Abstract: An integrated end structure for a vehicle comprises: a storage compartment module that comprises a shell forming a storage compartment therein, the storage compartment module configured to sit onto a frame rail of the vehicle; and a vehicle end module configured to be mounted onto a bracket in the vehicle that provides adjustability of the vehicle end module in a z-direction, the vehicle end module configured for holding a light unit of the vehicle. The storage compartment module is mounted onto the vehicle end module.

Abstract: A method of thermally conditioning an energy storage of a vehicle while charging includes: receiving, at a charging station, thermal information about the energy storage; supplying, by the charging station, electric energy to the energy storage in a charging session; and providing, by the charging station and based on the thermal information, thermal conditioning of the energy storage during at least part of the charging session.

Abstract: A system and method for identifying and responding to exceptional charge events of series-connected energy storage elements.

Abstract: A drive unit includes: an electric motor; a flux estimator circuit configured to estimate at least a flux angle; a synchronous frame generator coupled to a rotor of the AC induction motor and configured to detect a rotor mechanical angle; and a switch configured to selectively provide either the flux angle or the rotor mechanical angle for controlling the motor.

Abstract: An apparatus and method for identifying a presence of a short circuit in a battery pack. A fault-detection apparatus for a charging system that rapidly charges a collection of interconnected lithium ion battery cells, the safety system includes a data-acquisition system for receiving a set of data parameters from the collection while the charging system is actively charging the collection; a monitoring system evaluating the set of data parameters to identify a set of anomalous conditions; and a controller comparing the set of anomalous conditions against a set of predetermined profiles indicative of an internal short in one or more cells of the collection, the controller establishing an internal-short state for the collection when the comparing has a predetermined relationship to the set of predetermined profiles.

Abstract: A rotor includes: a shaft; a core around the shaft; at least one end ring connected to rotor bars that are at least partially enclosed in the core; and means for balancing the end ring around the shaft in a pre-balancing spinning process. A method includes: assembling rotor bars so that they are at least partially enclosed in a core of a rotor; connecting an end ring to ends of the rotor bars; inserting a shaft into the core; step for balancing the end ring around the shaft in a pre-balancing spinning process that involves spinning the rotor; and spinning the rotor in the pre-balancing spinning process.

Abstract: A system and method for providing energy management and maintenance of a high energy battery pack that does not require installation of the battery pack into an operational EV. A battery service unit has multiple access mechanisms to charge or discharge a high energy battery pack through a primary or secondary high voltage port of the pack, irrespective of whether the battery pack is installed into an operating environment by adding a capability of providing a signature duplicating installation of the pack in the operating environment when necessary.

Abstract: A method for charging at least one lithium ion cell the method includes: (a) applying, to the lithium ion cell, a constant first stage charging current until a first stage charging voltage is about equal to a first stage complete voltage less than a maximum cell voltage, the constant first stage charging current greater than about 1C; and thereafter (b) applying multiple constant second stage charging currents to the lithium ion cell at different current levels, wherein the constant second stage charging currents are applied based on accessing a lookup table that relates at least current, temperature and open source voltage to each other; and thereafter (c) applying, to the lithium ion cell, a constant third stage charging voltage about equal to a complete voltage from the multiple constant second stage charging currents.

Abstract: A method includes: determining a design for a longitudinal piece of a particular length, wherein first and second ends of the longitudinal piece have dissimilar shapes; extruding a piece that is at least twice the particular length, wherein a profile throughout the extruded piece has the first end shape; hydroforming the extruded piece to generate an expanded portion between ends of the extruded piece, wherein the ends retain essentially the first end shape; and cutting through the expanded portion to obtain a piece wherein one end has the first end shape and another end has the second end shape.

Abstract: An electromagnetic switch includes: a stationary electrical contact; a moveable electrical contact; an actuated member to which the moveable electrical contact is attached for driving the moveable electrical contact into and out of contact with the stationary electrical contact; and a damping interface between the moveable electrical contact and the actuated member.

Abstract: A vehicle crush rail includes: a body configured to be at least partially crushed along an axis between first and second ends thereof, the body having a cross section profile that comprises first, second and third cells that are substantially square, wherein at least one of the first, second and third cells extends from the first end to the second end, wherein the first, second and third cells have respective initiators arranged according to a crush pattern for the crush rail.

Abstract: A torque box for a vehicle includes: first and second clamshells joined to each other at respective top and bottom edges and configured to form at least first and second enclosures with an inner joint in between, the first and second enclosures configured to provide top and bottom shear planes at the top and bottom edges, respectively, and at least first and second shear planes at the inner joint.

Abstract: A subframe for a vehicle has a front attachment to a crush rail in the vehicle, and a rear attachment to the vehicle, the subframe comprising at least one initiator configured to cause the subframe to fold downward in event of impact, the subframe configured so that the front attachment detaches as a result of the impact and the subframe is deflected downward, while the rear attachment does not detach.

Abstract: An adapter for a vehicle includes: an adapter body configured to bridge between a crush rail at a vehicle end and a back-up structure, the adapter body having a socket configured to receive and enclose four sides of the crush rail, the adapter body having a plug configured to fit into the back-up structure; and an opening in the adapter body configured to have a drive shaft extend through the adapter.

Abstract: Continuous cross sectional profile guide tracks in an outer sliding sunroof/moonroof are provided where both the front and rear mechanism or mechanism links travel fore/aft in the same channels as each other and have fore/aft travel that is limited only by vehicle architecture. The guide track channel is partly or entirely outside/outboard of the primary water/wind sealing system of the sunroof.