Abstract: A final drive assembly for a vehicle drive axle having first and second axle-shafts that are configured to rotate about a common first axis. The final drive assembly includes a first gear-set configured to be operatively connected to the first axle-shaft. The final drive assembly also includes a second gear-set configured to be operatively connected to the second axle-shaft. The final drive assembly additionally includes an electric motor configured to provide an electric motor torque input to each of the first and second gear-sets and arranged on a second axis that is parallel to the first axis.

Abstract: An apparatus for in-situ monitoring of a welded joint in a workpiece includes an ultrasonic sending transducer and a receiving transducer. The ultrasonic sending transducer includes a probe head disposed on a plurality of individually-activatable piezoelectric elements, and a plurality of waveguide probes projecting orthogonally from a planar surface. A wave attenuator is disposed between individual ones of the waveguide probes. A receiving transducer is disposed therein. The workpiece is insertable between the waveguide probes of the ultrasonic sending transducer and the receiving transducer. The ultrasonic sending transducer urges the probe head towards the receiving transducer such that the waveguide probes physically contact the welded joint in the workpiece. The piezoelectric elements individually excite the waveguide probe that is in physical contact with the welded joint in the workpiece. The acoustic receiving transducer is disposed to monitor the welded joint in the workpiece.

Abstract: An apparatus for preventing mal-operation for an automatic transmission, which is formed as one body including a plurality of parts, is provided, whereby it is possible to simplify the structure and the manufacturing process thereof.

Abstract: Presented are deployable structures having multi-stable-state characteristics using skeletal architectures mounted onto textile backings, methods for making/using such structures, and vehicle components having bistable characteristics provided by polymeric exoskeletons printed onto textile substrates. A multi-stable-state deployable structure includes an elastic substrate fabricated from a (knitted) textile sheet, and an articulating (polymeric) framework mounted on the knitted textile sheet. The articulating framework and textile sheet structurally cooperate to transition from a first stable state, in which the deployable structure maintains a substantially planar shape, to a second stable state, in which the deployable structure maintains a first multidimensional topography, and from the second state to a third stable state, in which the deployable structure maintains a second multidimensional topography distinct from the first multidimensional topography.

Abstract: A system and method of mitigating errors in a device includes a controller having a processor and tangible, non-transitory memory on which is recorded instructions. The propulsion source is configured to generate propulsion torque in response to a command by the controller. The controller is configured to determine if at least one predefined enabling condition is met. If at least one predefined enabling condition is met, then the controller is configured to determine if a speed of the device is at a target speed. Operation of the device is controlled based at least partially on the speed of the device. If the speed of the device is above or below the target speed, the controller is configured to determine a propulsion torque sufficient to bring the device to the target speed. The propulsion torque is delivered to the device via the propulsion source.

Abstract: A vehicle includes a plurality of on-vehicle cameras, and a controller executes a method to evaluate a travel surface by capturing images for fields of view of the respective cameras. Corresponding regions of interest for the images are identified, wherein each of the regions of interest is associated with the portion of the field of view of the respective camera that includes the travel surface. Portions of the images are extracted, wherein each extracted portion is associated with the region of interest in the portion of the field of view of the respective camera that includes the travel surface and wherein one extracted portion of the respective image includes the sky. The extracted portions of the images are compiled into a composite image datafile, and an image analysis of the composite image datafile is executed to determine a travel surface state. The travel surface state is communicated to another controller.

Abstract: A perception module of a spatial monitoring system to monitor and characterize a spatial environment proximal to an autonomous vehicle is described. A method for evaluating the perception module includes capturing and storing a plurality of frames of data associated with a driving scenario for the autonomous vehicle, and executing the perception module to determine an actual spatial environment for the driving scenario, wherein the actual spatial environment for the driving scenario is stored in the controller. The perception module is executed to determine an estimated spatial environment for the driving scenario based upon the stored frames of data associated with the driving scenario, and the estimated spatial environment is compared to the actual spatial environment for the driving scenario. A first performance index for the perception module is determined based upon the comparing, and a fault can be detected.

Abstract: A battery for an electric vehicle includes first and second pairs of modules in electrical communication with each other. The first pair of modules includes a first module and a second module. The second module is in electrical and thermal communication with the first module via a first plurality of outer bus bars. The second pair of modules includes a third module and a fourth module. The fourth module is in electrical and thermal communication with the third module via a second plurality of outer bus bars. The first and second pairs of modules are coupled to each other via a first inner connecting bus bar and a second inner connecting bus bar proximate to a center region of each of the second and third modules.

Abstract: An electro-mechanical drive unit connectable with first and second motor/generators includes an output member, a stationary member, a gear-train, and a torque-transmitting device. The drive unit also includes a compound planetary gear arrangement having a ring gear structure, first and second sun gears, and a carrier structure. The gear arrangement includes first, second, third, and fourth junction points and has a double-pinion assembly having a first pinion gear in mesh with the first sun gear member and a second pinion gear in mesh with the first pinion gear and with the ring gear structure. The gear arrangement is operatively connected to the second motor/generator at the first junction point via the gear-train and to the first motor/generator at the fourth junction point. The output member is operatively connected to the second junction point. Furthermore, the torque-transmitting device is engageable to ground the third junction point to the stationary member.

Abstract: Disclosed are two-valve, split-layout engine cooling systems, methods for making and method for operating such cooling systems, engine coolant valve assembly configurations, and vehicles equipped with an active thermal management system for cooling select powertrain components. A disclosed thermal management system includes a radiator for cooling coolant fluid, and a coolant pump for circulating coolant fluid received from the radiator. A set of conduits fluidly connect the coolant pump to an engine block, a cylinder head, and an exhaust manifold. Another set of conduits fluidly connect the engine block, cylinder head, and exhaust manifold to the radiator, coolant pump, and one or more oil heaters. A first valve assembly is operable to regulate coolant flow between the coolant pump and the radiator. A second valve assembly is operable to regulate coolant fluid flow, individually and jointly, between the engine block, cylinder head, exhaust manifold, radiator, coolant pump, and oil heater(s).

Abstract: A method of controlling a change in net axle torque on a vehicle comprises receiving a request for a desired net axle torque that is different than a current net axle torque, determining whether a lash zone exists between the current net axle torque and the desired net axle torque, determining a progression of constant rates of change of the front axle torque and a progression of constant rates of change of the rear axle torque that will result in a constant rate of change of the net axle torque from the current net axle torque to the desired net axle torque, and commanding the progression of constant rates of change of the front axle torque and the progression of constant rates of change of the rear axle torque if the lash zone exists between the current net axle torque and the desired net axle torque.

Abstract: Systems for use in connection with custom powering of a vehicle that includes a charging station track and a charging base positioned at or along the charging station track at an available parking position. The system a controller having a processing hardware unit and a non-transitory storage device comprising computer-executable code that when executed causes the processing hardware unit performs operations including (i) receiving a power level indicating a current power level of the vehicle and/or a time stamp indicating an arrival time of the vehicle to a location proximate to the charging station track, (ii) sending a first signal to the vehicle causing the vehicle to move to the available position along the charging station track, (iii) charging the vehicle to a predetermined power level using the charging base, and (iv) sending a second signal to the vehicle causing the vehicle to move out of the available position at the charging station.

Abstract: Methods and systems for vehicle localization are disclosed. An exemplary system includes a navigation system configured to generate navigation data corresponding to a global position of the vehicle, at least one image sensor configured to capture image data of a selected roadway feature along a projected path of the vehicle, a database comprising map data corresponding to lateral and longitudinal coordinates for a plurality of roadway features along the projected path of the vehicle; and a controller, the controller configured to receive the image data, the map data, and the navigation data, calculate a first distance from the selected feature to the vehicle using the navigation data and the image data, calculate a second distance from the selected feature to the vehicle using the navigation data and the map data, and determine a localization error by comparing the first distance to the second distance.

Abstract: A method of predicting the health of and controlling a hydraulic pressure actuated torque converter lock-up clutch includes determining rotational input and output speeds of the torque converter. The method also includes determining a magnitude of the hydraulic pressure. The method additionally includes determining a level of performance of the clutch across multiple torque converter operating modes using the determined input and output torque converter speeds and the determined magnitude of the hydraulic pressure. The method also includes calculating a numeric state of health (SOH) coefficient of the clutch that quantifies a relative severity of degradation of a plurality of clutch characteristics across the multiple torque converter operating modes. Furthermore, the method includes executing a control action relative to the clutch when the calculated numeric SOH coefficient for specified torque converter operating mode(s) is less than a calibrated SOH threshold.

Abstract: A method of operating an electric power steering system installed on a vehicle. The electric power steering system includes a controller that receives a desired assist torque value and supplies a pulse-width modulation duty cycle to an electric motor. The method includes the step of controlling the electric motor to achieve a nominal value of power steering assist torque when the electrical power available to the motor is sufficient to achieve the nominal value of power steering assist torque. The method further includes the step of controlling the electric motor to achieve a reduced value of power steering assist torque less than the nominal value when the electrical power available to the motor is not sufficient to achieve the nominal value of power steering assist torque.

Abstract: A method controls multiple continuous actuators to achieve a discrete mode of operation in a system. The method may include determining a desired output state of the system, including processing a control input set for the multiple continuous actuators via a dynamical predictive model of the system, and then processing the control input set via the dynamical predictive model to determine possible control solutions for achieving the desired output state of the system at a calibrated future time point. The method may include using a cost function logic block to identify, from among the possible control solutions, a lowest-cost control solution for executing the discrete mode at the future time point, processing the lowest-cost control solution through a real-time optimization logic block to determine an optimized solution for the discrete mode, and then executing the optimized solution at the future time point.

Abstract: A method for predicting power capability of a battery pack in a system includes determining an open-circuit voltage of the battery pack via a controller, calculating pack resistance using measured voltage and current during a charge or discharge event, and calculating a maximum current of the pack using the open-circuit voltage and internal resistance. The method includes selecting the lower of an absolute value of each of the calculated maximum discharge current and predetermined current limit, calculating the discharge power capability of the battery pack using the selected lower absolute value, and controlling a state of the system using the calculated power capability. The method also controls the charging current and parameters during a DC fast-charging operation. A system includes the battery pack, electric machine, and controller. The system may be a vehicle having an electric powertrain, with an electric machine powered by the battery pack.

Abstract: A battery module includes a plurality of battery cells and a battery module 4 housing configured to at least partially enclose the plurality of battery cells. The battery module housing includes at least one wall defining an outer periphery and an opposing inner periphery. A fluid interchange system includes one or more channels formed in and extending at least partially through the at least one wall, at least one inlet portion defined in and extending at least partially through the at least one wall, and at least one outlet portion defined in and extending at least partially through the at least one wall. A coolant is introduced to the fluid interchange system through the at least one inlet portion, circulated through the one or more channels and exits the fluid interchange system through the at least one outlet portion to cool the plurality of battery cells in the battery module housing.

Abstract: A method of controlling a vehicle park system in a shift out of park includes receiving a shift out of park request, and commanding a park actuator to rotate an actuator shaft operatively connected to a park pawl movable from an engaged position in which the park pawl is engaged with a park gear, to a disengaged position in which the park pawl is disengaged from the park gear. The method includes determining whether a detent lever operatively connected to the park pawl has moved towards an out of park position within a predetermined period of time after commanding the park actuator to rotate the actuator shaft, and then commanding an electric propulsion motor to apply torque to the transmission output shaft to assist the park actuator if the detent lever has not moved towards the out of park position within the predetermined period of time.

Abstract: An electric starter system is usable with an engine and a power inverter module (PIM), e.g., of a powertrain. The starter system includes a poly phase/AC brushless starter motor connected to the PIM via an AC voltage bus and selectively connected to the engine during a requested engine start event. A sensor on the DC voltage bus outputs a signal indicative of a voltage level of the DC voltage bus. The controller executes a method using voltage stabilization logic having a proportional-integral (PI) torque control loop. Logic execution in response to the requested engine starting event causes the controller to control the starter motor, when the bus voltage exceeds a calibrated minimum voltage, using a starting torque determined via the control loop. The commanded starting torque limits inrush current to the starter motor such that the DC voltage bus remains above the minimum voltage.