Gm Global Technolgoy Operations, Inc.

Rivian IP Holdings, LLC

Faraday & Future Inc.

Young Mok Doo

Silva Hiti

Steven E Schulz

Mark D Korich

Mark L Selogie

Robert T Dawsey

Juan Lopez

Constantin C Stancu

David Yuang Tang

Richard Michael Breese

Eric R Ostrom

Shawn Warren Merritt

Yang Liu

Daniel L Kowalewski

Henry Huang

Anthony P Tata

Konstantinos Triantos

Erik Christopher Hatch

Jason Huang

Jimmy M Chang

Disclosed embodiments include alignment apparatuses for circuit boards, inverter assemblies, and methods for fabricating an assembly with a circuit board placed on an alignment apparatus. An illustrative apparatus includes an electrically insulative substrate having a first substantially planar surface and a second substantially planar surface forming an opposing side of the first substantially planar surface. The second substantially planar surface defines therein self-aligning features that are configured to align at least one power module pin with the electrically insulative substrate. The first substantially planar surface has at least one alignment feature configured to align a printed circuit board with the electrically insulative substrate. The apparatus also includes a routing feature coupled to the electrically insulative substrate. The routing feature is configured to route at least one low voltage conductor.

Inverter insulator apparatus and method

Various disclosed embodiments include illustrative inverter modules that are integratably mountable with a drive unit of a vehicle, illustrative drive units with an inverter module integratably mounted therewith, and illustrative vehicles with at least one drive unit with an inverter module integratably mounted therewith. Given by way of non-limiting example, an illustrative module for a drive unit of a vehicle includes a housing having an open face defined therein. Inverter circuitry is disposed in the housing.

Inverter module integratably mountable with drive unit of vehicle

A power electronics module for an industrial or vehicle battery charger system or the like is provided. The power electronics module utilizes a chassis housing including a heatsink surface and a plurality of sidewalls. A main power section printed circuit board is disposed adjacent to the heatsink surface of the chassis housing a. A low voltage, low power printed circuit board is disposed adjacent to the main power section printed circuit board opposite the heatsink surface of the chassis housing. An alternating current input filter portion printed circuit board including electromagnetics is disposed along one of the plurality of sidewalls of the chassis housing and separated from the low voltage, low power printed circuit board within the chassis housing.

Power electronics module with improved space utilization and thermal management characteristics

An illustrative drive unit for an electric vehicle includes a first electrical motor, a first axle mechanically couplable to the first electrical motor, a second electrical motor, a second axle mechanically couplable to the second electrical motor, and a dual power inverter module electrically couplable to a source of high voltage DC electrical power. The dual power inverter module includes: a first inverter configured to convert the high voltage DC electrical power to three phase, high voltage AC electrical power and electrically couplable to provide the three phase, high voltage AC electrical power to the first electrical motor; a second inverter configured to convert the high voltage DC electrical power to three phase, high voltage AC electrical power and electrically couplable to provide the three phase, high voltage AC electrical power to the second electrical motor; and a common controller configured to control the first inverter and the second inverter.

Drive unit for electric vehicle

An illustrative dual power inverter module includes a DC link capacitor electrically connectable to a source of high voltage direct current (DC) electrical power. A first power inverter is electrically connectable to the DC link capacitor and configured to convert high voltage DC electrical power to three phase high voltage alternating current (AC) electrical power and is configured to supply the three phase high voltage AC electrical power to a first electric motor. A second power inverter is electrically connectable to the DC link capacitor and configured to convert high voltage DC electrical power to three phase high voltage AC electrical power and is configured to supply the three phase high voltage AC electrical power to a second electric motor. A common controller is electrically connectable to the first power inverter and the second power inverter. The common controller is configured to control the first power inverter and the second power inverter.

Dual inverter with common control

Power inverter assemblies are provided herein for use with motor vehicles. An inverter assembly may have a symmetrical structure configured to convert DC input power to AC output power. The inverter assembly may include a housing enclosing a symmetrical DC input portion, a symmetrical AC output portion, a DC link capacitor, and a gate drive portion having a pair of power modules. The symmetrical DC input portion can include a DC input bus bar sub-assembly to which the DC link capacitor is coupled, and a second DC bus bar sub-assembly that may electrically couple the DC link capacitor with the power modules. The symmetrical AC output portion may include a three phase output AC bus bar sub-assembly to which the power modules can be electrically coupled. A cooling sub-assembly may be provided for cooling the power modules with fluid transfer using a coolant.

Inverter AC bus bar assembly

Inverter assembly

Inverter DC bus bar assembly

A three-phase current sensor for measuring currents running in three conductors of a three-phase conductor system includes at least a first magnetic measuring device. The magnetic measuring device includes a magnetic circuit provided with at least two gaps and a magnetic field sensor arranged in each gap of the magnetic circuit. The magnetic field sensors are positioned on both sides of a cavity sized to receive one of the three conductors. The gaps and thus the magnetic field sensors are positioned such that stray magnetic flux from an adjacent conductor has substantially equal amplitude passing through each of the sensors.

Dual gap current sensor for multi phase conduction system

An electrical system includes an alternating current (AC) connector rod assembly and a polyphase electric machine. The electric machine has a plurality of phase leads each electrically connected to the AC connector rod assembly. The assembly includes spaced AC connector rods each having a center axis. The assembly also includes insulating housings and a carrier plate defining through holes that receive and space the AC connector rods. The carrier plate defines features that engage mating features of the insulating housings while allowing each of the rods to rotate about its respective center axis within the carrier plate. A vehicle includes a direct current (DC) battery pack, a DC bus, an AC bus, a PIM that is electrically connected on a first side to the DC bus and on a second side to the AC bus, the AC connector rod assembly, a traction motor, and a transmission.

Connector rod assembly for AC inverter output

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

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.

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La Palma, CA, United States of America

Young Mok Doo