System for generating heat in electric power systems and electrified powertrains

Abstract

A power system has a power inverter system with a quasi-resonant circuit (QRC) and a controller, and couples a DC power source to an electric machine. The power inverter system comprises a positive inverter bus and a negative inverter bus. A first pair of switches; a positive DC bus terminal; and a negative DC bus terminal. The QRC includes an inverter inductance device, a capacitor, a first bus switch, and a second bus switch. The inverter inductance device and the second bus switch are arranged in series between the positive inverter bus and the first switch node, and the first bus switch is arranged between the positive DC bus terminal and the positive inverter bus. The controller is configured to control the QRC to generate alternating current in the DC power source.

Description

Background Art

[0001] The present disclosure relates to a multiphase inverter circuit for an electric motor / generator, including an architecture capable of inducing heating in an attached DC power supply without using an external heater (such as a convective heat source (e.g., a positive temperature coefficient or PTC heater)). Summary of the Invention

[0002] An architecture of an inverter circuit for a motor that utilizes power from a DC power supply is beneficial, which is capable of inducing heating in the attached DC power supply without using an external heater such as a convective source (e.g., a positive temperature coefficient or PTC heater).

[0003] In one embodiment, the present disclosure provides an architecture for a power system (e.g., an electrified powertrain for a vehicle), which includes a power inverter that incorporates elements of a quasi-resonant circuit (QRC), and the quasi-resonant circuit is capable of generating an AC current in a DC power bus under certain operating conditions, where due to the self-impedance of the DC power supply through which the AC current passes, the AC current causes self-heating of the attached DC power supply.

[0004] One aspect of the present disclosure may include a power system having a power inverter system with a quasi-resonant circuit (QRC) and a controller. The power inverter system is arranged to couple a DC power supply to a motor. The power inverter system includes: a positive inverter bus and a negative inverter bus; a first pair of switches arranged in series between the positive inverter bus and the negative inverter bus and joined at a first switch node; a positive DC bus terminal; and a negative DC bus terminal. The QRC includes an inverter inductor device, a capacitor, a first bus switch, and a second bus switch, where the capacitor is connected between the positive inverter bus and the negative inverter bus. The inverter inductor device and the second bus switch are arranged in series between the positive inverter bus and the first switch node arranged between the first pair of switches, and the first bus switch is arranged between the positive DC bus terminal and the positive inverter bus. The controller is configured to control the QRC to generate alternating current in the DC power supply.

[0005] Another aspect of the present disclosure may include the controller being configured to control the first bus switch and the second bus switch to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

[0006] Another aspect of the present disclosure may include the controller controlling the first bus switch to an open state and the second bus switch to a closed state to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

[0007] Another aspect of the present disclosure may include the controller controlling the first bus switch to an open state and the second bus switch to a closed state to generate an alternating current in the DC power source via the inverter inductor device and the capacitor to generate heat energy in the DC power source.

[0008] Another aspect of the present disclosure may include the controller controlling the second bus switch under pulse width modulation conditions between an open state and a closed state to generate an alternating current in the DC power source via the inverter inductor device and the capacitor.

[0009] Another aspect of the present disclosure may include the first switch node being connected to the motor via an AC power bus to transmit a pulse width modulated power signal thereto.

[0010] Another aspect of the present disclosure may include a power inverter system that includes a second pair of switches arranged in series between a positive inverter bus and a negative inverter bus and joined at a second switch node; wherein the QRC includes a third bus switch; wherein the inverter inductor device and the third bus switch are arranged in series between the positive inverter bus and the second switch node arranged between the second pair of switches; and wherein the controller is configured to control the first bus switch, the second bus switch, and the third bus switch to generate an alternating current in the DC power source via the inverter inductor device and the capacitor.

[0011] Another aspect of the present disclosure may include the controller controlling the first bus switch to an open state and one of the second bus switch and the third bus switch to a closed state to generate an alternating current in the DC power source via the inverter inductor device and the capacitor.

[0012] Another aspect of the present disclosure may include the controller using a first pulse width modulation signal to control the second bus switch between an open state and a closed state, and using a second pulse width modulation signal to control the third bus switch to generate an alternating current in the DC power source via the inverter inductor device and the capacitor.

[0013] Another aspect of the present disclosure may include the controller controlling the power inverter system to operate in a non-traction mode, wherein the controller is configured to control the first bus switch and the second bus switch to generate an alternating current in the DC power source during operation in the non-traction mode via the inverter inductor device and the capacitor.

[0014] Another aspect of the present disclosure may include an electrified powertrain system that includes a DC power source, a positive link and a negative link of a DC power bus, a power inverter system having a quasi-resonant circuit (QRC), an electric motor, and a controller. The electric motor is coupled to a torque actuator via a gear train, and the power inverter system couples the DC power source to the electric motor. The power inverter system includes: a positive inverter bus and a negative inverter bus; a first pair of switches arranged in series between the positive inverter bus and the negative inverter bus and joined at a first switch node; a positive DC bus terminal; and a negative DC bus terminal. The positive inverter bus is coupled to the positive link of the DC power bus, and the negative inverter bus is coupled to the negative link of the DC power bus. The DC power source includes a power unit that can be coupled to the positive link of the DC power bus via a first unit switch and a second unit switch, and the first unit switch is arranged in parallel with the second unit switch. The QRC includes an inductive device, a capacitor, a first bus switch, and a second bus switch; wherein the capacitor is connected between the positive inverter bus and the negative inverter bus; the inductive device and the second bus switch are arranged in series between the positive inverter bus and the first switch node arranged between the first pair of switches; the first bus switch is arranged between the positive DC bus terminal and the positive inverter bus; and the controller is configured to control the QRC, the first unit switch, and the second unit switch to generate alternating current in the DC power source.

[0015] Another aspect of the present disclosure may include an electrified powertrain system for a vehicle that includes a DC power source, a positive link and a negative link of a DC power bus, a first multiphase inverter system coupled to a first electric motor, a second multiphase inverter system coupled to a second electric motor, a first drivetrain, and a controller. The positive link of the DC power bus includes a first unit switch and a second unit switch arranged in series with a resistor, wherein the first unit switch is arranged in parallel with the second unit switch, and the second unit switch is arranged in series with the resistor. The controller controls the first bus switch to be in an open state and the second bus switch to be in a closed state to generate heat energy through the first multiphase inverter system and the resistor.

[0016] Another aspect of the present disclosure includes that one of the first bus switch or the second bus switch is an insulated gate bipolar transistor (IGBT).

[0017] Another aspect of the present disclosure includes that one of the first bus switch or the second bus switch is a gallium nitride (GaN) transistor.

[0018] Another aspect of the present disclosure includes that one of the first bus switch or the second bus switch is a silicon carbide (SiC) transistor.

[0019] The present disclosure also includes the following examples: Example 1. A power system, comprising: Power inverter system and controller with a quasi-resonant circuit (QRC); wherein the power inverter system is arranged to couple a DC power supply to an electric motor; wherein the power inverter system includes: a positive inverter bus and a negative inverter bus; a first pair of switches arranged in series between the positive inverter bus and the negative inverter bus and joined at a first switching node; a positive DC bus terminal; and a negative DC bus terminal; wherein the QRC includes an inverter inductance device, a capacitor, a first bus switch, and a second bus switch; wherein the capacitor is connected between the positive inverter bus and the negative inverter bus; wherein the inverter inductance device and the second bus switch are arranged in series between the positive inverter bus and the first switching node arranged between the first pair of switches; wherein the first bus switch is arranged between the positive DC bus terminal and the positive inverter bus; and wherein the controller is configured to control the QRC to generate alternating current in the DC power supply.

[0020] Example 2. The power system according to Example 1, wherein the controller is configured to control the QRC to generate alternating current in the DC power supply, including the controller being configured to control the first bus switch and the second bus switch to generate alternating current in the DC power supply via the inverter inductance device and the capacitor.

[0021] Example 3. The power system according to Example 1, including wherein the controller controls the first bus switch to an open state and controls the second bus switch to a closed state to generate alternating current in the DC power supply via the inverter inductance device and the capacitor.

[0022] Example 4. The power system according to Example 3, including wherein the controller controls the first bus switch to an open state and controls the second bus switch to a closed state to generate alternating current in the DC power supply via the inverter inductance device and the capacitor to generate heat energy in the DC power supply.

[0023] Example 5. The power system according to Example 3, further including wherein the controller controls the second bus switch under pulse width modulation conditions between an open state and a closed state to generate alternating current in the DC power supply via the inverter inductance device and the capacitor.

[0024] Example 6. The power system according to Example 1, wherein the first switching node is connected to the electric motor via an AC power bus to transmit a pulse width modulated power signal thereto.

[0025] Example 7. The power system according to Example 1 further includes: wherein the power inverter system includes: a second pair of switches, which are arranged in series between the positive inverter bus and the negative inverter bus and are joined at a second switch node; wherein the QRC includes a third bus switch; wherein the inverter inductance device and the third bus switch are arranged in series between the positive inverter bus and the second switch node arranged between the second pair of switches; and wherein the controller is configured to control the first bus switch, the second bus switch, and the third bus switch to generate alternating current in the DC power supply via the inverter inductance device and the capacitor.

[0026] Example 8. The power system according to Example 7 includes wherein the controller controls the first bus switch to an open state and controls one of the second bus switch and the third bus switch to a closed state to generate alternating current in the DC power supply via the inverter inductance device and the capacitor.

[0027] Example 9. The power system according to Example 8 further includes wherein the controller controls the second bus switch with a first pulse width modulation signal between an open state and a closed state, and wherein the controller controls the third bus switch with a second pulse width modulation signal to generate alternating current in the DC power supply via the inverter inductance device and the capacitor.

[0028] Example 10. The power system according to Example 1 further includes wherein the controller controls the power inverter system to operate in a non-traction mode; and wherein, the controller being configured to control the QRC to generate alternating current in the DC power supply includes the controller being configured to control the first bus switch and the second bus switch to generate alternating current in the DC power supply via the inverter inductance device and the capacitor during operation in the non-traction mode.

[0029] Example 11. An electrified powertrain system includes: a DC power supply, a positive link and a negative link of a DC power bus, a power inverter system having a quasi-resonant circuit (QRC), an electric motor, and a controller; wherein, the electric motor is coupled to a torque actuator via a gear train; wherein, the power inverter system couples the DC power supply to the electric motor; wherein, the power inverter system includes: a positive inverter bus and a negative inverter bus; a first pair of switches, which are arranged in series between the positive inverter bus and the negative inverter bus and are joined at a first switch node; a positive DC bus terminal; and a negative DC bus terminal; wherein the positive inverter bus is coupled to the positive link of the DC power bus, and wherein the negative inverter bus is coupled to the negative link of the DC power bus; wherein the DC power source includes a power unit that is coupleable to the positive link of the DC power bus via a first unit switch and a second unit switch; wherein the first unit switch and the second unit switch are arranged in parallel; wherein the QRC includes an inductive device, a capacitor, a first bus switch, and a second bus switch; wherein the capacitor is connected between the positive inverter bus and the negative inverter bus; wherein the inductive device and the second bus switch are arranged in series between the positive inverter bus and a first switch node disposed between the first pair of switches; wherein the first bus switch is disposed between the positive DC bus terminal and the positive inverter bus; and wherein the controller is configured to control the QRC, the first unit switch, and the second unit switch to generate alternating current in the DC power source.

[0030] Example 12. The electrified powertrain according to Example 11, wherein the controller is configured to control the QRC to generate alternating current in the DC power source, including the controller being configured to control the first bus switch and the second bus switch to generate alternating current in the DC power source via the inductive device and the capacitor.

[0031] Example 13. The electrified powertrain according to Example 11, including wherein the controller controls the first bus switch to an open state and controls the second bus switch to a closed state to generate alternating current in the DC power source via the inductive device and the capacitor.

[0032] Example 14. The electrified powertrain according to Example 13, including wherein the controller controls the first bus switch to an open state and controls the second bus switch to a closed state to generate alternating current in the DC power source via the inductive device and the capacitor to generate heat energy in the DC power source.

[0033] Example 15. The electrified powertrain according to Example 13, further including wherein the controller controls the second bus switch under pulse width modulation conditions between an open state and a closed state to generate alternating current in the DC power source via the inductive device and the capacitor.

[0034] Example 16. The electrified powertrain according to Example 11, wherein the first switch node is connected to an electric motor via an AC power bus to transmit a pulse width modulated power signal thereto.

[0035] Example 17. The electrified powertrain system according to Example 11 further includes: wherein the power inverter system includes: a second pair of switches, which are arranged in series between the positive inverter bus and the negative inverter bus and are joined at a second switching node; wherein the QRC includes a third bus switch; wherein the inductive device and the third bus switch are arranged in series between the positive inverter bus and the second switching node arranged between the second pair of switches; and wherein the controller is configured to control the first bus switch, the second bus switch, and the third bus switch to generate alternating current in the DC power source via the inductive device and the capacitor.

[0036] Example 18. The electrified powertrain system according to Example 17 further includes wherein the controller controls the second bus switch with a first pulse width modulation signal between an open state and a closed state, and wherein the controller controls the third bus switch with a second pulse width modulation signal to generate alternating current in the DC power source via the inductive device and the capacitor.

[0037] Example 19. The electrified powertrain system according to Example 11 further includes wherein the controller controls the power inverter system to operate in a non-traction mode; and wherein the controller being configured to control the QRC to generate alternating current in the DC power source includes the controller being configured to control the first bus switch and the second bus switch to generate alternating current in the DC power source via the inductive device and the capacitor during operation in the non-traction mode.

[0038] Example 20. An electrified powertrain system for a vehicle, including: a DC power source, a positive link and a negative link of a DC power bus, a first multiphase inverter system coupled to a first motor, a second multiphase inverter system coupled to a second motor, a first powertrain, and a controller; wherein the positive link of the DC power bus includes a first unit switch and a second unit switch arranged in series with an inductive device, wherein the first unit switch is arranged in parallel with the second unit switch, and the second unit switch is arranged in series with the inductive device; wherein the first multiphase inverter system includes: a plurality of pairs of switches, a positive inverter bus, a negative inverter bus, a first bus switch, a second bus switch, a positive DC bus terminal, and a negative DC bus terminal, wherein the positive DC bus terminal is connected to the positive inverter bus, wherein the negative DC bus terminal is connected to the negative inverter bus, wherein each of the plurality of pairs of switches is arranged in series between the positive inverter bus and the negative inverter bus, Each of a plurality of paired switches is coupled at a respective switch node, including a first paired switch of the plurality of paired switches being coupled at a first switch node, wherein a first bus switch is disposed on a positive inverter bus between a positive DC bus terminal and the positive inverter bus; wherein a second bus switch is electrically connected between the positive DC bus terminal and a first switch node of a first paired switch of the plurality of paired switches; wherein a DC power source is connected to the first multiphase inverter system at a positive DC bus terminal and a negative DC bus terminal via a positive link and a negative link of a DC power bus, respectively; wherein the controller is operably connected to the plurality of paired switches, the first bus switch, the second bus switch, a first unit switch, and a second unit switch; and wherein the controller controls the first bus switch to be in an open state and controls the second bus switch to be in a closed state to generate heat energy through the first multiphase inverter system and an inductive device.

[0039] The above features and advantages of the present teachings, as well as other features and advantages, will be apparent from the following detailed description of some of the best modes and other embodiments for carrying out the present teachings as defined in the appended claims when considered in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] One or more embodiments will now be described by way of example with reference to the accompanying drawings, in which: Figure 1 An embodiment of a power system according to the present disclosure is schematically illustrated, which is arranged as an element of an electrified powertrain for a vehicle.

[0041] Figure 2 An embodiment of a multiphase inverter system and a DC power source for operating a multiphase motor according to the present disclosure is schematically illustrated.

[0042] Figure 3 Another embodiment of a multiphase inverter system and a DC power source for operating a multiphase motor according to the present disclosure is schematically illustrated.

[0043] Figure 4 Another embodiment of a multiphase inverter system and a DC power source for operating a multiphase motor according to the present disclosure is schematically illustrated.

[0044] Figure 5 Another embodiment of a multiphase inverter system and a DC power source for operating a multiphase motor according to the present disclosure is schematically illustrated.

[0045] Figure 6Another embodiment of a multiphase inverter system and a DC power source for operating a plurality of multiphase motors in accordance with the present disclosure is schematically illustrated. Detailed Description

[0046] As described and illustrated herein, the components of the disclosed embodiments may be arranged and designed in a variety of different configurations. Thus, the following detailed description is not intended to limit the scope of the claimed disclosure, but is merely representative of its possible embodiments. Additionally, although numerous specific details are set forth in the following description to provide a thorough understanding of the embodiments disclosed herein, some embodiments may be practiced without some of these details. Further, certain technical materials understood in the relevant art are not described in detail to avoid unnecessarily obscuring the disclosure. Additionally, as shown and described herein, the disclosure may be practiced in the absence of elements not specifically disclosed herein. As used herein, the term "system" may refer to one or a combination of mechanical and electrical hardware, sensors, controllers, application specific integrated circuits (ASICs), combinational logic circuits, software, firmware, and / or other components arranged to provide the described functionality.

[0047] Reference is now made to the drawings, where the description is for purposes of illustration of certain embodiments only and is not intended to be limiting of these embodiments. Figure 1 Various embodiments of a power system 10 and multiphase inverter systems 100, 200, 300, 500, or 600 that have been manufactured in accordance with the concepts described and claimed herein are schematically illustrated. Throughout several of the drawings and embodiments, like reference numerals correspond to like or similar components.

[0048] Referring again to Figure 1 and Figure 2 , the power system 10 includes a multiphase inverter system 100, a DC power source 20, a motor 40, and a controller 30, where the multiphase inverter system 100 is controlled by the controller 30 to convert and transfer power between the DC power source 20 and the motor 40, thereby generating torque (e.g., propulsion mode) or generating power (e.g., regenerative braking mode). In one embodiment, the power system 10 is an element of an electrified powertrain 50 that provides propulsion torque to a vehicle 15. The vehicle 15 may include, but is not limited to, mobile platforms in the form of commercial vehicles, industrial vehicles, agricultural vehicles, passenger vehicles, airplanes, boats, trains, all-terrain vehicles, personal mobility devices, robots, etc. for purposes of implementing the present disclosure. Alternatively, the power system 10 may be an element of a fixed system. The concepts described herein may be used for both vehicle systems and fixed systems.

[0049] The controller 30 may be embodied as one or more digital computing devices and may include one or more processors 34 and a memory 32. The control program 36 may be stored in the memory 32 as an executable instruction set and executed by one of the processors 34 of the controller 30. The controller 30 communicates with the multiphase power inverter 100 via a communication link 35 to control its operation in response to the execution of the control routine 36, thereby operating the motor 40.

[0050] The terms “controller” and related terms such as control module, module, control, control unit, processor, and like terms refer to one or more combinations of application specific integrated circuits (ASICs), (multiple) electronic circuits, (multiple) central processing units such as (multiple) microprocessors, and (multiple) associated non-transitory memory components in the form of memories and storage devices (read only, programmable read only, random access, hard disk drives, etc.). The non-transitory memory components are capable of storing machine-readable instructions in the form of one or more software or firmware programs or routines, (multiple) combinational logic circuits, (multiple) input / output circuits and devices, signal conditioning and buffering circuits, and other components accessible by one or more processors to provide the described functionality. The (multiple) input / output circuits and devices include analog / digital converters and related devices that monitor inputs from sensors, where such inputs are monitored at a preset sampling frequency or in response to a triggering event. Software, firmware, programs, instructions, control routines, code, algorithms, and like terms refer to an instruction set executable by the controller, including calibration and look-up tables. Each controller executes (multiple) control routines to provide the desired functionality. The routines may be executed at regular intervals, such as every 100 microseconds during an ongoing operation. Alternatively, the routines may be executed in response to the occurrence of a triggering event. Communication between controllers and communication between a controller, an actuator, and / or a sensor may be implemented using direct wired point-to-point links, networked communication bus links, wireless links, or other suitable communication links. Communication includes exchanging data signals in a suitable form, including for example electrical signals via a conductive medium, electromagnetic signals via air, optical signals via an optical waveguide, etc. The data signals may include discrete, analog, or digitized analog signals representing inputs from sensors, actuator commands such as transistor gate drivers, and communication between controllers. The term “signal” refers to a physically distinguishable indicator that conveys information and may be a suitable waveform capable of propagating through a medium (e.g., electrical, optical, magnetic, mechanical, or electromagnetic), such as DC, AC, sine wave, triangular wave, square wave, vibration, etc.

[0051] As used herein, the term “motor” refers to a rotating electric motor, generator, or motor-generator device that includes a rotor and a stator and is capable of converting electrical energy into mechanical energy and / or converting mechanical energy into electrical energy by electromagnetic force.

[0052] The electric machine 40 may include a cylindrical rotor assembly disposed on a rotor shaft and arranged within an annular stator, where the rotor assembly is coaxial with a rotor opening formed in the stator. Other elements of the electric machine 40, such as end caps, bearings, electrical connections, etc., are included but not shown. The electrical windings of the stator are arranged with a certain number of electrical phases and a certain number of turns per phase. Depending on the specific arrangement, the number of electrical phases may be between 3 and 6, and the number of conductor layers may be between 4 and 12.

[0053] The DC power supply 20 is connected to the multiphase power inverter 100 via a high-voltage DC bus having a positive link 28 and a negative link 29, where the positive link 28 is connected to the multiphase power inverter 100 at the positive DC bus terminal 101, and the negative link 29 is connected to the multiphase power inverter 100 at the negative DC bus terminal 102.

[0054] The DC power supply 20 includes one or more power units 21, a first unit switch 22 arranged in parallel with a second unit switch 23 and a resistor 24, and an inductor 25, which are arranged to transmit DC power to the multiphase power inverter 100 via the positive link 28 and the negative link 29 of the high-voltage DC bus.

[0055] The power units 21 of the DC power supply 20 may be one or more rechargeable electrochemical battery devices, fuel cells, supercapacitors, and / or another electrical energy storage / generation technology.

[0056] The multiphase power inverter 100 is connected to the electric machine 40 via a plurality of AC power buses 105A, 105B, 105C to transmit pulse-width modulation signals thereto. In one embodiment, each of the AC power buses 105A, 105B, 105C is arranged as a single lead electrically connecting between the multiphase inverter 100 and the electric machine 40, and is illustrated as a solid line. Alternatively, each of the AC power buses 105A, 105B, 105C is arranged as a double lead electrically connecting between the multiphase inverter 100 and the electric machine 40, and is shown as a solid line and a dashed line.

[0057] In one embodiment, the electrified powertrain 50 includes a rotatable member 12 that is coupled via a gear train 54 to a torque actuator 56 in the form of a ground wheel or other device, where the torque actuator 56 transfers torque to the ground to effect forward movement as part of a propulsion system. The electric machine 40 is controllable to rotate and generate mechanical torque that, when operating in a torque generation mode, is transferred via the rotatable member 52 and the gear train 54 to the torque actuator 56. The electric machine 40 is controllable to generate AC power from the mechanical torque sourced at the torque actuator 56 via electromagnetic forces, and when operating in a power generation mode, such as may occur due to regenerative braking, the AC power is converted to DC power by a multiphase power inverter 100 for storage in a DC power source 20.

[0058] A quasi-resonant circuit (QRC) 60 includes elements arranged as part of the multiphase power inverter 100 to effect self-heating of the DC power source 20, such as when the multiphase power inverter 100 is operating in a non-traction mode. Under certain operating conditions, the QRC 60 is capable of generating an AC current in the positive link 28 of the high-voltage DC bus, where the AC current causes self-heating of the DC power source 20 due to the interaction of the AC current with its internal resistance. The QRC 60 may utilize elements within the DC power source 20 to supplement its operation.

[0059] Now referring Figure 2 , continuing to refer Figure 1 to the elements of, an embodiment of a multiphase inverter system 100 connected to the DC power source 20 is shown. In one embodiment, and as described herein, the multiphase inverter system 100 is configured as a three-phase inverter system. In one embodiment, the electric machine 40 is configured as a three-phase permanent magnet motor / generator having stator legs arranged in a star configuration. Alternative embodiments of the multiphase inverter system 100 may include 2-phase, 4-phase, 6-phase, etc. and other configurations of the electric machine 40.

[0060] In one embodiment, and as shown, the DC power source 20 has an inductor 25 serially electrically connected in the positive link 28 of the high-voltage DC bus.

[0061] The DC power source 20 includes one or more power cells 21, a first cell switch 22 arranged in parallel with a second cell switch 23 and a resistor 24, and an inductor 25, which are arranged to transfer DC power to the multiphase power inverter 100 via the positive link 28 and the negative link 29 of the high-voltage DC bus.

[0062] In one embodiment, the multiphase inverter system 100 includes a plurality of paired switches arranged in series between a positive inverter bus 103 and a negative inverter bus 104. In one embodiment and as shown, the paired switches include: a first pair of switches 121 and 122 (Q1 and Q2) that are arranged in series and joined at a first switch node 141; a second pair of switches 123 and 124 (Q3 and Q4) that are arranged in series and joined at a second switch node 142; and a third pair of switches 125 and 126 (Q5 and Q6) that are arranged in series and joined at a third switch node 143. The switch 121 of the first pair of switches 121 and 122 is connected to the positive inverter bus 103 at a drain / collector link 131, and the switch 122 is connected to the negative inverter bus 104. The switch 123 of the second pair of switches 123 and 124 is connected to the positive inverter bus 103 at a drain / collector link 132, and the switch 124 is connected to the negative inverter bus 104. The switch 125 of the third pair of switches 125 and 126 is connected to the positive inverter bus 103 at a drain / collector link 133, and the switch 125 is connected to the negative inverter bus 104.

[0063] This configuration of the multiphase inverter system 100 is illustrated and described as having three sets of paired switches, thereby enabling three-phase operation. Other embodiments within the scope of the present disclosure may include a single set of paired switches (enabling single-phase operation), two sets of paired switches (enabling two-phase operation), four sets of paired switches (enabling four-phase operation), etc., without limitation.

[0064] The first switch node 141 is connected to a first phase of the motor 40 via a first AC power bus 105A to transmit a pulse width modulation signal thereto. The second switch node 142 is connected to a second phase of the motor 40 via a second AC power bus 105B to transmit a pulse width modulation signal thereto. The third switch node 143 is connected to a third phase of the motor 40 via a third AC power bus 105C to transmit a pulse width modulation signal thereto.

[0065] The first pair of switches 121 and 122, the second pair of switches 123 and 124, and the third pair of switches 125 and 126 are controlled by a controller 30. The first pair of switches 121 and 122, the second pair of switches 123 and 124, and the third pair of switches 125 and 126 can be silicon carbide (SiC) power electronic devices, gallium nitride (GaN) power electronic devices, insulated gate bipolar transistor (IGBT) power electronic devices, or other power electronic devices.

[0066] The first bus switch 111 is arranged in the positive inverter bus 103 between the positive DC bus terminal 101 and the drain / collector link 131. The second bus switch 112 is arranged between the positive DC bus terminal 101 and the first switch node 141, and the first pair of switches 121 and 122 are joined at the first switch node 141. The first and second bus switches 111, 112 can be solid-state power electronic devices such as IGBTs, SiC, GaN, etc., electromagnetic relays, or other devices. The first and second bus switches 111, 112 are controlled by the controller 30.

[0067] In one embodiment and as shown, the inverter inductance device 115 is arranged in series between the positive DC bus terminal 101 and the second bus switch 112. The first bus switch 111 and the second bus switch 112 are operably connected to and controlled by the controller 30. In one embodiment, the inverter inductance device 115 is a wound coil sized for a particular application. The capacitor 113 is electrically connected between the positive inverter bus 103 and the negative inverter bus 104.

[0068] The QRC 60 consists of the first unit switch 22, the second unit switch 23, the capacitor 113, the first and second bus switches 111, 112, and the inverter inductance device L2 115. The QRC 60 can utilize the first unit switch 22 and the second unit switch 23 of the DC power supply 20 and can benefit from its internal inductance L1 25 to effect heating in the (multiple) power units 21. In one embodiment, the QRC 60 is operable to effect heating in the (multiple) power units 21 when the first unit switch (S1) 22 is closed, the second unit switch (S2) 23 is open, the first bus switch (S4) 111 is open, and the second bus switch (S3) 112 is closed, or when the second bus switch (S3) 112 cycles between an open state and a closed state via pulse width modulation. The QRC 60 is capable of operating when the polyphase inverter system 100 is controlled in a non-traction mode, which is achieved by controlling the first bus switch (S4) 111 in an open state and the second bus switch (S3) 112 in a closed state. The QRC 60 does not operate when the polyphase inverter system 100 is controlled in a traction mode, which is achieved by controlling the first bus switch (S4) 111 in a closed state and the second bus switch (S3) 112 in an open state.

[0069] The multiphase inverter system 100 employs a QRC 60 to selectively control operations in traction and non-traction modes and generate heat in the DC power supply 20 during non-traction mode operations. As used herein, the term "traction mode" refers to operations where the power system 10 generates positive or negative torque, and the term "non-traction mode" refers to other operating periods when the power system 10 does not generate positive or negative torque, which can enable and / or facilitate heat generation via the inverter inductor device L2115 in the QRC 60.

[0070] During operations in the traction mode, the power system 10 including the multiphase inverter system 100 is controlled by a controller 30 to operate a motor 40 to generate torque. In one non-limiting example, this includes when the power system 10 is an element of an electrified powertrain 50 of a vehicle 15, the multiphase inverter system 100 is controlled to operate the motor 40 to provide propulsion torque.

[0071] The controller 30 controls the multiphase inverter system 100 to operate the power system 10 in the traction mode by controlling a first unit switch 22 to an open state, a second unit switch 23 to a closed state, a first bus switch 111 to a closed or conducting state, a second bus switch 112 to an open or non-conducting state, and in response to an operator request to generate torque using the motor 40.

[0072] The controller 30 controls the power system 10 to operate in the non-traction mode by controlling the first unit switch 22 to a closed state, the second unit switch 23 to an open state, the first bus switch 111 to an open or non-conducting state, the second bus switch 112 to a closed or conducting state, and in response controls the multiphase inverter system 100, where the QRC 60 is enabled to effect heating in the (multiple) power units 21. The AC current flowing through the DC power supply 20 generates heat therein. In one embodiment, the second bus switch 112 is controlled to a closed or conducting state using pulse width modulation or another control sequence.

[0073] Now referring to Figure 3 and continuing to refer to the components described in Figure 1 and 2 Another embodiment of a multiphase inverter system 200 having a QRC 260 connected to a DC power supply 20 is shown. In Figure 1 , 2 and 3, the same numerals refer to the same components.

[0074] In this embodiment, the first bus switch 211 is arranged in the positive inverter bus 103 between the positive DC bus terminal 101 and the drain / collector link 131. The second bus switch 212 is arranged between the positive DC bus terminal 101 and the first switch node 141, and the first pair of switches 121 and 122 are joined at the first switch node 141. The third bus switch 213 is arranged between the first switch node 141 and the second switch node 142. The fourth bus switch 214 is arranged between the second switch node 142 and the third switch node 143. The first, second, third, and fourth bus switches 211, 212, 213, 214 can be solid-state power electronic devices such as IGBTs, SiC, GaN, etc., electromagnetic relays, or other devices. The first, second, third, and fourth bus switches 211, 212, 213, 214 are controlled by the controller 30.

[0075] In one embodiment, and as shown, the DC power supply 20 has an inductor 25 electrically connected in series in the positive link 28 of the high-voltage DC bus.

[0076] The QRC 260 is composed of the first unit switch 22, the second unit switch 23, the inverter inductor device L2 115, the capacitor 113, and the first, second, third, and fourth bus switches 211, 212, 213, 214 respectively. In one embodiment, the inverter inductor device 115 can be omitted, and when the magnitude of the inductor is sufficient to achieve self-heating in the DC power supply 20, the QRC 260 can be capable of operating with the inductor 25 arranged in the DC power supply 20 and in the absence of the inverter inductor device in the multiphase inverter system 200.

[0077] The multiphase inverter system 200 employs the QRC 260 to selectively control the operation in the traction mode and the non-traction mode and generate heat in the DC power supply 20 during the operation in the non-traction mode. During the operation in the traction mode, the power system 10 including the multiphase inverter system 200 is controlled by the controller 30 to operate the motor 40 to generate torque. In a non-limiting example, this includes when the power system 10 is an element of the electrified powertrain 50 of the vehicle 15, the multiphase inverter system 200 is controlled to operate the motor 40 to provide propulsion torque.

[0078] The controller 30 controls the multiphase inverter system 200 to operate the power system 10 in the traction mode by controlling the first unit switch 22 in the off state, the second unit switch 23 in the on state, the first bus switch 211 in the on or conducting state, the second bus switch 212 in the off or non-conducting state, and in response to an operator request to generate torque using the motor 40.

[0079] The controller 30 operates the power system 10 in a non-traction mode by controlling the first unit switch 22 to a closed state, the second unit switch 23 to an open state, the first bus switch 211 to an open or non-conducting state, the second, third, and fourth bus switches 212, 213, and 214 to a sequentially closed or conducting state, and as a response controls the multiphase inverter system 200. In one embodiment, the second bus switch 212 is controlled to a closed or conducting state using pulse width modulation or another control sequence. Heat is generated in the DC power supply 20 by inducting an AC current.

[0080] Now referring Figure 4 , and continuing to refer to the components described in Figure 1 and 2 , another embodiment of the multiphase inverter system 300 of the embodiment connected to the DC power supply 20 is shown. In Figure 1 , 2 and 4, the same numbers refer to the same components.

[0081] In this embodiment, the first bus switch 311 is arranged in the positive inverter bus 103 between the positive DC bus terminal 101 and the drain / collector link 131. The second bus switch 312 is arranged between the positive DC bus terminal 101 and the first switch node 141, where the first pair of switches 121 and 122 are joined. The third bus switch 313 is arranged between the positive DC bus terminal 101 and the second switch node 142. The fourth bus switch 314 is arranged between the positive DC bus terminal 101 and the third switch node 143. The first, second, third, and fourth bus switches 311, 312, 313, 314 can be solid-state power electronic devices such as IGBTs, SiC, GaN, etc., electromagnetic relays, or other devices. The first, second, third, and fourth bus switches 311, 312, 313, 314 are controlled by the controller 30.

[0082] In one embodiment, and as shown, the DC power supply 20 has an inductor 25 connected in series in the positive link 28 of the high-voltage DC bus.

[0083] The QRC 360 is respectively composed of the first unit switch 22, the second unit switch 23, the inverter inductor device L2 115, the capacitor 113, and the first, second, third, and fourth bus switches 311, 312, 313, 314. In one embodiment, when the inductor 25 is arranged in the DC power supply 20, the QRC 360 can operate in the absence of the inverter inductance device 115 in the multiphase inverter system 300.

[0084] The multiphase inverter system 300 employs a QRC 360 to selectively control operation in traction and non-traction modes and generates heat in the DC power supply 20 during operation in the non-traction mode. During operation in the traction mode, the power system 10 including the multiphase inverter system 300 is controlled by the controller 30 to operate the electric motor 40 to generate torque. In one non-limiting example, this includes when the power system 10 is an element of the electrified powertrain 50 of the vehicle 15, the multiphase inverter system 300 is controlled to operate the electric motor 40 to provide propulsion torque.

[0085] The controller 30 controls the multiphase inverter system 300 to operate the power system 10 in the traction mode by controlling the first unit switch 22 in the open state, the second unit switch 23 in the closed state, the first bus switch 311 in the closed or conducting state, the second, third, and fourth bus switches 312, 313, and 314 in the open or non-conducting state, and in response to an operator request to generate torque using the electric motor 40.

[0086] The controller 30 controls the multiphase inverter system 300 to operate the power system 10 in the non-traction mode by controlling the first unit switch 22 in the closed state, the second unit switch 23 in the open state, the first bus switch 311 in the open or non-conducting state, the second, third, and fourth bus switches 312, 313, and 314 in the sequentially closed or conducting state, and in response. The current flowing through the DC power supply 20 generates heat therein. In one embodiment, the second, third, and fourth bus switches 312, 313, and 314 are controlled in the closed or conducting state using pulse width modulation or another control sequence.

[0087] Now refer to Figure 5 and continue to refer to Figure 1 and 2 Elements of show an embodiment of a multiphase inverter system 500 connected to a DC power supply 520 and having a QRC 560. In one embodiment, and as described herein, the multiphase inverter system 500 is configured as a three-phase inverter system, and the electric motor 40 is configured as a three-phase permanent magnet motor / generator. A charging port 570 is also shown for connecting a fixed charging system (not shown) to the DC power supply 520.

[0088] In one embodiment, and as shown, the DC power supply 520 has an inductor 25 electrically connected in series in the positive link 28 of the high-voltage DC bus.

[0089] The charging port 570 includes a first (positive) power port 571 (DCFC+), a positive port switch 572, and a first diode 573, which is connected to the positive link 28 of the high-voltage DC bus. The first diode 573 is arranged such that its anode faces the first (positive) power port 571 (DCFC+), and its cathode faces the positive link 28 of the high-voltage DC bus.

[0090] The charging port 570 includes a second (negative) power port 575 (DCFC-), a negative port switch 576, and a second diode 577, which is connected to the negative link 29 of the high-voltage DC bus. The second diode 577 is arranged such that its cathode faces the second (negative) power port 572 (DCFC-), and its anode faces the negative link 29 of the high-voltage DC bus.

[0091] The DC power supply 20 includes one or more power units 21; a first unit switch 22, which is arranged in parallel with a second unit switch 23 and a resistor 24; and an inductor 25, all of which are arranged to transmit DC power to the multiphase power inverter 500 via the positive link 28 and the negative link 29 of the high-voltage DC bus. Other elements of the multiphase inverter system 500 are similar to those Figure 2 described.

[0092] The QRC 560 consists of the first unit switch 22, the second unit switch 23, the inverter inductance device L2 115, the capacitor 113, and the first and second bus switches 111, 112.

[0093] The multiphase inverter system 100 employs the QRC 560 to selectively control operations in traction and non-traction modes, which may include charging events, and generates heat in the DC power supply 20 during operation in non-traction mode.

[0094] During a charging event, the first and second diodes 573, 577 prevent AC ripple current from flowing into the charging device, where the AC ripple current may be generated during the heating of the DC power supply 20 by the inverter 500 under the action of the QRC 560. The current flowing through the DC power supply 20 generates heat therein.

[0095] Now referring to Figure 6 and continuing to refer to Figure 1 and 2 the elements of, a multiphase inverter system 600 is shown, which includes a DC power supply 20, first and second multiphase inverters 100, 100' respectively, first and second motors 40, 40' respectively, and a QRC 660. Its operation is controlled by a controller 630. The DC power supply 20 is arranged to supply DC power to the first and second multiphase inverters 100, 100' respectively, and the first and second multiphase inverters 100, 100' are respectively coupled to the corresponding first and second motors 40, 40'.

[0096] The QRC 660 is composed of a first unit switch 22, a second unit switch 23, a first inductor L1 115, a second inductor L2 115', a first capacitor C1 113, a second capacitor C2 113', and first, second, third, and fourth bus switches 111, 112, 111', and 112'. The first and second inverter inductor devices 115, 115' are in this embodiment.

[0097] In one embodiment, the first and second motors 40, 40' are coupled to corresponding driveline components to provide vehicle traction. Alternatively, the first motor 40 can be coupled to a non-traction device, such as an air conditioning compressor, and the second motor 40' can be coupled to the driveline components to provide vehicle traction. Alternatively, within the scope of the present disclosure, other arrangements of coupling the first and second motors 40, 40' to driven devices such as driveline components and non-traction devices can be implemented.

[0098] The first multiphase inverter 100 is configured with reference to Figure 2 the embodiment of the multiphase inverter system 100 described in detail.

[0099] In one embodiment, the second multiphase inverter 100' is also configured with reference to Figure 2 another embodiment of the multiphase inverter system 100 described in detail. In one embodiment, the second multiphase inverter system 100' includes a plurality of pairs of switches arranged in series between a positive inverter bus 103' and a negative inverter bus 104. In one embodiment, and as shown, the pairs of switches include: a first pair of switches 121' and 122' (Q1 and Q2), which are arranged in series and joined at a first switch node 141'; a second pair of switches 123' and 124' (Q3 and Q4), which are arranged in series and joined at a second switch node 142'; and a third pair of switches 125' and 126' (Q5 and Q6), which are arranged in series and joined at a third switch node 143'. The switch 121' of the first pair of switches 121' and 122' is connected to the positive inverter bus 103' at a drain / collector link 131', and the switch 122' is connected to the negative inverter bus 104'. The switch 123' of the second pair of switches 123' and 124' is connected to the positive inverter bus 103' at a drain / collector link 132', and the switch 124' is connected to the negative inverter bus 104. The switch 125' of the third pair of switches 125' and 126' is connected to the positive inverter bus 103' at a drain / collector link 133', and the switch 125' is connected to the negative inverter bus 104.

[0100] In this embodiment, the controller 630 may control the components of the multiphase inverter system 600 to operate the first and second multiphase inverters 100, 100' simultaneously in a traction mode, thereby generating traction torque under certain operating conditions.

[0101] In this embodiment, the controller 630 may control the components of the multiphase inverter system 600 to operate the first multiphase inverter 100 in a non-traction mode to generate heat in the DC power supply 20, and simultaneously operate the second multiphase inverter 100' in a traction mode to generate traction torque under certain operating conditions.

[0102] The controller 630 controls the first and second multiphase inverters 100, 100', the first and second motors 40, 40' and the operation of the QRC 600 in the traction mode by controlling the first unit switch 22 to be in a closed state, controlling the second unit switch 23 to be in an open state, controlling the first bus switches 111, 111' to be in a closed or conducting state, controlling the second, third and fourth bus switches 112, 112' to be in an open or non-conducting state, and in response to an operator request to generate torque using the first and second motors 40, 40'.

[0103] In addition, the controller 630 is capable of controlling the operation of the first and second multiphase inverters 100, 100', the first and second motors 40, 40' and the QRC 660 of the multiphase inverter system 600 simultaneously in a traction mode and a non-traction mode. This includes controlling the first unit switch 22 to be in an open state and controlling the second unit switch 23 to be in a closed state.

[0104] In one embodiment, the first multiphase inverter 100 is controlled to generate heat via the QRC 660 in a non-traction mode. This includes controlling the first bus switch 111 to be in an open state and controlling the second bus switch 112 to be in a closed state or a PWM state. At the same time, the second multiphase inverter 100' is controlled to generate traction force via the second motor 40' in a traction mode. This includes controlling the first bus switch 111 to be in a closed state and controlling the second bus switch 112 to be in an open state. In one embodiment, the second multiphase inverter 100' is controlled in response to an operator request to generate torque using the second motor 40'.

[0105] The concepts described herein provide an electric power system that includes one or more of a multiphase inverter system, a DC power source, an electric machine, a controller, and a quasi-resonant circuit (QRC), where in one embodiment, the control or active element of the QRC is included in the multiphase inverter system, or the control or active element of the QRC is included in the multiphase inverter system and the DC power source. Under certain operating conditions, the QRC is capable of generating an AC current in the DC power bus, where the AC current generates heat that can affect the heat generation available for heating the DC power source and / or the vehicle cabin. This includes triggering "self-heating" of the battery internal impedance when the vehicle is in motion. This arrangement may be more efficient than convective heating.

[0106] The detailed description and the drawings or figures support and describe the present teachings, but the scope of the present teachings is defined only by the claims. While some best modes and other embodiments for carrying out the present teachings have been described in detail, there are various alternative designs and embodiments for practicing the present teachings as defined in the appended claims.

Claims

1. A power system, comprising: A power inverter system and a controller having a quasi-resonant circuit (QRC); Wherein the power inverter system is arranged to couple a DC power supply to an electric motor; Wherein the power inverter system comprises: a positive inverter bus and a negative inverter bus; a first pair of switches, which are arranged in series between the positive inverter bus and the negative inverter bus and are joined at a first switch node; a positive DC bus terminal; and a negative DC bus terminal; Wherein the QRC comprises an inverter inductor device, a capacitor, a first bus switch and a second bus switch; Wherein the capacitor is connected between the positive inverter bus and the negative inverter bus; Wherein the inverter inductor device and the second bus switch are arranged in series between the positive inverter bus and the first switch node arranged between the first pair of switches; Wherein the first bus switch is arranged between the positive DC bus terminal and the positive inverter bus; and Wherein the controller is configured to control the QRC to generate alternating current in the DC power supply.

2. The power system according to claim 1, wherein the controller is configured to control the QRC to generate alternating current in the DC power supply, including that the controller is configured to control the first bus switch and the second bus switch to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

3. The power system according to claim 1, including that the controller controls the first bus switch to the off state and the second bus switch to the on state to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

4. The power system according to claim 3, including that the controller controls the first bus switch to the off state and the second bus switch to the on state to generate alternating current in the DC power supply via the inverter inductor device and the capacitor to generate heat energy in the DC power supply.

5. The power system according to claim 3, further including that the controller controls the second bus switch under pulse width modulation conditions between the off state and the on state to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

6. The power system according to claim 1, wherein the first switch node is connected to the electric motor via an AC power bus to transmit a pulse width modulated power signal thereto.

7. The power system according to claim 1, further comprising: Wherein the power inverter system comprises: a second pair of switches, which are arranged in series between the positive inverter bus and the negative inverter bus and are joined at a second switch node; Wherein the QRC comprises a third bus switch; Wherein the inverter inductor device and the third bus switch are arranged in series between the positive inverter bus and the second switch node arranged between the second pair of switches; and Wherein the controller is configured to control the first bus switch, the second bus switch and the third bus switch to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

8. The power system according to claim 7, including where the controller controls the first bus switch to an open state and controls one of the second bus switch and the third bus switch to a closed state to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

9. The power system according to claim 8, further including where the controller controls the second bus switch using a first pulse width modulation signal between the open state and the closed state, and where the controller controls the third bus switch using a second pulse width modulation signal to generate alternating current in the DC power supply via the inverter inductor device and the capacitor.

10. An electrified powertrain system includes: a DC power supply, a positive link and a negative link of a DC power bus, a power inverter system having a quasi-resonant circuit (QRC), an electric motor, and a controller; wherein the electric motor is coupled to a torque actuator via a gear train; wherein the power inverter system couples the DC power supply to the electric motor; wherein the power inverter system includes: a positive inverter bus and a negative inverter bus; a first pair of switches arranged in series between the positive inverter bus and the negative inverter bus and joined at a first switch node; a positive DC bus terminal; and a negative DC bus terminal; where the positive inverter bus is coupled to the positive link of the DC power bus, and where the negative inverter bus is coupled to the negative link of the DC power bus; where the DC power supply includes a power unit that can be coupled to the positive link of the DC power bus via a first unit switch and a second unit switch; where the first unit switch and the second unit switch are arranged in parallel; where the QRC includes an inductor device, a capacitor, a first bus switch, and a second bus switch; where the capacitor is connected between the positive inverter bus and the negative inverter bus; where the inductor device and the second bus switch are arranged in series between the positive inverter bus and the first switch node arranged between the first pair of switches; where the first bus switch is arranged between the positive DC bus terminal and the positive inverter bus; and where the controller is configured to control the QRC, the first unit switch, and the second unit switch to generate alternating current in the DC power supply.

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