BorgWarner Patente

A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter) connectable to a load; a DC to DC converter (DC-DC converter) connected to the AC-DC converter and connectable to a battery; and one or more controllers including a current limiting compensator to control an operation of the AC-DC converter to control a voltage from the battery to the load.

Disclosed is a heater rod comprising a tube housing, a ceramic heating resistor (5), a contact sheet (4) electrically contacting the heating resistor (5), and a dielectric (3) electrically isolating the contact sheet (4) from the tube housing, wherein the tube housing is formed by two half-shells (2), each half-shell (2) comprising opposing lateral sections and a main section connecting the lateral sections. On opposite sides of the tube housing, a part of the lateral section of one of the two half-shells (2) is on the inside of the tube housing and a part of the lateral section of the other half-shell (2) is on the outside of the tube housing. Also disclosed is a method for manufacturing a heater rod.

A system includes a power converter, wherein the power converter includes: a first power module; and a cooling module configured to extract heat from the first power module, wherein the cooling module includes: a first heatsink plate with a connector; and a second heatsink plate with an extruded connector, wherein the extruded connector of the second heatsink plate is laser welded to the connector of the first heatsink plate.

A system for a power converter includes a rectifier, a capacitor connected to the rectifier, a direct current to alternating current inverter (DC-AC inverter) connected to the capacitor, and a switch to operate in a first position to connect a motor to an AC side of the DC-AC inverter and disconnect the motor from an AC side of the rectifier, and a second position to connect the motor to the AC side of the rectifier and disconnect the motor from the AC side of the DC-AC inverter.

A multi-level inverter configured to convert DC power to AC power to drive a motor includes a first printed circuit board for a two-level inverter, a power module electrically connected to the first printed circuit board; one or more busbars, one or more extension capacitors electrically connected to the one or more busbars, and a second printed circuit board electrically connected to the power module and to the first printed circuit board, wherein the second printed circuit board includes: one or more extension switches electrically connected to the one or more busbars, and one or more extension controllers to control the one or more extension switches.

A system includes an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a galvanic isolator separating a high voltage area of the inverter from a low voltage area of the inverter; a low voltage controller in the low voltage area; and a high voltage controller in the high voltage area and configured to communicate with the low voltage controller via the galvanic isolator, wherein the galvanic isolator includes: a printed circuit board (PCB) including a substrate having a high voltage side defining the high voltage area and a low voltage side defining the low voltage area, a low voltage metal trace on the low voltage side of the substrate and connected to the low voltage controller, and a high voltage metal trace on the high voltage side of the substrate and connected to the high voltage controller.

A DC-DC converter includes a first switch, and a first diode in parallel with the first switch, a second switch, and a second diode in parallel with the second switch, a third switch, and a third diode in parallel with the third switch, a fourth switch, and a fourth diode in parallel with the fourth switch, and one or more controllers configured to operate in a first period to turn on the first switch and hold the fourth switch to remain turned off, and to turn on the third switch and hold the second switch to remain turned off during one or more of a synchronous rectification of the DC-DC converter, a discontinuous conduction or light load of the DC-DC converter, or a freewheeling of the DC-DC converter.

A power converter includes a first half-bridge configured to operate at a first frequency, a second half-bridge in parallel with the first half-bridge and configured to operate at the first frequency, a third half-bridge in parallel with the second half-bridge and configured to operate at the first frequency, and a neutral half-bridge of the power converter in parallel with the third half-bridge and configured to operate at a second frequency, wherein the second frequency is based on the first frequency.

The present disclosure relates to an electric compressor module (100) for a thermal management system of an electric vehicle. The electric compressor module (100) comprises a housing (110), an electric compressor (120), a heater (130), control electronics (140) and electric connectors (150). The housing (110) includes a compressor housing section (112) and a control housing section (114). The electric compressor (120) has a rotation axis (120a) along an axial direction (2). The electric compressor (120) is arranged in the compressor housing section (112). The heater (130) comprises a heating element (132) and a coolant channel (134) including coolant ports (136). The control electronics (140) comprises a circuit board (142). The electric connectors (150) are electrically connected to the control electronics (140). The heater (130) and the control electronics (140) are arranged within the control housing section (114). The control housing section (114) is arranged axially adjacent to the compressor housing section (112). The coolant ports (136) and the electric connectors (150) are arranged at the control housing section (114) and are oriented in the same direction.

A system includes a multi-level inverter configured to convert DC power to AC power to drive a motor, wherein the multi-level inverter includes: a first printed circuit board for a two-level inverter; a power module electrically connected to the first printed circuit board; and a second printed circuit board electrically connected to the power module and to the first printed circuit board, wherein the second printed circuit board includes: one or more switches; one or more capacitors electrically connected to the one or more switches; and one or more controllers to control the one or more switches.

An electric machine includes a machine housing, a stator including a stator core defining a stator core interior and a plurality of windings including first and second end windings, and an internal core including first and second upper portions and first and second lower portions. The electric machine additionally includes a first outer insert engaged with the first upper portion, a second outer insert engaged with the second upper portion, a first inner insert engaged with the first lower portion, and a second inner insert engaged with the first lower portion. The first outer insert, the first inner insert, the first upper portion, and the first lower portion collectively define a first cooling channel for encapsulating the first end windings, and the second outer insert, the second inner insert, the second upper portion, and the second lower portion collectively define a second cooling channel for encapsulating the second end windings.

An electric machine includes a machine housing, and a stator including a stator core defining a stator core interior and a plurality of windings disposed in the stator core interior. The plurality of windings has first and second end windings. The electric machine further includes an internal core surrounding the plurality of windings within the stator core interior. The internal core includes a first upper portion, a second upper portion, a first lower portion, and a second lower portion. The electric machine includes a first insert surrounding the first plurality of windings. The first insert is engaged with the internal core to define a first cooling channel for encapsulating the first end windings. The electric machine also includes a second insert surrounding the second plurality of windings. The second insert is engaged with the internal core to define a second cooling channel for encapsulating the second end windings.

An electric machine includes a first cooling channel encapsulating first end windings, a second cooling channel encapsulating second end windings, a first supply path, and a second supply path. The electric machine includes a first outlet path configured to receive fluid from a first outlet fluidly coupled to the first cooling channel and a first outlet path, and a second outlet path configured to receive fluid from a second outlet fluidly coupled to the second cooling channel and a second outlet path. The first supply path is fluidly separate from the second supply path. The first cooling channel is configured such that, when the fluid is pressurized, the fluid flows from a first lower cooling portion to a first upper cooling portion and such that, when the fluid is not pressurized, the fluid does not flow from the first lower cooling portion to the first upper cooling portion.

A system includes an inverter to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power module including: a positive DC power tab; a negative DC power tab; an AC power tab; a first neutral power tab; a second neutral power tab, wherein the first neutral power tab and the second neutral power tab are on opposite sides of the positive DC power tab and the negative DC power tab; a first switch electrically connected to the positive DC power tab and the AC power tab; a second switch electrically connected to the negative DC power tab and the AC power tab; and one or more switches electrically connected to the AC power tab and one or more of the first neutral power tab or the second neutral power tab.

A range extender system may include a first electric machine. A range extender system may include a first gearbox. A range extender system may include an engine. A range extender system may include a first connector to couple and decouple the first electric machine to and from the engine. A range extender system may include a second connector to couple and decouple the first electric machine to and from the first gearbox.

A system includes an inverter to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a capacitor assembly including: a first group of capacitors connected to one or more power modules, wherein the first group of capacitors are used when the one or more power modules operate as a two-level inverter; and a second group of capacitors connected to the one or more power modules, wherein the second group of capacitors are used when the one or more power modules operate as a three-level inverter or as the two-level inverter.

A system includes an inverter to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a capacitor assembly including: a first busbar; a second busbar; a third busbar between the first busbar and the second busbar; and one or more capacitors connected to one or more of the first busbar, the second busbar, or the third busbar.

A system includes an inverter configured to convert DC power from a main battery to AC power to drive a motor, wherein the inverter includes a galvanic isolator separating a high voltage (HV) area from a low voltage (LV) area, a gate driver in the HV area, the gate driver to control one or more switches in the HV area in response to a control signal from the LV area, an auxiliary battery assembly in the HV area, and a power supply to provide power to the HV area from each of the main battery and the auxiliary battery assembly.

A system includes a power conversion unit, wherein the power conversion unit includes: a power module; and a first cooling module configured to extract heat from the power module, wherein the power module includes: a printed circuit board; a switching power device embedded within the printed circuit board; and a first external isolation layer external to the printed circuit board, wherein the first cooling module directly contacts the first external isolation layer.

A system includes an inverter configured to convert DC power from a battery to AC power, wherein the inverter includes: a duty cycle adjustor including: a rising edge detector to detect a rising edge of a periodic signal; a ramp generator connected to the rising edge detector; a first comparator connected to the ramp generator; a duty cycle trimmer connected to the first comparator; and a bidirectional current trimmer connected to the duty cycle trimmer and the ramp generator.

A system includes an inverter configured to convert DC power from a battery to AC power, wherein the inverter includes: a pulse demodulator including: an analog timer including: a first stage pulse generator, a second stage pulse generator connected to the first stage pulse generator, and a third stage pulse generator connected to the second stage pulse generator; and a voltage translator including: a voltage divider connected to the first stage pulse generator, the second stage pulse generator, and the third stage pulse generator, and a comparator connected to the voltage divider.

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