Abstract: A method of analyzing the quality of a battery cell includes performing a high-throughput quality check on the battery cell with a quality control system, assessing a quality score to the battery cell, with quality score identifying the battery cell as low-quality or high-quality, and performing a comprehensive quality check on the battery cell if identified as low-quality. The method further includes assessing an enhanced quality score to the battery cell superseding the quality score of the quality control system identifying the battery cell as confirmed low-quality or confirmed high-quality and providing revised production instructions for manufacturing successive battery cells if confirmed low-quality.

Abstract: A method for constructing a rotor assembly for use with a rotary electric machine includes forming annular rotor laminations from metal blanks. Each lamination has a radial axis and an outer diameter surface. Multiple magnet web regions are defined in proximity to the outer diameter surface. Each web regions includes asymmetrical openings defined by a radially-extending strut and arcuate peripheral bridges. The method includes coaxially stacking the laminations into a rotor stack, including positioning every other lamination a predetermined angular distance with to unmask the bridges and/or struts and mask remaining surface area of the laminations. The rotor stack is subjected to a heat-treating process to harden only the unmasked bridges and/or struts. The method includes connecting a rotor shaft to the stack to construct the rotor assembly, with the web regions corresponding to a respective rotor magnetic pole.

Abstract: A method of analyzing the quality of a battery cell includes performing a high-throughput quality check on the battery cell with a quality control system, assessing a quality score to the battery cell, with quality score identifying the battery cell as low-quality or high-quality, and performing a comprehensive quality check on the battery cell if identified as low-quality. The method further includes assessing an enhanced quality score to the battery cell superseding the quality score of the quality control system identifying the battery cell as confirmed low-quality or confirmed high-quality and providing revised production instructions for manufacturing successive battery cells if confirmed low-quality.

Abstract: A computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Abstract: A method of forming a separator for a lithium-ion battery includes arranging a polymer film in contact with a sacrificial layer to form a cutting stack. The method includes disposing the cutting stack between a first vitreous substrate and a second vitreous substrate. The method includes applying an infrared laser to the cutting stack through the first vitreous substrate to generate heat at the sacrificial layer. The method also includes transferring heat from the sacrificial layer to the polymer film to thereby cut out a portion of the polymer film and form the separator. A method of cutting a polymer film and a cutting system are also explained.

Abstract: A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.

Abstract: A method for constructing a rotor assembly for use with a rotary electric machine includes forming annular rotor laminations from metal blanks. Each lamination has a radial axis and an outer diameter surface. Multiple magnet web regions are defined in proximity to the outer diameter surface. Each web regions includes asymmetrical openings defined by a radially-extending strut and arcuate peripheral bridges. The method includes coaxially stacking the laminations into a rotor stack, including positioning every other lamination a predetermined angular distance with to unmask the bridges and/or struts and mask remaining surface area of the laminations. The rotor stack is subjected to a heat-treating process to harden only the unmasked bridges and/or struts. The method includes connecting a rotor shaft to the stack to construct the rotor assembly, with the web regions corresponding to a respective rotor magnetic pole.

Abstract: A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

Abstract: A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.

Abstract: A weld inspection system is adapted to inspect a weld of a work product via thermographic technology. The weld inspection system includes a heat source assembly, a thermal imaging camera, and a controller. The heat source assembly is adapted to sequentially direct a plurality of heat pulses upon the work product from varying perspectives and within a pre-determined time period. Thea thermal imaging camera is configured to thermally image the weld over the pre-determined time period and collect thermal imaging data of heat dissipation from the work product. The thermal imaging data is associated with the weld and the plurality of heat pulses. The controller is configured to control the heat source assembly and the thermal imaging camera. The controller includes a processor configured to receive and transform the thermal imaging data into a binary image for evaluation of the weld.

Abstract: A computer software product adapted for use in a weld inspection system is executed by a processor and is stored in an electronic storage medium of the weld inspection system adapted to facilitate the inspection of a weld of a work product. The computer software product includes a first module and a combination module. The first module is configured to transform first and second raw thermal images, associated with respective first and second heat pulses of at least a portion of the work product having the weld, into respective first and second binary images. The combination module is configured to transform the first and second binary images into a combined binary image for the reduction of noise.

Abstract: Motor housings with controlled radial thermal expansion include a cylindrical body with at least one circumferential groove extending inward from an outer surface of the cylindrical body, and a fiber composite band disposed within each groove. The grooves can be dovetail shaped and extend inward from the outer surface of the cylindrical body to a groove bottom, wherein each groove has a first width at the outer surface and a second width at the groove bottom that is greater than the first width. Methods for controlling radial thermal expansion of motor housings include providing a motor housing including a cylindrical aluminum body with a plurality of circumferential grooves extending inward from an outer surface of the cylindrical body, disposing a plurality of continuous fibers within the grooves, applying a matrix to the continuous fibers, and curing the matrix to form a fiber composite band within the grooves.

Abstract: A method of forming a rotor includes isolating a bridge area of an electrical steel lamination. The bridge area is disposed between a first portion of the electrical steel lamination and a second portion of the electrical steel lamination that is adjacent to the first portion. Each of the first portion, the second portion, and the bridge area has an initial hardness, and the electrical steel lamination has an initial magnetic permeability. After isolating, the method includes hardening only the bridge area so that the bridge area has a treated hardness that is greater than the initial hardness. Concurrent to hardening, the method includes decreasing the initial magnetic permeability at only the bridge area.

Abstract: A functionalized adhesive and systems and methods employing the same are disclosed. The functionalized adhesive is configured to form an adhesive joint between a first substrate and a second substrate. The functionalized adhesive comprises a neat adhesive selected to have a bonding strength above a predetermined bonding threshold and a filler selectively dispersed within the neat adhesive. The filler is selected to modify electrical properties of the neat adhesive such that the functionalized adhesive is electrically conductive with a tailored resistivity and such that a resistance of the adhesive joint is greater than a resistance of the first substrate and the second substrate.

Abstract: A method of forming a separator for a lithium-ion battery includes arranging a polymer film in contact with a sacrificial layer to form a cutting stack. The method includes disposing the cutting stack between a first vitreous substrate and a second vitreous substrate. The method includes applying an infrared laser to the cutting stack through the first vitreous substrate to generate heat at the sacrificial layer. The method also includes transferring heat from the sacrificial layer to the polymer film to thereby cut out a portion of the polymer film and form the separator. A method of cutting a polymer film and a cutting system are also explained.

Abstract: An electronic transmission range selection (ETRS) system for a motor vehicle transmission includes an ETRS housing disposed on the transmission, the ETRS housing having a magnetic field sensor in communication with a transmission controller; and a magnetic field source including a magnet component and a high magnetic permeability component. The magnetic field source disposed on a transmission selector shaft, the magnetic field source detectable by the magnetic field sensor at a plurality of predetermined positions along a movement path of the transmission selector shaft; and the magnetic field sensor detecting magnetic flux generated by the magnetic field source, and communicating magnetic field source position information to the controller. The high magnetic permeability component homogenizes the magnetic flux generated by the magnet component and the controller generates an electronic transmission mode signal based on the magnetic field source position information.

Abstract: A welded assembly and a method of reaction metallurgical welding are disclosed. The assembly includes a first metallic workpiece and a second metallic workpiece attached together by at least two overlapping weld joints. The overlapping weld joints are reaction metallurgically joined (RMJ) weld joints, and each overlapping weld joint overlaps with the other overlapping weld joint by 10-75%. The method of welding includes providing a reactive material between and in contact with the first and second workpieces. In a first position, the workpieces and the reactive material are pressed together, heated, and held between first and second tools to form a first RMJ weld joint between the workpieces. Then, in a second position, the workpieces are pressed together, heated, and held between the tools to form a second RMJ weld joint that overlaps with the first RMJ weld joint.

Abstract: A stack assembly having a battery tab with a localized weld and method of making the same is disclosed. The assembly is made by a process including the steps of arranging a plurality of battery tabs into a stack assembly; providing a resistive coating on at least one of the interior surfaces and the exterior surfaces of the battery tabs; and resistive heating the stack assembly. The resistive coating is a nickel-phosphorous (Ni—P) alloy containing 5 to 7 weight percent phosphorus. Resistive heating includes reacting the Ni—P alloy with an electric current to generate concentrated heat localized between adjacent battery tabs such that the Ni—P alloy undergoes solid-state bonding with the Cu in the first batter tab.

Abstract: A functionalized adhesive and systems and methods employing the same are disclosed. The functionalized adhesive is configured to form an adhesive joint between a first substrate and a second substrate. The functionalized adhesive comprises a neat adhesive selected to have a bonding strength above a predetermined bonding threshold and a filler selectively dispersed within the neat adhesive. The filler is selected to modify electrical properties of the neat adhesive such that the functionalized adhesive is electrically conductive with a tailored resistivity and such that a resistance of the adhesive joint is greater than a resistance of the first substrate and the second substrate.

Abstract: A transmission range selection sensor includes a housing defining a bore extending along a central axis. A piston is slideably disposed within the bore. A magnet carrier is attached to and moveable with the piston. A magnet is supported by and moveable with the magnet carrier. A first magnetic sensor and a second magnetic sensor are supported by the housing and are spaced from each other along the central axis. A position of the magnet carrier along the central axis is determinable from a sensed magnetic flux from the first and second magnetic sensors. The sensor includes at least one magnetic flux concentrator attached to one of the magnet carrier or the housing. The flux concentrator is operable to concentrate the magnetic flux toward at least one of the first magnetic sensor or the second magnetic sensor depending upon a position of the magnet along the central axis.