A vehicle power module assembly includes a modular manifold, an upper frame, and a plurality of power stages. The modular manifold includes a first base unit defining an inlet chamber, a second base unit defining an outlet chamber, a mid-unit defining one or more ports open to the chambers, and an upper unit defining a first set of slots and a second set of slots in fluid communication with the chambers via the ports. The plurality of power stages is housed within the frame and each of the power stages are spaced from one another to define inner channels therebetween. The chambers, channels, and ports are arranged with one another such that coolant flowing through the inner channels is in thermal communication with the power stages. The mid-unit may further include flow guides each sized to partially extend into one of the inner channels.

A power inverter includes a plurality of power modules each having a power stage encased in a frame that defines an opening. The power modules are stacked in an array with the power stages being spaced apart to define coolant chambers interleaved with the power stages. The openings cooperate to form a manifold cavity extending along a length of the stack and in fluid communication with the chambers. A manifold insert is disposed in the cavity and extends through the openings.

Methods and systems are provided for an electric heavy-duty vehicle. In one example, the vehicle includes a battery pack for supplying current to an electric motor of the vehicle, the battery pack arranged in a chassis of the vehicle and configured to form part of a floor of the vehicle. The vehicle also includes a motor coupled to front wheels of the vehicle, the front wheels having hub assemblies housing drive shaft adapters configured to permanently couple the hub assemblies to drive shafts of the front wheels, and a cradle configured to be mounted with electrical sub-systems of the vehicle.

An electric vehicle propulsion control device includes a power converter that applies an alternating-current voltage to an induction machine and a controller that controls the power converter based on an external operation command. The controller includes a first calculation unit. The first calculation unit calculates, from current information (id and iq) detected at the induction machine and current command values (id*1 and iq*1) that are based on the operation command, a d-axis voltage command (Vd*1) and a q-axis voltage command (Vq*1) for the power converter, and a primary magnetic flux φds and a secondary magnetic flux φdr of the induction machine. The first calculation unit also adds to or subtracts from a term including the q-axis voltage command (Vq*1) an interference term stemming from the d-axis voltage command (Vd*1) in calculating a first speed ω1 that is a free-run speed of the induction machine.

An inductor for a boost converter in a hybrid vehicle includes a core, a coil winding, and an end cap. The coil winding is disposed about the core. The end cap is disposed over a first end of the inductor, overhangs the coil winding, defines a channel that is configured to receive fluid from a pump, defines at least one nozzle that is configured to direct fluid from an overhanging portion of the end cap and onto the coil, and defines a fluid reservoir that is in fluid communication with the channel and the at least one nozzle.

A motor assembly includes a motor, a housing that accommodates the motor, an inverter electrically connected to the motor, an inverter case that accommodates the inverter, an auxiliary device provided in a lower portion of the housing to oppose a road surface, a wire harness that includes a first connector connected to a connector provided in the inverter case, a second connector connected to a connector provided in the auxiliary device, and an electric wire connecting the first connector and the second connector, and a lower connector cover provided in the lower portion of the housing and covering the second connector from a lower side.

According to some embodiments, a traction system is disclosed. The traction system includes a DC bus, an energy storage device coupled to the DC bus, and a voltage converter assembly coupled to the energy storage device. The voltage converter assembly includes a plurality of phase legs. The traction system further includes an electromechanical device including a plurality of windings coupled to the voltage converter assembly. The traction system also includes a switch coupled to the DC bus between the voltage converter assembly and the energy storage device. The traction system includes a controller configured to control the switch and the voltage converter assembly such that a phase leg and a winding of the electromechanical device form a DC/DC converter.

A vehicle electric machine may include a rotor. The rotor may cooperate with a stator including a core having an end face, and end windings extending from the end face. A cooling tunnel may encase the end windings, sealing against the end face at opposing sides of the end windings, and defining an inlet configured to receive coolant. The cooling tunnel may be arranged to contain the coolant during passage over the end windings and direct the coolant toward an outlet.

A control apparatus includes a first determination section determining whether a power-supply voltage has decreased below a first threshold value, an interruption section interrupting a current flow to an inverter if the voltage has decreased below the first threshold value, a second determination section that determining whether the power-supply voltage has increased above a second threshold value, an interruption releasing section releasing the interruption based on the fact that the voltage has increased above the second threshold value, a count section counting the number of interruptions, a limiting section determining whether the decrease in the power-supply voltage is caused by a first factor of an electric rotating machine or a second factor, and limits the counting if the decrease in the power-supply voltage is caused by the second factor, and a third determination section determining whether the interruption is allowed to be released based on the number of interruptions.

A cooling system includes: a coolant circuit through which a coolant for cooling an electric motor and electrical equipment circulates; a pump that feeds the coolant; and a degas tank that separates the bubbles from the coolant. The coolant circuit connects the devices in series. The degas tank is disposed at an upper stage, a first device as at least one of the electric motor, the electrical equipment, and the pump is disposed at a lower stage, and a remaining second device is disposed at a position that is above the lower stage and is as high as the degas tank or lower than the degas tank. The coolant circuit connects the degas tank, the second device, and the first device in this order, and the coolant flows in this order.