Abstract: A method for controlling an electric machine in a powertrain system in which a driven load is connected to a rotor of the electric machine includes measuring phase currents at a starting point of a sample period using current sensors connected to phase windings of the electric machine. The individual phase currents also are determined at a midpoint of the previous sample period. An angular position of the rotor is determined at the starting point and previous midpoint before calculating synchronous reference frame currents of the electric machine at the starting and previous midpoint using the phase currents and angular position. The method includes calculating average synchronous reference frame currents over the sample period and regulating operation of the electric machine using the average. An electrical system includes the electric machine, a power inverter module, and a controller that executes the method.

Abstract: A method for controlling a vehicle includes: receiving, by a controller, route data, wherein the route data is continuously updated while the vehicle is moving, and the vehicle includes a plurality of vehicle operating modes; receiving, by the controller, feature data, wherein the feature data is information about a plurality of features needed for each of the plurality of vehicle operating modes; determining, by the controller, a plurality of ranges for each of the plurality of vehicle operating modes, wherein each of the plurality of ranges is a function of the route data and the feature data for each of the plurality of vehicle operating modes; and commanding, by the controller, a user interface to display a list of range-mode combinations, wherein the list of range-mode combinations includes the plurality of ranges for each of the plurality of vehicle operating modes.

Abstract: A vehicle system including a propulsion system coupled to a drive wheel and a friction brake configured to apply braking torque to a vehicle wheel is described. Operation thereof includes an instruction set that is executable to monitor vehicle speed, vehicle grade, and an operator braking request, and execute instructions upon achieving a vehicle speed that is less than a threshold speed. The instructions include controlling, via the friction brake, the braking torque to achieve a desired vehicle speed, and determining an operator acceleration request and the vehicle grade. The controller determines a minimum vehicle grade-based operator acceleration request, and releases the friction brake only when the operator acceleration request is greater than the minimum vehicle grade-based operator acceleration request.

Abstract: A method is provided for controlling a transition between over-modulation and six-step pulse width modulation (PWM) modes in an electrical system having a polyphase electric machine driven by a polyphase output voltage of a power inverter. The method includes receiving input values via a PWM controller, including a holding angle, rotational speed of the electric machine, and present voltage angle of the power inverter. The method includes calculating a future voltage angle of the inverter using the input values and adjusting pulse widths of a baseline PWM pulse train based on a duty cycle of the power inverter. The power inverter output voltage is controlled during the transition using the adjusted baseline PWM pulse train, such that the transition is continuous. An electrical system includes the power supply, power inverter, electric machine, and the PWM controller, the latter of which is configured to execute the method.

Abstract: Presented are manufacturing control systems for fabricating composite-material structures, methods for making/operating such systems, and resin transfer molding techniques for ameliorating race-tracking effects in fiber-reinforced polymer panels. A method for forming a composite-material construction includes confirming, via a system electronic control unit (ECU), that a fiber-based preform is placed in a mold cavity and that opposing mold segments of the molding apparatus are sealed together. A filler, such as a compressible bladder, a cluster of spring-biased pins, or a spray-chopped fiber bed, is introduced into a void between the fiber-based preform and a tool face of one mold segment to thereby eliminate an unwanted resin race track. The system ECU commands a resin pump to inject resin through a primary gate of the molding apparatus and into the mold cavity to thereby impregnate the fiber-based preform with the resin. One or more vents operate to evacuate air from the mold.

Abstract: A running board configured for absorbing energy includes an attachment portion extending along a longitudinal axis and a step-assist portion extending from the attachment portion along a latitudinal axis that is perpendicular to the longitudinal axis. The attachment portion defines a plurality of voids therein each disposed along a respective one of a plurality of horizontal axes that are perpendicular to the longitudinal axis. The running board further includes a plurality of tubes disposed within a respective one of the plurality of voids. A device including the running board and a method of forming a running board are also set forth.

Abstract: A hybrid powertrain includes an internal combustion engine and a multi-speed transmission coupled to the internal combustion engine. The multi-speed transmission includes an input member, an output member, and a first, second, third, fourth, and fifth planetary gear set each having a sun gear member, a planet carrier assembly member and a ring gear member. The multi-speed transmission further includes a first, second, third, fourth, and fifth planetary gear sets each having a sun gear member, a planet carrier assembly member and a ring gear member. The multi-speed transmission further includes seven torque-transmitting devices configured to selectively interconnect the first, second, third, fourth, and fifth planetary gear sets with one another in combinations of at least four to establish at least ten forward speed ratios and at least one reverse speed ratio between the input member and the output member.

Abstract: A method of rivet bonding a workpiece stack-up that includes one or more polymer composite workpieces, such as carbon fiber composite workpieces, involves several steps. In one step, adhesive is applied to a surface of the workpiece stack-up. In another step, workpieces—including the polymer composite workpiece(s)—are brought together. In yet another step the adhesive is partially or more cured. A rivet is installed through the workpiece stack-up and through the adhesive in another step. The method strengthens the resulting rivet-bonded joint by minimizing or altogether precluding fracture, cracking, and/or delamination thereat.

Abstract: An electric starter system is used with an engine. The starter system may include a solenoid device coupled to a pinion gear, a brushless starter motor connectable to the engine via the pinion gear during a requested engine start event, and a controller. In response to the start event, when the engine speed is less than a threshold speed, the controller delivers a control current to the solenoid device at a peak current level sufficient for translating the pinion gear into contact with the flywheel. The control current is reduced to a holding current level less than the peak current level after the pinion gear is engaged with the flywheel. Motor torque is commanded from the starter motor, through the pinion gear, and to the flywheel while maintaining the holding current level, and held for a duration sufficient for starting the engine.

Abstract: A method for dynamically determining a mass of a vehicle including a propulsion system coupled to a drive wheel is described, and includes monitoring vehicle operating conditions, executing an event-based estimation method based upon the vehicle operating conditions to determine a first vehicle mass state, and executing a recursive estimation method based upon the vehicle operating conditions to determine a second vehicle mass state. A final vehicle mass is determined based upon the first and second vehicle mass states.

Abstract: A method of updating an identification algorithm of a vehicle includes sensing an image and drawing boundary boxes in the image. The algorithm attempts to identify an object-of-interest within each respective boundary box. The algorithm also attempts to identify a component of the object-of-interest within each respective boundary box, and if component is identified, calculates an excluded amount of a component boundary that is outside an object boundary. When the excluded amount is greater than a coverage threshold, the algorithm communicates the image to a processing center, which may identify a previously un-identified the object-of-interest in the image. The processing center may add the image to a training set of images to define a revised training set of images, and retrain the identification algorithm using the revised training set of images. The updated identification algorithm may then be uploaded onto the vehicle.

Abstract: A guidance system for a user includes a first haptic device disposed on a first, rightward side and a second haptic device disposed on a second, leftward side of the user. A local controller is disposed on the user to communicate with the first and second haptic devices. A remote server is configured to communicate with the local controller. A vehicle includes a global positioning system sensor, and is in communication with the remote server. The local controller includes a control routine that is executable to determine a desired location of the vehicle, and determine a present location of the user. The control routine guides, via the first and second haptic devices, movement of the user towards the desired location of the vehicle, and indicates, via the first and second haptic devices, arrival of the vehicle at the desired location. The control routine pairs the user with the vehicle.

Abstract: Presented are battery pack voltage-switching (“V-switch”) systems, methods for making/operating such systems, and multi-pack, electric-drive motor vehicles with battery pack V-switch capabilities. A method for controlling operation of a vehicle includes a vehicle controller receiving a voltage switch signal to change a voltage output of the vehicle's battery system. The vehicle controller determines if a speed of a traction motor is less than a calibrated base speed; if so, the controller transmits a pack isolation signal to a power inverter to electrically disconnect the traction battery packs from the traction motor. The vehicle controller determines if a bus current of a DC bus is less than a calibrated bus current threshold; if so, the controller transmits an open signal to open one or more pack contactor switches and a close signal to close one or more pack contactor switches thereby causing the vehicle battery system to output the second voltage.

Abstract: Presented are electrical capacitors with interleaved busbar architectures, methods for making/operating such capacitors, and electric-drive vehicles equipped with such capacitors. A bulk capacitor includes multiple capacitor devices disposed within an outer housing and operable to modify electric current transmitted between a power source and an electrical load. An interleaved busbar package is interposed between the capacitor devices and outer housing. The interleaved busbar package includes a first busbar plate that electrically connects to first terminals of the capacitor devices and defines a busbar pocket. A second busbar plate is seated within the busbar pocket and electrically connects to second terminals of the capacitor devices. The second busbar plate includes a capacitor basin that seats therein the capacitor devices. An isolator sheet is interleaved between and electrically insulates the first and second busbar plates.

Abstract: Presented are manufacturing control systems for composite-material structures, methods for assembling/operating such systems, and transfer molding techniques for predicting and ameliorating void conditions in fiber-reinforced polymer panels. A method for forming a composite-material construction includes receiving a start signal indicating a fiber-based preform is inside a mold cavity, and transmitting a command signal to inject pressurized resin into the mold to induce resin flow within the mold cavity and impregnate the fiber-based preform. An electronic controller receives, from a distributed array of sensors attached to the mold, signals indicative of pressure and/or temperature at discrete locations on an interior face of the mold cavity. The controller determines a measurement deviation between a calibrated baseline value and the pressure and/or temperature values for each of the discrete locations.

Abstract: An exemplary method for determining rattle noise of a vehicle steering system includes providing an intermediate shaft assembly including a first shaft member coupled to a second shaft member by a first joining member, a third shaft member coupled to the second shaft member by a second joining member, the first shaft member coupled to a first motor and the third shaft coupled to a second motor, providing a first sensor coupled to the first joining member and a second sensor coupled to the second joining member, sensors configured to measure an acceleration of the first joining member and the second joining member, applying a first torque and a second torque to the intermediate shaft assembly, receiving first acceleration data from the first sensor and second acceleration data from the second sensor, and analyzing the first and second acceleration data to determine a rattle noise of the intermediate shaft assembly.

Abstract: A direct-injection stratified charge internal combustion engine includes a combustion cylinder to receive an air-fuel mixture, and an air intake port to inlet air into the combustion cylinder. The direct-injection engine also includes a fuel injector configured to deliver fuel within the cylinder in a spray pattern substantially aligned to a cylinder central axis to create the air-fuel mixture. A spark igniter is located within a path of the spray pattern to ignite combustion of the air-fuel mixture. The direct-injection engine further includes a movable piston defining a lower boundary of the combustion cylinder to contain the combustion of the air-fuel mixture. The piston is configured to include a bowl portion having local geometric features located on an intake port side of the combustion cylinder to redirect fluid flow towards a vortex in fluid communication with a combustion location near the cylinder central axis.

Abstract: An electric motor control system of a vehicle includes a temperature module configured to, based on a motor torque request, (i) determine a plurality of stator current values based on a plurality of temperatures and (ii) generate a maximum stator current based on a lowest value of the plurality of stator current values. A torque module configured to, based on the maximum stator current, the motor torque request, and a maximum allowable flux, generate a maximum torque output. A current command module configured to, based on a speed of a rotor of the electric motor and the maximum torque output, generate a d-axis current adjustment and a q-axis current adjustment. A switching control module configured to, based on the d- and q-axis current adjustments, control switching of an inverter module and apply power to stator windings of the electric motor from an energy storage device.

Abstract: A method for estimating remaining energy in a battery pack having series-connected cells/cell groups includes measuring battery parameters, including a battery voltage, current, and temperature. The controller estimates a static state of charge difference ( ?SOC) value and a current-dependent ?SOC value in real-time using the parameters, including calculating the static ?SOC value as a difference between an average SOC of the battery pack and an SOC of a weakest/lowest energy cell group. The current-dependent ?SOC value is a percentage SOC per unit of the current. The static ?SOC value and current-dependent ?SOC values are filtered via a multi-parameter state estimator block. Using the filtered state values, the controller executes a control action responsive to the estimated remaining energy, including displaying the remaining energy and/or a quantity derived from the remaining energy via a display device. A powertrain system includes the controller, electric machine, and battery pack.

Abstract: Systems, methods, and high performance electrochemical devices employing electroactive particles having a sandwich structure are described. The electroactive particle includes an electroactive layer between a pair of dimension-control layers. The electroactive layer includes an electroactive material configured to receive cations and experience a volumetric change in response thereto. The dimension-control layers are configured to inhibit planar dimensional changes of the electroactive particle such that the volumetric change of the electroactive layer occurs through a vertical dimension of the electroactive particle. The vertical dimension is orthogonal to the planar dimensions.