Abstract: Presented are flutter countermeasure devices and control logic for active aerodynamic systems, methods for making/using such active aero systems, and vehicles equipped with spoiler flutter countermeasure devices for increasing downforce and decreasing drag. A method of operating an active aerodynamic system of a motor vehicle includes detecting, via a system controller based on sensor data received from one or more sensing devices, a flutter excitation experienced by a spoiler of the active aero system during operation of the motor vehicle. The controller determines a harmonic oscillation amplitude of the flutter excitation experienced by the spoiler, and then determines if this harmonic oscillation amplitude exceeds a vehicle-calibrated threshold amplitude. If so, the system controller determines a damping force sufficient to mitigate or eliminate the harmonic oscillation amplitude.

Abstract: A method of operating a vehicle includes a vehicle controller receiving an operator-input vehicle control command with an associated torque request, and identifying any propulsion actuator constraints that limit a brake torque capacity available from the vehicle powertrain. Using the propulsion actuator constraint(s) and torque request, the controller determines a propulsion brake torque distribution for the vehicle's road wheels and a maximum brake torque capacity for the powertrain actuator(s). A first brake torque request is determined using the propulsion brake torque distribution and a vehicle control mode of the powertrain system, and a second brake torque request is determined using the maximum brake torque capacity and the vehicle control mode. A friction brake torque command is determined by arbitrating between the first and second brake torque requests.

Abstract: An induction motor includes a stator and a rotor. The stator is configured to generate a rotating magnetic field. The rotor is disposed inside the stator, separated from the stator by an air gap, and is configured to rotate around an axis in response to the rotating magnetic field. The rotor includes a rotor core, multiple end rings, and multiple collars. The end rings are attached at opposite ends of the rotor core. Each end ring has one of multiple regions disposed outside the air gap. Each region has an outer surface. The collars are attached in a prestressed condition around the outer surface of each region. The prestressed condition is configured to maintain a compressive stress in the end rings at a maximum-designed rotational speed of the rotor.

Abstract: A method for controlling forward lighting of a vehicle includes projecting, from a headlamp of the vehicle, an optimization pattern ahead of the vehicle and capturing, by a vehicle sensor, image data of the optimization pattern. The method also includes receiving, by a vehicle controller, the image data of the optimization pattern, measuring, from the image data, a headlamp aim offset defined as a difference in a position of the optimization pattern from a nominal position, and controlling an aim of the headlamp of the vehicle based on the headlamp aim offset.

Abstract: Presented are fiber-reinforced polymer (FRP) composite components for vehicle body structures, methods for making/using such components, and motor vehicles equipped with such components. A vehicle body structure includes one or more elongated support rails (e.g., a pair of lateral roof rails) each with an inner contoured rail panel joined to an outer contoured rail panel to define an internal rail cavity. One or more elongated support pillars (e.g., front, side, and/or back vehicle pillars) adjoin the support rail(s) and each includes an inner contoured pillar panel joined to an outer contoured pillar panel to define an internal pillar cavity coupled to the internal rail cavity. One or both contoured pillar panels and one or both contoured rail panels is/are formed, in whole or in part, from an FRP material. A structural reinforcement insert may be located inside the adjoined pillar and rail, filling a discrete region within the internal cavities.

Abstract: A propulsion control system has an electric motor configured to generate an axle torque in response to a final torque command, and has a motor constraint that specifies a maximum torque. A motor controller is configured to generate the final torque command in response to an intermediate torque command and a distributed power limit command. An open-loop function in supervisory controller is configured to calculate an initial torque command vector in response to a driver torque command, calculate an intended operating vector by mapping the initial torque command vector into a multidimensional power space, generate the intermediate torque command by clipping the intended operating vector in response to the motor constraint, generate a constrained command vector by clipping the intended operating vector in response to the motor constraint and a plurality of energy storage constraints, and generate the distributed power limit command in response to the constrained command vector.

Abstract: Methods and systems are provided for continuously producing cast metal components. An exemplary method includes feeding molten metal into a first mold at a fill station; maintaining a pressurized chamber at an elevated pressure; moving the first mold into the pressurized chamber, wherein the molten metal solidifies in the first mold under the elevated pressure; and removing the first mold from the pressurized chamber.

Abstract: Methods and systems are provided for learning a neural network and to determine a pose of a vehicle in an environment. A first processor performs a first feature extraction on sensor-based image data to provide a first feature map. The first processor also performs a second feature extraction on the aerial image data to provide a second feature map. Both feature maps are correlated to provide a correlation result. The first processor learns a neural network using the correlation result and ground-truth data, wherein each of the first feature extraction and the second feature is learned to extract a portion of features from the respective image data. A geo-tagged second feature map can then be retrieved by an on-board processor of the vehicle which, along with on-board processed sensor-based data by the network trained by the first processor, determines the pose of the vehicle.

Abstract: A vascular jet cooling system for use with a planar power module and a coolant supply includes a manifold housing and one or more jet impingement plates. The manifold housing is constructed of a dielectric polymer molding material, and defines a coolant inlet port configured to fluidly connect to the coolant supply, an internal cavity in fluid communication with the coolant inlet port and containing the power module, and a coolant outlet port in fluid communication with the internal cavity. The jet impingement plate(s) is arranged in the internal cavity. Openings of the plates direct coolant passing through the coolant inlet port onto a respective major surface of the power module. A power module assembly includes a planar power module and the vascular jet cooling system. A method of constructing the power module assembly uses sacrificial materials and overmolding of the jet impingement plates.

Abstract: A joining material for bonding overlapping components of a power electronic device together via a liquid phase sintering process. The joining material includes a mixture of composite particles. Each of the composite particles exhibits a core-shell structure having a core made of a copper-based material and a shell surrounding the core that is made of a low melting point material having a melting temperature or a solidus temperature less than that of the copper-based material of the core. The mixture of composite particles includes a first particulate fraction having a first median particle size and a second particulate fraction having a second median particle size. The first median particle size is at least one order of magnitude larger than the second median particle size.

Abstract: A method for increasing a default electric stall torque limits in a motor vehicle having an electrified powertrain inclusive of a traction power inverter module (TPIM) connected to an electric traction motor includes receiving vehicle level inputs via a controller. The controller is programmed with the default electric stall torque limits. The method includes selecting an inverter control strategy, via the controller, as a selected inverter control strategy in response to the vehicle level inputs, the strategy including temporarily increasing the default electric stall torque limits while applying a pulse width modulation (PWM) type at a corresponding PWM switching frequency. The method also includes controlling an output state of the TPIM and the electric traction motor over a calibrated duration, via the controller, using the selected inverter control strategy. A motor vehicle includes the controller, road wheels, TPIM, and traction motor.

Abstract: A system for monitoring and controlling vehicle operation includes a monitoring unit disposed at a vehicle, the vehicle including rear brakes and front brakes, the monitoring unit configured to monitor driver inputs, and automatically detect a driver's intention to perform a combined brake and propulsion maneuver based on the driver inputs meeting a first set of conditions. The system also includes a control unit configured to receive a brake request and an engine torque request from the driver during the maneuver, and based on detecting the first set of conditions, apply a front braking force via the front brakes according to the brake request, and automatically control a rear braking force applied by the rear brakes during the maneuver, so that the rear braking force is less than the front braking force.

Abstract: A busbar assembly includes a base having a width and a length. The base has a first surface and a second surface and has a first side and a second side. A distance between the first side and the second side comprises the width, and the base defines a slot centered between approximately 75% and approximately 79% of the width.

Abstract: A pick-up truck cargo area includes a cargo floor having a forward end, a rearward end and a pair of side edges extending between the forward end and the rearward end. A pair of inflatable bedside panels extend along the pair of side edges. A pair of bed side rails extend above the cargo floor and support the pair of inflatable bedside panels.

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: A battery having a plurality of electrodes immersed in a water-in-salt electrolytic solution is disclosed. The water-in-salt electrolytic solution includes a sufficient amount of a lithium salt disposed in an aqueous solvent, at least 14 moles of lithium salt per kg of aqueous solvent, such that a dissociated lithium ion is solvated by less than 4 water molecules. The plurality of electrodes includes a first type electrode, a second type electrode, and a third type electrode selectively assembled in a predetermined order of arrangement into an electrode stack assembly. The first type electrode includes an activated carbon, the second type electrodes include one of a lithium manganese oxide (LMO) and titanium dioxide (TiO2), and the third type electrodes include the other of the LMO and TiO2. The first type electrode may be that of a cathode and/or anode.

Abstract: An automated lane change system for a motor vehicle includes one or more environmental sensors for generating an input signal indicative of a position of an object relative to the motor vehicle, with the object being disposed at a distance from the motor vehicle. The input signal is further indicative of a velocity of the object relative to the motor vehicle. The system further includes a steering wheel sensor generating a gripped signal, in response to a driver gripping a steering wheel. A controller generates an activation signal, in response to the controller receiving the input signal from the environmental sensor and the gripped signal from the steering wheel sensor. An actuator controls the steering wheel, a propulsion mechanism, and a braking mechanism for maneuvering the motor vehicle from a current driving lane to a target driving lane, in response to the actuator receiving the activation signal from the controller.

Abstract: A seat belt pretensioner for a motor vehicle includes a cam that rotates, a cable with a first end and a second end, a section of the cable positioned on an outer portion of the cam. Upon deployment the cam rotates and guides the first end from a first location to a second location.

Abstract: A battery enclosure, support beam for a battery enclosure and method of manufacturing the support beam. The battery enclosure includes a base and the support beam is securable within the base. The support beam includes a body, a nut channel secured to the body, and a mechanical fastener attached to the nut channel. The nut channel is formed into a u-shaped channel. The mechanical fastener is attached to the nut channel and the nut channel is secured to the body of the support beam.

Abstract: Methods and systems involve generating a family of codewords. Each codeword of the family of codewords including three segments with one of the three segments being a hyperbolic frequency modulation (HFM) segment and two of the three segments being linear frequency modulation (LFM) segments. A method includes transmitting each codeword of the family of codewords using a different transmit antenna element.