Abstract: A method of making a calendered electrode for a battery cell comprises introducing a coated electrode having a first surface extending thereover. The coated electrode has a predetermined density of active materials for ion transport. The method further comprises selectively modifying the coated electrode by patterning the first surface to define a patterned electrode having a first portion and a second portion. After the step of selectively modifying, the method further comprises compressing the patterned electrode by calendering the first surface to provide the first portion having a first density of active materials and the second portion having a second density of active materials. The second density is greater than the first density to define the calendered electrode having a spatial variation of active material density.

Abstract: A system in a vehicle includes a current regulator to obtain current commands from a controller based on a torque input and provide voltage commands and an inverter to use the voltage commands from the current regulator and direct current (DC) supplied by a battery to provide alternating current (AC). The system also includes an electric traction motor to provide drive power to a transmission of the vehicle based on injection of the AC from the inverter. The current regulator adjusts parameters of a transfer function implemented by the current regulator, based on feedback of an input to and an output from the electric traction motor to achieve the AC corresponding with the torque input in no more than two control cycles.

Abstract: A rechargeable energy storage system (RESS) includes a battery controller and battery modules, each respective module having battery cells, a cell sense board, and a semiconductor switch. The switch is connected in parallel with the cells within the respective module, and configured to conduct an electrical current during a thermal runaway propagation (TRP) event in which one or more cells is in an open-circuit state. This action bypasses the module and enables electrical components to be powered by the RESS during the TRP event. A battery electric system includes a direct current (“DC”) voltage bus, an electrical component connected thereto, the battery controller, and the RESS. A method for constructing the RESS includes connecting a respective semiconductor switch in parallel with the at least one battery cell of each respective one of the multiple battery modules, and electrically connecting the multiple battery modules together to construct the RESS.

Abstract: A motor control system includes: a voltage command module configured to determine a target d-axis voltage for an electric motor and a target q-axis voltage for the electric motor; a target frequency module configured to: selectively set a target switching frequency to a first predetermined switching frequency; and selectively set the target switching frequency to a second predetermined switching frequency that is at least 2 kilohertz (kHz) greater than the first predetermined switching frequency; and a switching module configured to: based on the target d-axis voltage and the target q-axis voltage, determine target pulse width modulation (PWM) duty cycles for phases, respectively, of the electric motor; and switch switches of legs of an inverter module connected to the phases of the electric motor at the target PWM duty cycles, respectively, and the target switching frequency.

Abstract: A draw bar stowage apparatus includes an opening through the bed floor of the cargo box of a pickup truck for receiving the insertion end of a draw bar. The stowage apparatus may include an additional bracket beneath the bed floor, bed protection, a plug and adjustable tether for securing a stowed draw bar.

Abstract: The present disclosure relates to electrolyte systems and/or separators for electrochemical cells that cycle lithium ions and which may have lithium metal electrodes. The electrochemical cell includes a liquid electrolyte system that fills voids and pores within the electrochemical cell. The electrolyte system includes two or more lithium salts and two or more solvents. The two or more lithium salts include bis(fluorosulfonyl)imide (LiN(FSO2)2) (LIFSI) and lithium perchlorate (LiClO4). The two or more solvents include a first solvent and a second solvent. The first solvent may be a fluorinated cyclic carbonate. The second solvent may be a linear carbonate. A volumetric ratio of the first solvent to the second solvent may be 1:4. The electrochemical cell may include a surface-modified separator that has one or more coatings or fillers.

Abstract: A control system includes a refrigerant recovery module and at least one of a valve control module and a compressor control module. The refrigerant recovery module is configured to generate a refrigerant recovery signal to initiate a recovery of refrigerant from a first heat exchanger of a thermal system for an electric vehicle, and to stop the refrigerant recovery based on a temperature of refrigerant circulating through the first heat exchanger. The valve control module is configured to open a first valve to allow refrigerant to flow through the first heat exchanger in response to the refrigerant recovery signal. The compressor control module is configured to increase a speed of a compressor disposed upstream from the first heat exchanger in response to the refrigerant recovery signal.

Abstract: A multi-module battery pack includes a battery tray defining multiple battery tray compartments, battery modules each disposed within a corresponding one of the compartments, and a thermal barrier arranged in a predefined heat transfer path through the tray between an adjacent pair of the battery modules. The thermal barrier has a thickness of at least about 1 mm and a thermal conductivity of less than about 4 W/m-K, such that the thermal barrier blocks the heat transfer path to mitigate a thermal runaway event of one of the adjacent pair of battery modules. An electric powertrain system includes a rotary electric machine having phase leads and an output member, a driven load coupled to the output member, and the multi-module battery pack. A method includes providing the tray, identifying the heat transfer path, and arranging the thermal barrier in the heat transfer path.

Abstract: A composite panel for a vehicle includes a plurality of layers bonded together by resin. A sensing assembly is arranged between at least two of the plurality of layers. The sensing assembly includes at least one of a piezoelectric layer to sense vibration of the composite panel when installed on the vehicle and a thermopile configured to sense changes in temperature of the composite panel when installed on the vehicle. The sensing assembly further includes a transmitter configured to transmit data to the vehicle based on an output of the at least one of the piezoelectric layer and the thermopile.

Abstract: A vehicle control system for automated driver-assistance includes a low-resolution color camera that captures a color image of a field of view at a first resolution. The vehicle control system further includes a high-resolution scanning camera that captures a plurality of grayscale images, each of the grayscale images at a second resolution. The second resolution is higher than the first resolution. The grayscale images encompass the same field of view as the color image. The vehicle control system further includes one or more processors that perform a method that includes overlaying the plurality of grayscale images over the color image. The method further includes correcting motion distortion of one or more objects in the grayscale images. The method further includes generating a high-resolution output image by assigning color values to one or more pixels in the grayscale images based on the color image using a trained neural network.

Abstract: A roof for a vehicle upper body structure includes a body extending between a first side and a second side, and between a front end and a back end. The front end is configured to be coupled to a header. The body includes a polymer and a plurality of fibers. At least a portion of the body has a transparency of greater than 0% to less than or equal to about 20%. A header for a vehicle upper body structure includes an elongated body extending between a first side and a second side, a front end that is configured to be coupled to a windshield, and a back end that is configured to be coupled to a roof. The body includes a polymer and a plurality of fibers. At least a portion of the body has a transparency of greater than 0% to less than or equal to about 20%.

Abstract: A visual perception system includes a scanning camera, color sensor with color filter array (CFA), and a classifier node. The camera captures full color pixel images of a target object, e.g., a traffic light, and processes the pixel images through a narrow band pass filter (BPF), such that the narrow BPF outputs monochromatic images of the target object. The color sensor and CFA receive the monochromatic images. The color sensor has at least three color channels each corresponding to different colors of spectral data in the monochromatic images. The classifier node uses a predetermined classification decision tree to classify constituent pixels of the monochromatic images into different color bins as a corresponding color of interest. The color of interest may be used to perform a control action, e.g., via an automated driver assist system (ADAS) control unit or an indicator device.

Abstract: An electrode for an electrochemical cell includes a positive electroactive material and a polymeric binder. The positive electroactive material is present in an amount greater than 95 weight percent of the electrode. The positive electroactive material includes first, second, and third electroactive materials. The first electroactive material includes a lithium nickel manganese cobalt oxide (NMC), a lithium nickel manganese cobalt aluminum oxide (NMCA), a lithiated nickel cobalt aluminate (NCA), or a combination thereof. The first electroactive material has a nickel content of greater than or equal to about 60 mole percent. The second electroactive material includes a phosphate-containing positive electroactive material. The third electroactive material includes a lithium manganese oxide (LMO).

Abstract: Presented are intelligent vehicle communications systems for cellular link monitoring and failure detection, methods for making/using such systems, and vehicles equipped with such systems. A method for operating a wireless-enabled vehicle component of a motor vehicle includes a cellular communications device of the vehicle component detecting an uplink (or downlink) network data packet transmitted by (or to) the vehicle. An electronic vehicle controller then establishes an observation period as a function of the time at which the network data packet was transmitted. The opposite downlink (or uplink) of the wireless-enabled vehicle component is monitored to determine if a downlink (or uplink) network data packet is received within the observation period, thereby indicating detection of a cellular link failure.

Abstract: A battery system includes a multi-cell rechargeable energy storage system (RESS) and an electronic controller configured to process RESS cell data. The controller is programmed with a battery cell open circuit voltage (OCV) versus state of charge (SOC) data table used to calculate a peak OCV movement for a representative battery cell at predetermined capacity and maximum discharge/charge rate. The controller is configured to acquire voltage data for one of the cells during active RESS cycling. The controller is also configured to pass the acquired voltage data through a first-order lag filter algorithm to generate an overpredicted OCV for the subject cell. The controller is additionally configured to determine an overpredicted SOC value for the subject cell in the data table using an OCV value from the overpredicted OCV. Furthermore, the controller is configured to regulate the RESS using the determined overpredicted SOC value for the subject cell.

Abstract: A battery module includes a first battery cell and a neighboring second battery cell, and an insulating member positioned therebetween. The battery module also includes a battery module enclosure surrounded by an external environment and configured to house each of the first battery cell, the second battery cell, and the insulating member. The battery module additionally includes a battery module cover mounted to the battery module enclosure. The battery module cover includes a vent feature configured to expel high temperature gases from the first battery cell and divert the high temperature gases away from the second battery cell directly to the external environment. The cover is thereby configured to minimize transfer of the high temperature gases from the first battery cell to the second battery cell and control propagation of a thermal runaway event in the battery module.

Abstract: An electrical connection unit for a battery pack includes a busbar having a first hole therein, a top surface and a bottom surface, an annular bushing having a top end abutting the bottom surface, a bottom end opposed to the top end and a bore hole therein registered with the first hole, a busbar cage secured to the busbar and retaining the annular bushing in abutment with the busbar, the busbar cage having a cavity therein above the top surface, and a fastener having a head portion captured within the cavity and a shank portion extending through the first hole. The annular bushing may include one or more indents formed on an outer surface thereof, and the busbar cage may include a plurality of fingers extending along the outer surface and interfacing with the one or more indents. Each finger may include a protrusion configured to rest within an indent.

Abstract: The concepts herein provide for a rechargeable lithium-ion battery cell having an anode with improved properties, including a capability to suppress formation of lithium dendrites after cell formation and in-use. This includes an anode for a rechargeable battery that includes a current collector having an indium nitride layer, wherein the indium nitride layer includes indium nitride, an electrically conductive material, and a polymeric binder.

Abstract: Systems, methods, and apparatus are provided in a vehicle having a Hitch Articulation Angle (HAA) calculation system for estimating an HAA between the vehicle and a towed trailer. The method includes: receiving a plurality of ultrasonic sensor (USS) range measurements for a first USS on the vehicle while the vehicle is towing the trailer in a forward direction; receiving a plurality of HAA values calculated using geometric equations or a kinematic model that correspond to the plurality of USS range measurements; receiving a USS range measurement for the first USS while the vehicle is operating in a reverse direction or experiencing a high HAA but not from a second USS; estimating an HAA value from the USS range measurement by applying the USS curve characteristics for the first USS; and providing the estimated HAA value to a vehicle motion control system for use in controlling vehicle and trailer motion.

Abstract: A battery electric system includes a battery, sensor suite, and controller. The sensor suite includes a current sensor, voltage sensor, and temperature sensor. The controller is operable for determining an estimated open circuit voltage of the battery at different time points using a current signal and a voltage signal from the current and voltage sensors, and an equivalent circuit model (ECM). The controller determines an ECM-based state of charge (SOC) of the battery at the different time points, via a calibrated SOC map, using the open circuit voltage and temperature, and calculates a sensor gain value using the ECM-based SOC and a coulomb counting-based SOC, both at the different time points. A control action is executed with respect to the battery when the sensor gain value exceeds a predetermined gain fault threshold, including generating a fault notification signal indicative of a fault of the current sensor.