Abstract: A current command module is configured to, based on a direct current (DC) bus voltage for an electric motor of the vehicle, generate a d-axis current command for the electric motor and a q-axis current command for the electric motor. A voltage command module configured to generate voltage commands based on the d-axis current command and the q-axis current command. A battery switching control module is configured to: determine a voltage operating state of a battery based on the voltage commands; compare a battery parameter to at least one of a predetermined voltage parameter and a predetermined current parameter during a dwell time when a plurality of switches of the battery are open; and generate a switch control signal to transition at least one switch of the plurality of switches to cause the battery to operate in the voltage operating state based on the comparison.

Abstract: Presented are model predictive control (MPC) systems, methods, and devices for regulating operation of hybrid powertrains. A method of controlling a hybrid powertrain includes a controller determining path plan data, including a vehicle origin, destination, and predicted path. Based on this path plan data, the controller estimates vehicle velocities for multiple rolling road segments of the predicted path and, based on the estimated velocities, determines an estimated power request—transmission input torque and/or vehicle axle torque—for each road segment. The controller calculates a minimum cost function such that total fuel consumption to generate the engine power output is minimized. Minimizing the cost function is subject to battery pack current limits and state of charge (SOC) terminal costs at the ends of the rolling road segments. Command signals are sent to the engine and motor to output engine and motor torque based on the calculated minimum cost function.

Abstract: A control system to control slip of a torque converter clutch includes a clutch plant model configured to predict a value of a parameter that relates to torque converter clutch slip as a function of clutch plant model inputs comprising commanded clutch pressure and of torque from the torque generative device. The control system also includes a model predictive controller configured to receive signals that allow determination of a desired value of the parameter that relates to torque converter clutch slip and a predicted value of the parameter that relates to torque converter clutch slip, receive a signal representing reported torque of the torque generative device, identify an optimal commanded clutch pressure value that will result in an optimal value of an objective function based on the clutch plant model, and provide a command signal to an actuator effective to control commanded clutch pressure to the torque converter clutch.

Abstract: Powerflow of a rechargeable energy storage system (RESS) is managed according to a method. The RESS has series-connected first and second battery elements with different characteristics. Each element, e.g., a pack, has a corresponding maximum or minimum voltage or current limit. Currents are predicted for each of the first and second battery elements via a controller using a corresponding voltage limit. A requested operating mode of the RESS is used to select a current for the elements. A voltage across the elements is predicted using the selected current and a corresponding battery state space model. The method predicts a total power capability of the RESS over a prediction horizon using the selected current to generate predicted power capability values. The requested operating mode is controlled over the horizon using the power capability values. A powertrain system includes the RESS, an inverter, an electric machine, and the controller.

Abstract: Presented are battery pack voltage-switching (“V-switch”) systems, methods for making/operating such systems, and multi-pack, electric-drive motor vehicles with battery pack V-switch capabilities. A method for controlling operation of a vehicle includes a vehicle controller receiving a voltage switch signal to change a voltage output of the vehicle's battery system. The vehicle controller determines if a speed of a traction motor is less than a calibrated base speed; if so, the controller transmits a pack isolation signal to a power inverter to electrically disconnect the traction battery packs from the traction motor. The vehicle controller determines if a bus current of a DC bus is less than a calibrated bus current threshold; if so, the controller transmits an open signal to open one or more pack contactor switches and a close signal to close one or more pack contactor switches thereby causing the vehicle battery system to output the second voltage.

Abstract: Powerflow is managed using a method, e.g., in a powertrain system having a multi-pack rechargeable energy storage system (RESS) with parallel battery packs. Each pack has a corresponding maximum electrical (current or voltage) limit. The method includes predicting a corresponding terminal voltage for each pack using the corresponding maximum electrical limit. The method includes selecting a terminal voltage as a selected voltage based on a requested operating mode, including selecting a maximum of the terminal voltages when the requested operating mode is a discharging mode and a minimum of the same when the requested operating mode is a charging mode. A pack current through each pack is predicted using the selected voltage and a corresponding battery state space model. A total power capability of the RESS is predicted over a predetermined prediction horizon using the selected voltage, with the operating mode controlled over the prediction horizon via the controller.

Abstract: A system for monitoring operation of a vehicle includes a processing device including an interface configured to receive measurement data from sensing devices configured to measure parameters of a vehicle system. The processing device is configured to receive measurement data from each of the plurality of sensing devices, and in response to detection of a malfunction in the vehicle, input at least a subset of the measurement data to a machine learning classifier associated with a vehicle subsystem, the classifier configured to define a class associated with normal operation of the vehicle subsystem. The processing device is also configured to determine whether the subset of the measurement data belongs to the class, and based on at least a selected amount of the subset of the measurement data being outside of the class, output a fault indication, the fault indication identifying the vehicle subsystem as having a contribution to the malfunction.

Abstract: Presented are intelligent vehicle systems and control logic for predictive charge planning and powertrain control of electric-drive vehicles, methods for manufacturing/operating such systems, and electric-drive vehicles with smart charge planning and powertrain control capabilities. Systems and methods of AI-based predictive charge planning for smart electric vehicles use machine-learning (ML) driver models that draws on available traffic, location, and roadway map information to estimate vehicle speed and propulsion torque requirements to derive a total energy consumption for a given trip. Systems and methods of AI-based predictive powertrain control for smart hybrid vehicles use ML driver models with deep learning techniques to derive a drive cycle profile defined by a preview route with available traffic, geopositional, geospatial, and map data.

Abstract: A control system to control slip of a torque converter clutch includes a clutch plant model configured to predict a value of a parameter that relates to torque converter clutch slip as a function of clutch plant model inputs comprising commanded clutch pressure and of torque from the torque generative device. The control system also includes a model predictive controller configured to receive signals that allow determination of a desired value of the parameter that relates to torque converter clutch slip and a predicted value of the parameter that relates to torque converter clutch slip, receive a signal representing reported torque of the torque generative device, identify an optimal commanded clutch pressure value that will result in an optimal value of an objective function based on the clutch plant model, and provide a command signal to an actuator effective to control commanded clutch pressure to the torque converter clutch.

Abstract: Presented are battery pack voltage-switching (“V-switch”) systems, methods for making/operating such systems, and multi-pack, electric-drive motor vehicles with battery pack V-switch capabilities. A method for controlling operation of a vehicle includes a vehicle controller receiving a voltage switch signal to change a voltage output of the vehicle's battery system. The vehicle controller determines if a speed of a traction motor is less than a calibrated base speed; if so, the controller transmits a pack isolation signal to a power inverter to electrically disconnect the traction battery packs from the traction motor. The vehicle controller determines if a bus current of a DC bus is less than a calibrated bus current threshold; if so, the controller transmits an open signal to open one or more pack contactor switches and a close signal to close one or more pack contactor switches thereby causing the vehicle battery system to output the second voltage.

Abstract: System and method of dynamically balancing a rechargeable energy storage assembly having two or more respective units, a respective switch for each of the respective units and at least one sensor. The system includes a controller configured to control operation of the respective switch. The respective switch is configured to enable a respective circuit connection to the respective units when in an ON state and disable the respective circuit connection when in an OFF state. The respective units are characterized by a respective state of charge obtained based in part on the at least one sensor. A controller is configured to selectively employ at least one of a plurality of charging modes to charge one or more of the respective units, through operation of the respective switch. The plurality of charging modes includes a rest charging mode, a rapid initial charging mode and a rapid final charging mode.

Abstract: An exhaust aftertreatment system for an internal combustion engine includes a selective catalytic reduction (SCR) device, an injection system disposed to inject reductant into the exhaust pipe upstream of the SCR device. A single ammonia sensor is disposed to monitor an exhaust gas feedstream downstream of the SCR device. A controller is in communication with the single ammonia sensor and the internal combustion engine and operatively is connected to the injection system. The controller includes an instruction set that is executable to monitor, via the single ammonia sensor, a magnitude of ammonia in the exhaust gas feedstream downstream of the SCR device and determine NOx efficiency of the SCR device based upon the magnitude of ammonia in the exhaust gas feedstream downstream of the SCR device. A fault is detected in the SCR device based upon the NOx efficiency.

Abstract: An emissions control system for a motor vehicle that includes an internal combustion engine includes a first selective catalytic reduction (SCR) device and a reductant injector, The system further includes a model-based controller that is configured to calculate a target amount of reductant to inject to maintain a predetermined ratio between an amount of NH3 and an amount of NOx at the outlet of the first SCR device, and to send a command for receipt by the reductant injector to inject the calculated amount of reductant. The model-based controller is further configured to send a command for receipt by an engine controller to influence NOx production by the engine by modifying an engine operating parameter, based on a calculated target amount of NOx at the inlet of the first SCR device.

Abstract: An LPV/MPC engine control system is disclosed that includes an engine control unit connected to multiple sensors. The engine control unit receives, from the sensors, signals indicative of desired engine torque and engine torque output, and determines, from these signals, optimal engine control commands using a piecewise LPV/MPC routine. This routine includes: determining a nonlinear and a linear system model for the engine assembly, minimizing a control cost function in a receding horizon for the linear system model, determining system responses for the nonlinear and linear system models, determining if a norm of an error function between the system responses is smaller than a calibrated threshold, and if the norm is smaller than the predetermined threshold, applying the linearized system model in a next sampling time for a next receding horizon to determine the optimal control command. Once determined, the optimal control command is output to the engine assembly.

Abstract: Presented are model-based control systems for operating parallel hybrid powertrains, methods for making/using such systems, and motor vehicles with parallel hybrid powertrains and model-based torque and speed control capabilities. A method for controlling operation of a hybrid powertrain includes receiving a command signal for a hybrid powertrain operation associated with a driver input and a current operating mode of the powertrain. A desired output torque for executing the powertrain operation is then determined. The method determines if a speed differential between an engine speed of an engine and a torque converter output speed of a torque converter is less than a calibrated threshold; if so, the method responsively engages a clutch device to operatively connect the engine's output member to the transmission's input member. Engine torque is then coordinated with motor torque such that the sum of the engine and motor torques is approximately equal to the desired output torque.

Abstract: An electrical system includes a rechargeable energy storage system (RESS) and a controller. The RESS includes first and second battery packs connected to a voltage bus, each pack having a respective plurality of battery cells and a corresponding cell balancing circuit. The RESS further includes switches that selectively connect or disconnect the packs to or from each other to achieve series and parallel modes. The controller executes a method by detecting a requested series to parallel mode transition. Responsive to a threshold imbalance being present in a state of charge or pack voltage of the packs relative to each other, the controller balances the state of charge/voltage using open/closed state control of the cell balancing circuits, and possibly a switching block having PWM-controlled switches and a circuit element. The controller may execute the requested mode transition upon balancing.

Abstract: Presented are intelligent vehicle systems and control logic for predictive charge planning and powertrain control of electric-drive vehicles, methods for manufacturing/operating such systems, and electric-drive vehicles with smart charge planning and powertrain control capabilities. Systems and methods of AI-based predictive charge planning for smart electric vehicles use machine-learning (ML) driver models that draws on available traffic, location, and roadway map information to estimate vehicle speed and propulsion torque requirements to derive a total energy consumption for a given trip. Systems and methods of AI-based predictive powertrain control for smart hybrid vehicles use ML driver models with deep learning techniques to derive a drive cycle profile defined by a preview route with available traffic, geopositional, geospatial, and map data.

Abstract: A method of estimating a compressor inlet pressure for a turbocharger includes: measuring an ambient temperature of air flowing into the compressor; measuring a flow rate of the air into the compressor; measuring a boost pressure of the air from the compressor to an engine; determining a speed of a turbine of the turbocharger; defining a pressure ratio as the ratio of the boost pressure to the compressor inlet pressure; defining a function as the function of the compressor flow rate, the ambient temperature, the compressor inlet pressure and the turbine speed; and equating the pressure ratio and the function and recursively solving for the compressor inlet pressure.

Abstract: A two-stage air charging system for an internal combustion engine with mixed exhaust gas recirculation includes a high pressure exhaust gas recirculation loop, a low pressure exhaust gas recirculation loop, an air throttle system, a turbo air charging system, and an electric air charging system. A method to control the system includes monitoring desired operating target commands and operating parameters. Feedback control signals are determined based upon the monitored desired operating target commands and the monitored operating parameters. The two-stage air charging system is controlled based on system control commands for each of the high pressure exhaust gas recirculation loop, the low pressure exhaust gas recirculation loop, the air throttle system, the turbo air charging system and the electric air charging system.

Abstract: Presented are model-based control systems for operating parallel hybrid powertrains, methods for making/using such systems, and motor vehicles with parallel hybrid powertrains and model-based torque and speed control capabilities. A method for controlling operation of a hybrid powertrain includes receiving a command signal for a hybrid powertrain operation associated with a driver input and a current operating mode of the powertrain. A desired output torque for executing the powertrain operation is then determined. The method determines if a speed differential between an engine speed of an engine and a torque converter output speed of a torque converter is less than a calibrated threshold; if so, the method responsively engages a clutch device to operatively connect the engine's output member to the transmission's input member. Engine torque is then coordinated with motor torque such that the sum of the engine and motor torques is approximately equal to the desired output torque.