Abstract: Methods and apparatus are provided for a functional high-voltage interlock system. The apparatus includes an enclosure, a high-voltage terminal, a low-voltage circuit, and a control circuit. The enclosure includes an access point that may be breached. The high-voltage terminal is disposed at least partially within the enclosure, is accessible by breaching the high-voltage access point, and is configured to be energized from a high-voltage electrical power source. The low-voltage circuit is disposed within the enclosure, and is coupled to selectively receive a low-voltage electrical signal. The control circuit is coupled to, and is configured to supply the low-voltage electrical signal to, the low-voltage circuit only when the high-voltage access point is not breached. The control circuit implements a first function and a disparate second function.

Abstract: A vehicle includes a high-voltage (HV) energy storage system (ESS), an HV device having HVIL source and return (SR) pins and an HV receptacle, an HV cable, and an HV terminal assembly. The assembly includes a tray portion and retainer for aligning the HV cables with the HV receptacle. An HVIL jumper device is connected to the tray portion and electrically connectable to the HVIL SR pins. The assembly includes a cover portion removably mountable to the tray portion to provide a suitable EMF shield and weather seal. The cover portion includes an HVIL shorting plug. HV electrical energy is supplied from said ESS to the HV device only when all three of the HVIL components, i.e., the HVIL SR pins, the HVIL jumper device, and the HVIL shorting plug, are electrically interconnected to form a closed HVIL circuit, while at the same time the HV cable is properly connected.

Abstract: An oil-cooled motor/generator for an automotive powertrain located outside of the transmission is provided, such as a BAS motor/generator. The motor/generator may have a stator, a rotor circumscribed by the stator, and a motor shaft on which the rotor is mounted for rotation. A housing assembly may surround the stator and the rotor, with a bearing positioned between the housing assembly and the motor shaft. A flow control member may at least partially circumscribe the rotor axially adjacent the stator. A bearing retainer may be positioned axially adjacent the bearing. A rotor end ring may be axially adjacent the rotor. The housing assembly may have an inlet configured to receive cooling oil. The housing assembly, the flow control member, the bearing retainer and the rotor end ring may be configured to distribute the cooling oil from the inlet to cool the stator, the rotor and the bearing.

Abstract: An oil-cooled motor/generator for an automotive powertrain located outside of the transmission is provided, such as a BAS motor/generator. The motor/generator may have a stator, a rotor circumscribed by the stator, and a motor shaft on which the rotor is mounted for rotation. A housing assembly may surround the stator and the rotor, with a bearing positioned between the housing assembly and the motor shaft. A flow control member may at least partially circumscribe the rotor axially adjacent the stator. A bearing retainer may be positioned axially adjacent the bearing. A rotor end ring may be axially adjacent the rotor. The housing assembly may have an inlet configured to receive cooling oil. The housing assembly, the flow control member, the bearing retainer and the rotor end ring may be configured to distribute the cooling oil from the inlet to cool the stator, the rotor and the bearing.

Abstract: Methods and apparatus are provided for a functional high-voltage interlock system. The apparatus includes an enclosure, a high-voltage terminal, a low-voltage circuit, and a control circuit. The enclosure includes an access point that may be breached. The high-voltage terminal is disposed at least partially within the enclosure, is accessible by breaching the high-voltage access point, and is configured to be energized from a high-voltage electrical power source. The low-voltage circuit is disposed within the enclosure, and is coupled to selectively receive a low-voltage electrical signal. The control circuit is coupled to, and is configured to supply the low-voltage electrical signal to, the low-voltage circuit only when the high-voltage access point is not breached. The control circuit implements a first function and a disparate second function.

Abstract: A vehicle includes a high-voltage (HV) energy storage system (ESS), an HV device having HVIL source and return (SR) pins and an HV receptacle, an HV cable, and an HV terminal assembly. The assembly includes a tray portion and retainer for aligning the HV cables with the HV receptacle. An HVIL jumper device is connected to the tray portion and electrically connectable to the HVIL SR pins. The assembly includes a cover portion removably mountable to the tray portion to provide a suitable EMF shield and weather seal. The cover portion includes an HVIL shorting plug. HV electrical energy is supplied from said ESS to the HV device only when all three of the HVIL components, i.e., the HVIL SR pins, the HVIL jumper device, and the HVIL shorting plug, are electrically interconnected to form a closed HVIL circuit, while at the same time the HV cable is properly connected.

Abstract: A fuel economy control method for a hybrid vehicle includes estimating a temperature of a battery, measuring a current of the battery, and measuring a voltage of the battery. A nominal optimum charging voltage is determined as a function of a state of charge (SOC) of the battery and the estimated temperature. The nominal optimum charging voltage is reduced to a fuel economy minimum charging voltage if the SOC is above a predetermined level and the current is within a predetermined range. The battery is then charged at the fuel economy minimum charging voltage using a DC/DC converter.