BorgWarner US Technologies LLC

A system includes: a battery charger to convert AC power to DC power to charge a battery, wherein the battery charger includes: an upper switch to condition an input voltage and input current; a lower switch to condition the input voltage and the input current: an upper silicon controlled rectifier (SCR); a lower SCR; and a bulk capacitor.

A method for controlling vehicle propulsion includes receiving signal data corresponding to a signaled intersection of a route being traversed by a vehicle. The method further includes determining an intersection propulsion profile for the signaled intersection based on at least a current vehicle speed and the signal data. The method further includes determining, based on the intersection propulsion profile, whether to deviate from a vehicle energy consumption profile corresponding to the route being traversed by the vehicle. The method further includes, in response to a determination to deviate from the vehicle energy consumption profile, selectively controlling vehicle propulsion of the vehicle according to the intersection propulsion profile. The method further includes, in response to traversing the intersection, selectively controlling vehicle propulsion according to the vehicle energy consumption profile.

A method for controlling vehicle energy consumption includes identifying, using a cumulative net energy consumption of a vehicle traversing a route, one or more route segments of the route being traversed by the vehicle. The method also includes determining, for each route segment of the one or more route segments, a vehicle energy consumption profile and determining, for each of the one or more route segments, a profile for a target vehicle speed based on at least one route characteristic and a corresponding vehicle energy consumption profile. The method also includes, for a respective route segment of the one or more route segments generating one or more torque commands based on at least the target vehicle speed profile corresponding to the respective route segment, and selectively controlling, using the one or more torque commands, vehicle propulsion of the vehicle to achieve the target vehicle speed profile.

A system includes: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: one or more switches; and one or more controllers configured to: determine a gate voltage to operate the one or more switches of the inverter based on a temperature of the inverter; operate the one or more switches based on a pulse width modulated (PWM) signal and the gate voltage to initiate an active discharge of a bus voltage of the inverter; and while the bus voltage is greater than a first threshold voltage, accelerate the active discharge of the bus voltage by operating the one or more switches and by performing one or more of increasing the gate voltage or decreasing a wait time following a pulse of the PWM signal.

A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter) including a bulk capacitor, the AC-DC converter connectable to a line voltage; a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including: one or more transformers having a secondary side connectable to a battery, and a bridge rectifier connected to the secondary side of the one or more transformers, the bridge rectifier including a bridge rectifier switch; and one or more controllers configured to control an operation of the bridge rectifier switch to control a voltage of the bulk capacitor.

An inverter assembly may include a housing with a base and side walls, wherein one of the side walls includes an opening extending through the wall, and wherein the side walls form a periphery around an interior of the housing. An inverter assembly may include a header with a body, the body having a first end and a second end, wherein the body further includes a flange disposed between the first end and the second end, and wherein a portion of the body extends through the opening such that the flange abuts the side wall. An inverter assembly may include a bracket positioned within the interior of the housing and coupled to the housing. An inverter assembly may include a choke that is fully enclosed in a circumferential direction, wherein the choke is positioned within the bracket and against an inner surface of the bracket facing the opening.

A system includes: a bidirectional alternating current (AC) to direct current (DC) converter (AC-DC converter) connectable to a line voltage and a battery, the AC-DC converter including: one or more leaves connectable to the line voltage and the battery, the one or more leaves configured to receive DC voltage from the battery and generate AC voltage for the line voltage, and a neutral leaf connectable to the line voltage and the battery, the neutral leaf configured to provide a return path for the generated AC voltage from the line voltage to the AC-DC converter; and one or more controllers configured to control an operation of the one or more leaves and the neutral leaf to control the AC voltage.

A system comprises 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 from a low voltage area; a low voltage phase controller in the low voltage area, the low voltage phase controller configured to receive a pulse width modulation (PWM) signal from an inverter controller and adjust the received PWM signal based on a feedback signal; and a high voltage phase controller in the high voltage area, the high voltage phase controller configured to receive the adjusted PWM signal from the low voltage phase controller, provide the adjusted PWM signal to a phase switch, and provide the feedback signal based on an on-time measurement of the phase switch.