Abstract: Robotic systems are provided for flexibility in assembly operations. A robotic system includes a suction module having a front side with a face shaped to match a mating component and a rear side with a coupling for a suction line. Openings extend through the face. The suction module defines internal passages connecting the coupling with the at least one opening through the face. An end-effector has a base plate, a mounting plate selectively moveable relative to the base plate, and a clamp. The suction module is selectively mounted to the mounting plate and releasably secured by the clamp. An actuator is mounted to selectively move the mounting plate and the suction module relative to the base plate.

Abstract: A vehicle stalactite passive lubrication system includes a drive unit having an electric motor and a gear. A sump has a sump extension. A lubricant is collected in the sump for gravity flow into the sump extension. A stalactite member is fixed to the drive unit and is positioned above an element to be filled with a fluid, lubricated or cooled. The stalactite member is directed downwardly toward the sump with the lubricant splashed by gear rotation collected on neighboring walls and the stalactite member and directed downwardly by gravity into the sump or target element. The stalactite member includes: a drip edge oriented at an angle to a horizontal plane; and a tip defining an end of the drip edge. The angle is selected to direct the lubricant to discharge off the stalactite member at the tip as a lubricant stream into the sump or target element.

Abstract: Control of an AC motor includes rotation over an operating speed range with the output from an inverter by operating the inverter at switching frequencies that vary in proportion to rotor speed. The operating speed range is parsed into a plurality of speed regions and the switching frequencies within each operating speed region may correspond to a respective pulse ratio that is different from the respective pulse ratio corresponding to an adjacent speed region.

Abstract: Evaporative emission purge control systems and methods use a cost factor to incentivize operation of an internal combustion at torques favorable for purge. An evaporative emission control system is configured to collect fuel vapor. A controller determines whether an operating speed of the internal combustion engine is within a target purge region that is bounded by a lower speed threshold and an upper speed threshold of the internal combustion engine. When the operating speed of the internal combustion engine is within the target purge region, the controller applies a cost factor to operating points for the internal combustion engine, and based on the cost factor, the operating points are set to include an operating torque for the internal combustion engine to generate an intake pressure of the internal combustion engine at a level below atmospheric pressure for a purge of the evaporative emission control system.

Abstract: A method and system for estimating state of charge of a lithium battery cell of a vehicle is provided. The method comprises providing a non-linear function of the lithium battery cell, a normalized lithium surface density and an actual voltage at a current of the lithium battery cell having an internal resistance. The method further comprises determining an actual lithium surface density based on the actual voltage relative to an inverse of the non-linear function. The method further comprises determining a varying parameter based on the actual lithium surface density relative to a first diffusion model. The method further comprises determining a predicted lithium surface density based on the varying parameter relative to a second diffusion model. The method further comprises determining an estimated state of charge of the lithium battery cell when a difference between the predicted and actual lithium surface densities is less than a first threshold.

Abstract: A system includes a state of charge (SOC) calculation module configured to calculate an SOC of a battery cell based on a measured current of the battery cell and an overpotential calculation module configured to receive the measured current and output lagged currents based on the measured current and respective time constants, output a weighted measured current and weighted lagged currents based on a plurality of weighting factors, wherein a sum of the plurality of weighting factors is 1, calculate an equivalent constant current corresponding to the measured current based on the weighted measured current and the weighted lag currents, and calculate an overpotential of the battery cell based on the equivalent constant current. The system is configured to output a predicted voltage of the battery cell based on the calculated SOC and the calculated overpotential of the battery cell.

Abstract: An electric drive system, method and apparatus includes a rechargeable energy storage unit, a power inverter, and a rotary electric machine. Transfer of electrical power between the rechargeable energy storage unit and the rotary electric machine is governed by a pulse width modulation (PWM) switching frequency, which is one of a non-six-step switching mode or a six-step switching mode. Executable instructions determine a rotational speed, a torque command, a torque direction, a bus voltage, and a hysteresis band, determine a modulation index command in response to the rotational speed, the torque command, the torque direction, and the bus voltage, and command operation of the rotary electric machine in one of the non-six-step switching mode or the six-step switching mode employing the modulation index command.

Abstract: Air management systems are provided for optimizing airflow in laser welding with deflectors. A system for a welder includes a blower to generate an airflow stream. A plenum receives the airflow stream, directs it toward the workpiece, and defines an outlet facing the workpiece to expel the airflow stream toward the workpiece. A deflector adjacent the outlet is formed as a conical section converging from the plenum toward the workpiece, and is defined by an angled wall with an open center. The deflector concentrates the airflow stream to impart a velocity increase to the airflow stream after leaving the outlet and to impart a favorable directional component to the airflow stream toward a weld zone, as well as protecting the laser lens by increasing the downward momentum force of the air stream to eliminate the potential of spatter impinging the lens.

Abstract: An electric vehicle charging port includes a pair of charging pins each connected to a respective charging cable by a base. A pair of porous metallic cages surround the base of the pair of charging pins. A phase change material disposed in the pair of porous metallic cages and a vapor chamber is disposed between the base of the pair of charging pins and the pair of porous cage. The phase change material with an optional vapor chamber and high thermal conductivity (metal or graphite) foam or mesh to provide faster response of transient heat generation.

Abstract: An automobile vehicle engine includes multiple water jackets individually formed in a cast engine block proximate to successive ones of multiple cylinder bores. Multiple cast-in place transition regions are individually formed during a casting operation of the cast engine block at entrances to individual ones of the multiple water jackets. Individual ones of multiple sawcuts open into individual ones of the multiple cast-in place transition regions.

Abstract: An ego vehicle includes decider modules and a grader module coupled to a resolver module. The decider modules generate trajectory decisions at a current time, generate a current two-dimensional slice of a flat space around the ego vehicle, generate future two-dimensional slices of the flat space by projecting the current two-dimensional slice of the flat space forward in time, and generate a three-dimensional state space by stacking the current two-dimensional slice and the future two-dimensional slices. The grader module generates rewards for the trajectory decisions based on a recent behavior of an ego vehicle. The resolver module selects a final trajectory decision for the ego vehicle from the trajectory decisions based on the three-dimensional state space and the rewards. The current two-dimensional slice includes a current ego vehicle location and current neighboring vehicle locations. The future two-dimensional slices include future ego vehicle locations and future neighboring vehicle locations.

Abstract: A multi-view display device is provided for a collaborative co-pilot system (system) of a vehicle having a windshield. The system includes one or more input devices for generating an input signal associated with a road condition. The multi-view display device includes one or more single-user viewing devices, with each single-user viewing device including an Augmented Reality Head Up Display module (ARHUD) for generating a dedicated display associated with the road condition. The ARHUD projects the dedicated display onto an associated portion of the windshield that is visible to a corresponding single user and overlaying a road geometry associated with the road condition. The multi-view display device further includes an Extended View Display module (EV display module) for generating a common display that is visible to a plurality of users including each one of the single users.

Abstract: A compound dowel for positioning a first component defining a first aperture relative to a second component defining a second aperture in a motor vehicle body structure in response to a determined misalignment between the first and second components includes a compensation pin. The compensation pin is selected in response to the determined misalignment and configured to be inserted into the second aperture. The compensation pin has a center axis and an indexing feature configured to orient and fix the compensation pin to the first component. The compound dowel also includes a nominal pin arranged parallel to the center axis and offset therefrom by a distance. The nominal pin is configured to be inserted through the first aperture, such that position of the first component is set relative to the second component. A method of positioning components in a vehicle body structure using a compound dowel is also considered.

Abstract: A display comprises a substrate. Sets of light emitting diodes (LEDs) are arranged on the substrate. Each of the sets of LEDs comprises a red LED, a green LED, a blue LED, and each of the sets of LEDs forming a pixel of the display. A sensor is embedded in each of the sets of LEDs. The sensor is arranged in a plane in which the red, green, and blue LEDs are arranged in each of the sets of LEDs. A cover including a dielectric material covers the sets of LEDs. The sensor is configured to sense at least one of ambient light and proximity of an object to the cover.