Abstract: A chassis cast power connector with coaxial shielding is presented according to the present invention. In an exemplary embodiment, the chassis cast power connector comprises a connector receptacle which is integrally cast with a chassis and extends away from one surface of the chassis. The connector receptacle includes an opening which receives male and female connector members, wherein the male connector member is capable of being slidably received in the female connector receptacle to form an electrical connection therebetween. The integral connector receptacle provides coaxial shielding of the electrical connection.

Abstract: An apparatus for balancing a battery module in a vehicle including a plurality of batteries in the battery module, the plurality of batteries connected in series, the plurality of batteries each having a battery voltage, and at least one battery providing power to an electrical system of the vehicle, an electric generator producing a generator voltage to charge the plurality of batteries, and a DC—DC converter coupled to the electrical generator and receiving power from the electrical generator, the DC—DC converter monitoring at least one of the battery voltages of at least one of the plurality of batteries and controlling the battery voltage of the battery providing power to the electrical system of the vehicle with reference to the monitored battery voltage.

Abstract: Power-generating apparatus and a voltage generation method employing null vector modulation for use with an electric vehicle. A DC power supply voltage is provided or generated from a power source and is inverted by a three-phase inverter to generate three phase AC that is supplied to an AC motor or load. One phase of the three phase AC is filtered and transformed by a DC rejection capacitor and single phase transformer of an auxiliary power supply to generate an AC voltage. The AC voltage is rectified and filtered by a rectifier and low pass filter of the auxiliary power supply to produce a DC output voltage. The one phase of the three phase AC and the DC output voltage are processed by a controller to control frequencies of null line-to-line zero voltage vectors during inversion so that the transformed AC voltage does not affect or is not seen by the AC motor or load. This allows for independent control of the voltage at the output of the auxiliary power supply.

Abstract: An improved vehicle yaw control that does not require a yaw sensor, wherein the validity of an estimate of vehicle yaw is determined and used to select an appropriate control methodology. The vehicle yaw is estimated based on the measured speeds of the un-driven wheels of the vehicle, and various other conditions are utilized to determine if the estimated yaw rate is valid for control purposes. When it is determined that the estimated yaw rate is valid, a closed-loop yaw rate feedback control strategy is employed, whereas in conditions under which it is determined that the estimated yaw rate is not valid, a different control strategy, such as an open-loop feed-forward control of vehicle yaw, is employed. The validity of the estimated yaw rate is judged based on a logical analysis of the measured wheel speed information, braking information, and steering wheel angle. The measured speeds of the un-driven wheels are used to compute an average un-driven wheel speed and an average un-driven wheel acceleration.

Abstract: An improved traction control system in which a wheel spin condition is detected based on measured vehicle acceleration instead of measured wheel speeds. An electronic controller detects a wheel spin condition by computing the acceleration of the vehicle drive shaft and comparing the computed acceleration to an acceleration threshold stored as function of vehicle speed and wheel torque. If the computed acceleration exceeds the threshold for more than a predetermined time, the engine torque is reduced in relation to the amount by which the computed acceleration exceeds the threshold. When the computed acceleration falls below the threshold, the torque reduction is gradually removed. The wheel torque, vehicle speed and drive shaft acceleration are easily determined and filtered, and the incremental cost of the traction control function is primarily related to the memory requirements to accommodate the acceleration threshold look-up table.

Abstract: An improved control method that utilizes active brake controls to provide vehicle control during conditions of carriage motion tendency about a longitudinal vehicle axis. Accordingly, the control may be integrated with known active brake controls that regulate yaw rate and/or slip angle or traction controls that regulate front wheel slippage, thereby significantly improving the functionality of the respective control for little or no additional cost. A measure of vehicle carriage motion tendency is determined by computing a control parameter based on the roll angle of the vehicle and the rate of change of roll angle. If the computed control parameter exceeds a first calibrated threshold, a condition of carriage motion tendency is detected and the active brake control actuators are activated to reduce the velocity of the front wheels of the vehicle by a delta velocity command determined as a function of the roll angle and roll angle rate.

Abstract: Distributed staged power systems and control methods for use in supplying power to a load of electric and hybrid electric vehicles. The systems comprise a plurality of parallel DC-to-DC power modules whose output power is controlled in accordance with the various control methods. The distributed staged power systems provide higher efficiency because of smart staging of the power modules. The control methods enable or disable selected power modules as determined to provide the highest possible power conversion efficiency.

Abstract: An improved vehicle active brake control based on an estimate of vehicle yaw rate and slip angle, wherein the estimate is based on a weighted average of two yaw rate values developed with two different estimation techniques. In general, the first estimate of yaw rate is based on the relative velocity of the un-driven wheels, and the second estimate is based on a measure of lateral acceleration. Confidence levels in each estimate are determined and used to form a third or preliminary yaw rate estimate based on a weighted average of the first and second estimates, and the third estimate is supplied to a closed-loop nonlinear dynamic observer which develops the final estimate of yaw rate, along with estimates of lateral velocity and side-slip angle.

Abstract: A position sensorless interior permanent magnet drive system and methods for use in electric and hybrid electric vehicles. The interior permanent magnet drive system and method use two rotor position estimation techniques for low and high speed operation and an initial rotor magnet polarity detection technique used at stand-still conditions. The use of the two different rotor position estimation techniques in combination enhances system efficiency and accuracy.

Abstract: The present invention comprises a power-factor-corrected, single-stage inductive charger that may be used to charge a load, such as batteries of an electric vehicle. The inductive charger system is a single stage inductive charger compatible with the Society of Automotive Engineers inductive charging standard SAE J-1773. The single stage power processing provided by the inductive charger system includes both power factor correction and output power regulation using a relatively low parts count. The inductive charger system is fully soft switched over the line voltage and power range, resulting in high efficiency. The inductive charger system uses the current source operation of a series-parallel resonant converter feeding the SAE J- 1773 interface to provide voltage gain for power factor correction over the full AC line cycle. The operating frequency of the converter is modulated around the current-source frequency to regulate the output power from zero to full load.

Abstract: A distributed staged power system for use in electric and hybrid electric vehicles, and the like. The system comprises a plurality of parallel DC-to-DC power modules that are controlled by way of input and output control signal interfaces using a smart controller. The distributed staged power system provides higher efficiency because of smart staging of the power modules. The distributed staged power system enables or disables each of the modules as determined by a smart controller to provide the highest possible conversion efficiency.

Abstract: A method of determining the acceleration of a rotating body by counting the number of teeth on a rotating gear member for one or more revolutions. The method minimizes the measurement lag using an overlapping method and calculating acceleration on each control loop that a new revolution count is available. The method determines the new tooth count based on the tooth count estimated for the next update. The old tooth count is discarded and the new tooth count is adjusted to match the old tooth count within the system constraints to provide less interrupts and faster acceleration updates. The number of gear revolutions to be counted are increased at higher gear speeds.