Abstract: A method for estimating a state of a battery pack using a controller having battery state estimator (BSE) logic includes receiving or delivering a constant baseline current via the battery pack. Current oscillations having time-variant frequency content are selectively injected into the baseline current via the controller in response to a predetermined condition. The baseline current and the current oscillations combine to form a final current. The method includes estimating a battery parameter via the BSE logic concurrently with the current oscillations to generate an estimated battery parameter, and estimating the present state of the battery pack via the controller using the estimated battery parameter. An electrical system includes a rotary electric machine that is electrically connected to and driven by the battery pack, and a controller configured to execute the method.

Abstract: A method for estimating a state of a battery pack using a controller having battery state estimator (BSE) logic includes receiving or delivering a constant baseline current via the battery pack. Current oscillations having time-variant frequency content are selectively injected into the baseline current via the controller in response to a predetermined condition. The baseline current and the current oscillations combine to form a final current. The method includes estimating a battery parameter via the BSE logic concurrently with the current oscillations to generate an estimated battery parameter, and estimating the present state of the battery pack via the controller using the estimated battery parameter. An electrical system includes a rotary electric machine that is electrically connected to and driven by the battery pack, and a controller configured to execute the method.

Abstract: A vehicle includes a torque device providing input torque, a transmission, an axle connected to drive wheels, a final drive unit, and a controller. The controller includes proportional-integral (PI) logic, and is programmed to determine a speed of the drive wheels and output shaft. The controller executes a method to calculate a reference output speed using the drive wheel speed and applies a calibrated offset profile to the calculated reference output speed during a lash state transition of the final drive unit, output shaft, and axle. This controls, via the PI logic, a speed difference between the output shaft and drive axle. The calibrated offset profile is higher in an early portion of the lash state to speed a transition from the lash state, and lower in a later portion of the lash state to reduce driveline clunk upon transition from the gear lash state.

Abstract: A method to predict a driveline lash condition includes monitoring an axle torque request signal, determining a predicted axle torque request value at a lead time based upon the monitored axle torque request signal, and predicting the driveline lash condition at the lead time based upon the predicted axle torque request value indicating an upcoming zero torque condition.

Abstract: A method for controlling a hybrid powertrain includes monitoring input torque of an input member and may include determining an oscillation torque. The method monitors critical vehicle characteristics, including at least a transmission operating mode and an input speed, and operates the powertrain at the input torque. The method compares input torque to a minimum threshold or oscillation torque to a fatigue threshold and identifies a first critical event, which occurs when input torque exceeds the minimum threshold or oscillation torque exceeds the fatigue threshold. The method identifies a first peak with the on-board controller during the first critical event. Peak events occur when the monitored input torque or oscillation torque changes between positive and negative slope. The method identifies a first CVC set occurring with the first peak and may record the first CVC set and the first peak in a look-up table.

Abstract: A method for controlling a multi-mode transmission system employing torque machines under dynamic operating conditions includes calculating a phase shift between a control parameter of one of the torque machines and a response parameter of the multi-mode transmission system under dynamic operating conditions, comparing the calculated phase shift and an expected phase shift, and executing remedial action when the calculated phase shift exceeds a threshold associated with the expected phase shift.

Abstract: One embodiment of the invention includes a method comprising: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert comprising a plurality of connecting post extending inbetween so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material; casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface for the product.

Abstract: A method for controlling a hybrid powertrain includes monitoring input torque of an input member and may include determining an oscillation torque. The method monitors critical vehicle characteristics, including at least a transmission operating mode and an input speed, and operates the powertrain at the input torque. The method compares input torque to a minimum threshold or oscillation torque to a fatigue threshold and identifies a first critical event, which occurs when input torque exceeds the minimum threshold or oscillation torque exceeds the fatigue threshold. The method identifies a first peak with the on-board controller during the first critical event. Peak events occur when the monitored input torque or oscillation torque changes between positive and negative slope. The method identifies a first CVC set occurring with the first peak and may record the first CVC set and the first peak in a look-up table.

Abstract: A method for controlling a multi-mode transmission system employing torque machines under dynamic operating conditions includes calculating a phase shift between a control parameter of one of the torque machines and a response parameter of the multi-mode transmission system under dynamic operating conditions, comparing the calculated phase shift and an expected phase shift, and executing remedial action when the calculated phase shift exceeds a threshold associated with the expected phase shift.

Abstract: A method for optimizing torque control in a vehicle having a controller and a rotating member includes generating a closed-loop total proportional torque command using a state space feedback portion of the controller, and splitting the total proportional torque command into high-frequency and low-frequency proportional torque components. A total proportional torque is passed to the rotating member to provide driveline damping control when speed control is not required. The high-frequency proportional torque component is passed to the rotating member to provide driveline damping control, and the low-frequency torque component is passed with a total integral torque command to the rotating member to provide speed control, when speed control is required. A vehicle includes a controller having proportional-integral control capabilities and a state space observer, and a powertrain having a rotating member whose speed and damping characteristics are controlled by the controller.

Abstract: An example vehicle includes a motor and a gearbox. A controller is configured to identify oscillation peaks of a performance signal representing the rotational speed of the motor, the input speed of the gearbox, or the amount of torque generated by the motor or provided to the gearbox. The controller is configured to simultaneously detect unstable regular and irregular oscillations of the performance signal given the oscillation peaks identified and substantially dampen the unstable oscillations detected. An example method may include determining a mean of the performance signal and defining peak values, including peak moving average values or filtered peak values, representing a magnitude of at least two oscillation peaks. The method further includes simultaneously detecting the unstable regular and irregular oscillations of the performance signal using the defined values and substantially dampening the unstable oscillations.

Abstract: One embodiment of the invention includes a method comprising: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert comprising a plurality of connecting post extending inbetween so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material; casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface for the product.

Abstract: A system and method for monitoring the stability of a hybrid powertrain system includes monitoring the system and its subsystems output response signals to its inputs to identify the system operating status. For example, for a hybrid powertrain system equipped with an electrically variable transmission (EVT), three signals are monitored. They are the two electrical motor speeds representing the direct subsystem response to their feedback control inputs and the EVT output speed representing the entire system's response. A stability monitoring system includes a mean determination module that determines a mean signal of the signals and an oscillation determination module that determines a signal oscillation signal based on the instant signal and the mean signal.

Abstract: A method to predict a driveline lash condition includes monitoring an axle torque request signal, determining a predicted axle torque request value at a lead time based upon the monitored axle torque request signal, and predicting the driveline lash condition at the lead time based upon the predicted axle torque request value indicating an upcoming zero torque condition.

Abstract: An example vehicle includes a motor and a gearbox. A controller is configured to identify oscillation peaks of a performance signal representing the rotational speed of the motor, the input speed of the gearbox, or the amount of torque generated by the motor or provided to the gearbox. The controller is configured to simultaneously detect unstable regular and irregular oscillations of the performance signal given the oscillation peaks identified and substantially dampen the unstable oscillations detected. An example method may include determining a mean of the performance signal and defining peak values, including peak moving average values or filtered peak values, representing a magnitude of at least two oscillation peaks. The method further includes simultaneously detecting the unstable regular and irregular oscillations of the performance signal using the defined values and substantially dampening the unstable oscillations.

Abstract: A method including: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert including a plurality of connecting posts extending in between so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert including a first material; casting a molten second material into the casting mold so that the second material flows between the first insert the second insert and solidifying the second material.

Abstract: A method for optimizing torque control in a vehicle having a controller and a rotating member includes generating a closed-loop total proportional torque command using a state space feedback portion of the controller, and splitting the total proportional torque command into high-frequency and low-frequency proportional torque components. A total proportional torque is passed to the rotating member to provide driveline damping control when speed control is not required. The high-frequency proportional torque component is passed to the rotating member to provide driveline damping control, and the low-frequency torque component is passed with a total integral torque command to the rotating member to provide speed control, when speed control is required. A vehicle includes a controller having proportional-integral control capabilities and a state space observer, and a powertrain having a rotating member whose speed and damping characteristics are controlled by the controller.

Abstract: A system and method for monitoring the stability of a hybrid powertrain system includes monitoring the system and its subsystems output response signals to its inputs to identify the system operating status. For example, for a hybrid powertrain system equipped with an electrically variable transmission (EVT), three signals are monitored. They are the two electrical motor speeds representing the direct subsystem response to their feedback control inputs and the EVT output speed representing the entire system's response. A stability monitoring system includes a mean determination module that determines a mean signal of the signals and an oscillation determination module that determines a signal oscillation signal based on the instant signal and the mean signal.

Abstract: One embodiment of the invention includes a method comprising: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert comprising a plurality of connecting post extending inbetween so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material; casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface for the product.