Abstract: A torque box includes a box body extending along a longitudinal axis and a reaction wall coupled to the box body. The reaction wall is obliquely angled relative to the longitudinal axis to receive an offset load. The torque box further includes a plurality of ribs coupled to the reaction wall. Each of the plurality of ribs is oriented perpendicularly to the reaction wall to resist the offset frontal load received by the reaction wall. The torque box also includes a bridge rail coupled to the box body. The bridge rail is configured to allow load transfer between the frame rail and the rocker panel. At least a portion of the bridge rail is obliquely angled relative to the longitudinal axis.

Abstract: A modular battery pack system includes a battery pack and controller. The battery pack has first and second battery modules interconnected via electrical cables, with each module having a battery cell string. The pack has first, second, and third electrical connectors and four switches that selectively connect the strings to one or more of the electrical connectors. A DC charging connector is electrically connected to one of the cables between the first electrical connectors of the battery modules, and electrically connects the pack to an off-board DC fast-charging station. In response to input signals corresponding to a requested mode, the controller commands an open/closed state of each of the switches, via switching control signals, to establish a series charge mode, a parallel charge mode, and one or more of a series and/or parallel drive mode of the battery pack. A motor vehicle includes the system.

Abstract: A floor-mounted console assembly includes a stationary floor bracket having a longitudinal first support bar and a longitudinal second support bar positioned parallel to the first support bar. The console assembly further includes a cradle having a first connector wing and a second connector wing. The first connector wing is slidably received over the first support bar and the second connector wing is slidably received over the second support bar. The console assembly further includes a console connected to the cradle and supported by the first connector wing and the second connector wing such that the console is vertically spaced above the first support bar and the second support bar. The console and the cradle are configured to translate along the first support bar and the second support bar.

Abstract: Presented are scenario-planning and route-generating distributed computing systems, methods for operating/constructing such systems, and vehicles with scenario-plan selection and real-time trajectory planning capabilities. A method for controlling operation of a motor vehicle includes determining vehicle state data, such as a current position and velocity of the vehicle, and path plan data, such as an origin and desired destination of the vehicle. A remote computing node off-board from the motor vehicle generates a list of trajectory plan candidates based on the vehicle state data, the path plan data, and current road scenario data. The remote computing node then calculates a respective travel cost for each candidate in the trajectory plan candidates list, and sorts the list from lowest to highest travel cost. The candidate with the lowest travel cost is transmitted to a resident vehicle controller. The vehicle controller executes an automated driving operation based on the received trajectory plan candidate.

Abstract: A synchronous reluctance motor includes a stator and a rotor. The rotor is configured to rotate relative to the stator about a rotational axis. The rotor is spaced apart from the stator to define an air gap between the stator and the rotor and includes a rotor core defines an outermost rotor surface and an innermost rotor surface opposite the innermost rotor surface. The rotor core includes a plurality of ribs separating rotor cavities from each other and includes a plurality of rotor bridges separating the air gap and the rotor cavities. Permanent magnets are each disposed in one of the rotor cavities. The magnet surface area of the permanent magnets is less than cavity surface area of the rotor cavities. Each of the permanent magnets is adjacent to the outermost rotor surface to maximize magnetic saturation at the ribs and the rotor bridges.

Abstract: Disclosed are battery management systems with control logic for battery state estimation (BSE), methods for making/using/assembling a battery cell with a reference electrode, and electric drive vehicles equipped with a traction battery pack and BSE capabilities. In an example, a battery cell assembly includes a battery housing with an electrolyte composition stored within the battery housing. The electrolyte composition transports ions between working electrodes. A first working (anode) electrode is attached to the battery housing in electrochemical contact with the electrolyte composition. Likewise, a second working (cathode) electrode is attached to the battery housing in electrochemical contact with the electrolyte composition. A reference electrode is interposed between the first and second working electrodes, placed in electrochemical contact with the electrolyte composition.

Abstract: A shock absorber includes a first tube defining a first chamber and a piston head movably disposed within the first chamber. A hollow piston rod extends from the piston head. The hollow piston rod defines a rod chamber, and a tuned vibration absorber is disposed within the rod chamber of the hollow piston rod.

Abstract: The present application generally relates communications and hazard avoidance within a monitored driving environment. More specifically, the application teaches a system and method for improved target object detection in a vehicle equipped with a laser detection and ranging LIDAR system by transmitting a light pulse for a known duration and comparing a duration of the received pulse to the transmitted pulse in order to determine an orientation of a surface of a target.

Abstract: Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure.

Abstract: A latch mechanism includes a detent lever attached to a vehicle, and a release lever attached adjacent the detent to move between a pulled position, pushing the detent lever to an unlocked position responsive to activation of a release handle, and a released position, releasing the detent to move to a locked position responsive to deactivation of the release handle. A forkbolt is attached to the vehicle to move between: a first position—engaging the detent, retaining the striker at one location, and latching a compartment closure assembly closed; a second position—disengaging the detent, retaining the striker at another location, and latching the closure assembly in one pop-up position; a third position—reengaging the detent, retaining the striker at yet another location, and latching the closure assembly in another pop-up position; and a fourth position—disengaging the detent and allowing the closure assembly to open.

Abstract: Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure.

Abstract: A method of selectively removing a contaminant from an optical component formed from lithium tantalate includes washing the optical component with a washing solution that includes a hard anion. The contaminant includes a hard cation. The method also includes forming a compound including the hard anion and the hard cation and rinsing the compound from the lithium tantalate to thereby selectively remove the contaminant from the optical component.

Abstract: A powertrain system including an electric machine rotatably coupled to a crankshaft of an internal combustion engine via a belt is described, wherein the electric machine is disposed to generate torque. A method for controlling the electric machine includes monitoring rotational position of the electric machine, and periodically executing a speed observer to determine a rotational speed of the electric machine based upon the monitored rotational position of the electric machine. An acceleration observer is periodically executed to determine an acceleration rate, wherein the acceleration rate is determined based upon a time-based change in the rotational speed of the electric machine. A virtual inertia term is determined based upon the acceleration rate, and a torque compensation term is determined based upon the virtual inertia term and the acceleration rate. The electric machine is controlled to generate torque based upon the torque compensation term.

Abstract: A number of variations may include at least one bipolar plate which may include at least one bead, the bead may include a plurality of crest portions and a plurality of trough portions having at least one tangent portion disposed between adjacent crest portions and trough portions; the bipolar plate further may include at least one tunnel defining at least one through hole within the at least one tangent portion.

Abstract: Evaluation of a DC power source can include communication with a voltmeter that is arranged to monitor electrical potential across positive and negative electrodes. The method includes determining a full-cell open-circuit voltage (“OCV”), an associated positive half-cell OCV, and an associated negative half-cell OCV at a start-of-life point of the DC power source. A lithium balance model is executed to determine a plurality of beginning states associated with an electrode alignment of the DC power source. An in-use state for the full-cell OCV is determined. An optimization routine is executed employing the lithium balance model to determine in-use states associated with the electrode alignment of the DC power source based upon the in-use state for the full-cell OCV and the beginning states associated with electrode alignment. A negative-to-positive (“N/P”) ratio is determined based upon the in-use states, and battery life is evaluated based upon the N/P ratio.

Abstract: A engine exhaust system includes a diesel oxidation catalyst (DOC) configured to receive the engine exhaust gases, a first electric heater coupled to the DOC, and a selective catalytic reduction (SCR) device in fluid communication with the DOC. The engine exhaust system further includes a second electric heater coupled to the DOC, a power switch controller in electronic communication with the first electric heater and the second electric heater, and a single power source electrically coupled to the power switch controller, the first electric heater, and the second electric heater. The power switch controller includes a switch to control a power distribution between the first electric heater and the second electric heater as a function of time.

Abstract: A method of forming a surface in a panel includes positioning a panel blank between a stationary die and a moveable die of a die set, and moving the moveable die toward the stationary die to deform the panel blank therebetween. Positive stresses in the panel blank are maintained in the region of the panel blank that will form the surface by forming a bead along a length of the surface to be formed in the panel blank, as the moveable die moves toward the stationary die. The moveable die continues to move toward the stationary die, while maintaining positive stresses in the panel blank in the region of the panel blank that will form the surface, to further deform the panel blank into a formed shape that includes the surface.

Abstract: A method of diagnosing a lubrication system of an engine includes controlling an oil pump with a control signal. The control signal is a command having a value for a desired lubrication fluid pressure from the oil pump for a current operating state of the engine. A processing unit compares the value of the control signal for the current operating state of the engine to a threshold control value for the current operating state of the engine. When the processing unit determines that the value of the control signal for the current operating state of the engine deviates from the threshold control value for the current operating state of the engine, the processing unit analyzes the value of the control signal to identify a fault in the lubrication system.

Abstract: A door inner support panel for a vehicle door assembly includes a header section with a window frame for receiving a windowpane. A shell section is attached to the header section and mounts to a door frame of a body of a vehicle. The shell section has a hardware frame for mounting a hardware module. The hardware frame includes: a mounting interface on the an inboard surface of the shell section for coupling to an outboard surface of the hardware module; a mounting interface on a flanged surface of the shell section for sealingly attaching to a peripheral surface of the hardware module; and a mounting interface on the outboard surface of the shell section for coupling to an inboard surface of the hardware frame. A method of making the door inner support panel is also disclosed.