC fault (ACF) are provided. In one implementation, one or more of these methods can be combined to provide a fast, simple, low cost and reliable ACF detection, verification and/or identification.

Methods for common mode voltage-based AC fault detection, verification and/or identification

RF signal noise in a powertrain utilizing a power inverter module and electric motor is attenuated by providing a low impedance connection between a transmission output shaft and housing.

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Shelby Township, MI, United States of America

William T Ivan