Abstract: A vehicle-based microgrid includes a controller and a vehicle having a power source and a network. The controller is operable to operate the power source to supply power to the network for consumption by loads on the network and to adjust operation of the power source in supplying power to the network upon a battery source being added to the network. The power source may be (i) a traction battery, (ii) an electrical generator, or (iii) a non-traction battery. The battery source may be (i) a battery that is on-board the vehicle and that is not the power source or (ii) a battery that is off board the vehicle.

Abstract: A system for managing energy of a building includes a controller in communication with a charger and configured to responsive to predicting (i) a coming power outage of an expected duration and (ii) a total energy reserve of a battery of a vehicle and an electric energy storage being less than an anticipated amount of energy to be used by the building during the expected duration, instruct the vehicle to recharge the battery at a target charge station and return before stored energy of the energy storage falls below a predefined value, and responsive to encountering the power outage, command the charger to supply electric energy to the building from the battery and electric energy storage.

Abstract: A vehicle electric machine assembly including a stator core and a terminal block is provided. The stator core includes one or more three-phase terminals connected to end windings. The terminal block includes a connector for each of the three-phase terminals. A portion of the end windings extending from the stator core, the three-phase terminals, and the terminal block are overmolded as a single unit such that a portion of each of the connectors is exposed for connection to an inverter. The terminal block may further include one or more threaded apertures, each sized to receive a threaded stud to facilitate an electrical connection between one of the one or more three-phase terminals and the inverter. Each of the one or more three-phase terminals may extend axially along an axis substantially parallel to a central axis of a rotor disposed within a cavity defined by the stator core.

Abstract: A hands-free charging system includes a power source and a charging unit electrically connected to the power source. The charging unit includes an energy-storage device and a robotic coupler connectable to a charge port of a vehicle. The charging unit is configured to charge the vehicle with the power source, and the energy-storage device is configured to independently power the robotic coupler irrespective of an energization state of the power source. A controller is programmed to, in response to the power source becoming de-energized during a vehicle charging session, retract the robotic coupler from the charge port using power from the energy-storage device.

Abstract: A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.

Abstract: An electric machine includes a plurality of planar laminations stacked to form an electrical steel rotor having openings defining magnet pockets and adjacent inner side pockets. The adjacent inner side pockets define a center bridge therebetween and have blasted surface portions such that compressive stress layers are induced along edges of the center bridge to strengthen the center bridge.

Abstract: A system for a vehicle includes a converter configured to, responsive to a first signal from a first adaptor indicating a first plug type having a first electrical parameter configuration, output power to the adaptor according to the first electrical parameter configuration, and responsive to a second signal from a second adaptor indicating a second plug type having a second electrical parameter configuration, output power to the adaptor according to the second configuration.

Abstract: An electric machine rotor includes a plurality of plates stacked along an axis of rotation. Each of the plates defines a plurality of cavities. Each cavity defines a pole arc angle, has at least one permanent magnet pocket, and has magnetic field guide chambers extending outward from the at least one permanent magnet pocket. Offset angles between the magnetic field guide chambers and the at least one permanent magnet pockets vary between at least two of the cavities of the plurality of cavities within each plate such that each plate defines at least two different pole arc angles. The plates are stacked such that the at least one permanent magnet pockets between adjacent plates are axially aligned and such that the magnetic field guide chambers between adjacent plates are axially offset.

Abstract: A method of forming an annealed magnet includes positioning a magnetizing array ring concentrically with a ring of bulk magnetic material to form an assembly, the magnetizing array ring having a magnetic field defining directions for orienting grains of the ring of bulk magnetic material, placing the assembly in a furnace, and operating the furnace to anneal the ring of bulk magnetic material and grow the grains in the directions. A magnetic array assembly includes a furnace; and an assembly including (i) a ring of bulk magnetic material having grains and (ii) a magnetizing array ring concentric with the ring of bulk magnetic material, and having a magnetic field defining directions for orienting the grains during growth thereof in a presence of heat from the furnace.

Abstract: A vehicle includes an electric machine having a number of pole pairs, N, a position sensor having a number of pole pairs, M, that generates output indicative of a rotational position of the electric machine, and one or more controllers. The one or more controllers generate a remapped rotational position according to a product of the rotational position and L/N, generate a scaled position according to a product of the remapped rotational position and N/M, and command the electric machine to produce a specified torque or speed based on the scaled position. M is not equal to and not a factor of N, and L is a minimum common multiplier of N and M.

Abstract: A vehicle includes an electric machine, a battery, an inverter, and a controller. The controller switches the inverter at a switching frequency selected to generate an AC current to heat the battery, adjusts a d-axis current of the electric machine to increase a battery heating power, and adjusts a q-axis current of the electric machine according to the adjusted d-axis current.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: An electrical current sensing arrangement includes a busbar, a dielectric material containing therein a magnetic field sensor, and a ferromagnetic over-mold encapsulating a portion of the busbar and the dielectric material. The dielectric material is disposed against the busbar such that the magnetic field sensor is spaced away from the busbar and the ferromagnetic over-mold is not between the busbar and the magnetic field sensor.

Abstract: A system of a vehicle includes a processor configured to control output current of a remote power distribution circuit (PDC) connected to the vehicle according to a temperature change of a power line or return line of the PDC. The temperature change is derived from a PDC output voltage or output current change. The PDC output voltage and output current are measured at an input to a load connected to the PDC. And, the PDC output voltage is measured between a ground line of the PDC and one of the power and return lines.

Abstract: A winding assembly for a stator has a plurality of bridges each including an arcuate center section extending circumferentially over an end surface of a core at a first axial level relative thereto, first and second necks contiguous with respective first and second ends of the center section and extending therefrom axially away from the end surface, and first and second blocks contiguous with the respective necks and connected to the respective terminals of a pair of conductors at a second axial level farther from the end surface than the first axial level.

Abstract: A charge system includes a charge cable containing a coolant to be circulated therethrough, and wires submersed and in direct contact with the coolant. The charge system also includes a controller that alters a pressure of the coolant within the charge cable to maintain nucleate boiling of the coolant.

Abstract: A hands-free charging system includes an electrical power source and a ground unit electrically connected to the power source. The ground unit includes an energy-storage device and a robotic coupler having a connector and an actuator configured to move the connector into engagement with a vehicle charge port. The energy-storage device is configured to power the actuator. A switching arrangement is configured to selectively electrically connect the power source to the energy-storage device and to the connector. A controller is programmed to, in response to a request to charge a vehicle, connect the connector to a charge port when the connector is electrically disconnected from the power source using an internal power source.

Abstract: An electric machine stator includes a soft magnetic yoke having a cylindrical yoke body extending along a central axis, with an outer surface and an inner periphery defining a central opening about the central axis, and a plurality of soft magnetic stator teeth. Each stator tooth defines a first set of air pockets, and a second set of air pockets. An electric machine rotor and permanent magnet material with air pockets are also provided.

Abstract: A vehicle-based microgrid includes a controller and a vehicle having a power source and a network. The controller is operable to operate the power source to supply power to the network for consumption by loads on the network and to adjust operation of the power source in supplying power to the network upon a battery source being added to the network. The power source may be (i) a traction battery, (ii) an electrical generator, or (iii) a non-traction battery. The battery source may be (i) a battery that is on-board the vehicle and that is not the power source or (ii) a battery that is off board the vehicle.

Abstract: An electric machine includes a rotor and a stator. The rotor is configured to generate rotational motion. The stator is disposed radially about the rotor. The stator has a core and windings. The core defines a first array of orifices about an inner diameter of the core and a second array of orifices radially outward from the first array of orifices. The windings are disposed within the first array of orifices. A magnetic material is configured to advance into and retract from the second array of orifices to adjust a magnetic flux within an airgap defined between the rotor and the stator.