Abstract: A system and method of controlling operation of a vehicle door assembly for a vehicle includes monitoring a door handle sensor to detect at least one open request generated by the door handle. A first control signal is transmitted by a controller to a door unlatching actuation mechanism in response to a first open request. The door unlatching actuation mechanism is actuated for a first time period T1 in response to the first control signal. A door position sensor is monitored by the controller and determines the position of the door at completion of the first time period T1. The controller transmits a second control signal to actuate the door unlatching actuation mechanism for a second time period T2 in response to a second open request when the door position sensor detects the door in the closed position at the completion of the first time period T1.

Abstract: A sprocket gerotor pump includes an outer gerotor gear configured to rotate about a first axis. The outer gerotor gear includes an outer gear body including a plurality of internal gear teeth extending from the outer gear body toward the first axis. The sprocket gerotor pump includes an inner gerotor gear configured to rotate about a second axis. The inner gerotor gear includes an inner gear body and a plurality of external gear teeth extending from the inner gerotor gear away from the second axis. The external gear teeth mesh with the internal gear teeth. Rotating the outer gerotor gear causes rotation of the inner gerotor gear. The sprocket gerotor pump further includes a sprocket integrally coupled with the outer gerotor gear such that the sprocket and the outer gerotor gear collectively form a one-piece structure. The sprocket is driven by a chain.

Abstract: A method of controlling a vehicle having an electric power steering system includes generating a plurality of possible routes. Each of the plurality of possible routes that require a steering torque that is within an available torque range is identified as a system compliant route. Each of the plurality of possible routes that require an angular position of an electric motor of the electric power steering system at all time indices throughout that route that are within an available motor position range are also identified as a system compliant route. One of the identified system compliant routes is selected based on at least one selection criteria, and designated as an active route. The electric power steering system is then controlled to maneuver the vehicle along the active route. The electric power steering system is monitored as the vehicle moves along the active route to identify degradation of its capabilities.

Abstract: A fuel cell assembly includes a fuel cell stack. A vehicle includes a propulsion system and the fuel cell assembly configured to provide power to the propulsion system in at least one mode. The fuel cell assembly also includes an air compressor and an air pump spaced from the air compressor. The air compressor includes an on position in which the air compressor is configured to supply air to the fuel cell stack and an off position in which the air compressor does not supply air to the fuel cell stack. The air compressor also includes a bearing configured to be levitated via air. The air pump is configured to supply air to the fuel cell stack when the air compressor is in the off position and configured to supply air to the bearing when the air compressor is in the on position.

Abstract: A connecting rod includes a shank formed of a composite. The connecting rod also includes a first end portion coupled to the shank and a second end portion coupled to the shank. The first end portion has an annular shaped portion, and the second end portion has an annular shaped portion. The shank defines a channel coupled to the first and second end portions. A method of manufacturing a connecting rod includes placing a plurality of fibers in a predetermined arrangement, and adding a resin to the plurality of fibers to connect the fibers together and form a composite of at least a shank. The method also includes disposing a component inside the shank, and the component is utilized to define a channel in the shank. The method further includes coupling a first end portion to the shank, and coupling a second end portion to the shank.

Abstract: Systems and methods for growth of multi-component single crystals are described. A first solution is flowed over a surface of a seed crystal coupled to a nozzle such that a plurality of first ions solvated in the first solution and a plurality of second ions in a second solution combine on the surface of the seed crystal to grow the single-crystal thereon. The first solution and the second solution are immiscible. A feed tank is fluidly coupled to the at least one nozzle and includes the first solution. In some aspects, the nozzle is configured to flow both the first solution and the second solution over the seed crystal.

Abstract: A compressor includes a compressor impeller configured to rotate about an axis of rotation as intake gases flow along the compressor impeller. The compressor impeller includes an inducer and an exducer. The compressor impeller defines a first impeller end at the inducer and a second impeller end at the exducer. The second impeller end extends along a radial axis. The compressor further includes a compressor housing encasing the compressor impeller. The compressor housing defines a compressor volute. The compressor housing partially defines a diffuser in fluid communication with the compressor volute. The diffuser is elongated along a diffuser axis. The diffuser axis is obliquely angled relative to the axis of rotation. The diffuser axis is obliquely angled relative to the radial axis to minimize a turbulence of the intake gases flowing from the diffuser to the compressor volute.

Abstract: A method is used to evaluate a camera-related subsystem in a digital network, e.g., aboard a vehicle or fleet, by receiving, via a camera diagnostic module (CDM), sensor reports from the subsystem and possibly from a door sensor, rain/weather sensor, or other sensor. The CDM includes data tables corresponding to subsystem-specific fault modes. The method includes evaluating performance of the camera-related subsystem by comparing potential fault indicators in the received sensor reports to one of the data tables, and determining a pattern of fault indicators in the reports. The pattern is indicative of a health characteristic of the camera-related subsystem. A control action is executed with respect to the digital network in response to the health characteristic, including recording a diagnostic or prognostic code indicative of the health characteristic. The digital network and vehicle are also disclosed.

Abstract: A DC-DC power converter is described, and includes switched inductance circuits arranged in parallel, current sensors disposed to monitor one of the switched inductance circuits, and a controller. The DC-DC power converter supplies electric power originating from a DC power source to a high-voltage bus. Control and operation includes determining a desired control mode for operating the DC-DC power converter, wherein the desired control mode includes one of a voltage control mode and a current control mode. A desired voltage and a desired differential current for operating the DC-DC power converter are determined based upon the desired control mode. A desired current for operating the DC-DC power converter is determined based upon the desired differential current. Operation of the DC-DC power converter is controlled in the desired control mode based upon the desired voltage and the desired current.

Abstract: A modular rear drive unit for a hybrid vehicle comprises a torque distributing unit, an electric motor-generator, and a gearing arrangement operatively connecting the electric motor-generator with the torque distributing unit. The modular rear drive unit also includes an integrated housing and rear cradle supporting and surrounding the torque distributing unit, the electric motor-generator, and the gearing arrangement. The integrated housing and rear cradle operatively mounts to the vehicle body.

Abstract: A permanent magnet electric machine (PM machine) for a vehicle or other system includes a rotor assembly, fixed permanent magnets, a stator, an actuator, and one or more repositionable/moveable flux-shunting elements. The flux-shunting element is repositioned to control flux at specific operating points of the PM machine. The rotor assembly has a rotor coaxially surrounding and coupled to a rotor shaft. The permanent magnets are mounted to or in the rotor, and the moveable flux-shunting element is positioned between the rotor shaft and a respective one of the permanent magnets. Inboard and outboard ends of each respective permanent magnet may be oriented toward the rotor shaft and stator, respectively. The actuator selectively positions the moveable flux-shunting element at one or more operating points of the PM machine to vary reluctance in a magnetic circuit formed by the stator and rotor assembly.

Abstract: High performance electrodes for electrochemical devices having a polymer network with an electroactive material chemically attached to a crosslinked polymer matrix are disclosed. A method includes mixing an electrode slurry and forming a polymer network within the electrode slurry. The electrode slurry includes an electroactive material, an electrically conductive filler, a plurality of polymer chains, and a plurality of chemical crosslinking precursors. Each chemically crosslinking precursor is configured to (i) chemically crosslink the plurality of polymer chains and (ii) chemically attach the electroactive material to the plurality of polymer chains.

Abstract: A method of forming a separator for a lithium-ion battery includes arranging a polymer film in contact with a sacrificial layer to form a cutting stack. The method includes disposing the cutting stack between a first vitreous substrate and a second vitreous substrate. The method includes applying an infrared laser to the cutting stack through the first vitreous substrate to generate heat at the sacrificial layer. The method also includes transferring heat from the sacrificial layer to the polymer film to thereby cut out a portion of the polymer film and form the separator. A method of cutting a polymer film and a cutting system are also explained.

Abstract: A method of forming at least one channel within a substrate includes coupling a fitting to a mold, and securing together the fitting and an insert via threads. A system includes a mold configured to form the substrate. The method also includes inserting a component into an opening of the fitting. Part of the component is disposed outside of the opening of the fitting, and the component is utilized to define the at least one channel within the substrate. The method further includes molding at least one material to the component and the insert to form the substrate. Furthermore, the method includes removing the fitting from the insert while the insert remains molded to the substrate.

Abstract: High performance electrodes for electrochemical devices having a semi-crystalline binder are disclosed. A method of forming an electrode includes forming an electrode slurry, applying the electrode slurry to a current collector to form an electrode, and curing the electrode to thereby form the semi-crystalline binder. The electrode slurry includes a solvent, a semi-crystalline-binder precursor solution, an electroactive material, and an electrically conductive filler. The semi-crystalline binder includes the electroactive material and the electrically conductive filler dispersed therethrough. The semi-crystalline binder includes a plurality of polymer chains. Each of the plurality of polymer chains includes a plurality of crystalline sites interspersed with a plurality of amorphous sites. The semi-crystalline binder is capable of forming hydrogen bonds.

Abstract: A trim component for attachment to a vehicle seat includes a first portion and a second portion. The first portion is disposed on a first side of the trim component and defines a first knit. The second portion is disposed on a second side of the trim component and defines a second knit distinct from the first knit. The first and second portions are integrally knitted. The trim component is configured to be installed on or more support members of the seat. The first side is configured to face the support member. The second portion is configured communicate with an occupant of the seat. In various aspects, the first portion includes a first yarn and the second portion includes a second yarn that is distinct from the first yarn with respect to one or more of density, thickness, and material. In various aspects, the first yarn is a heat-activated yarn.

Abstract: A cascaded inverter system is described and includes an electric machine that is electrically connected in series between first and second inverters. A controller is in communication with the first and second inverters, and includes an executable instruction set. A first dead-time compensation term and a first voltage compensation term are determined based upon an initial phase current and a switching frequency for the first inverter, and a final first duty cycle is determined based thereon. Simultaneously, a second dead-time compensation term and a second voltage compensation term are determined based upon the inverted initial phase current and a switching frequency for the second inverter, and a final second duty cycle is determined based thereon. Operation of the first and second inverters are dynamically controlled based upon the final first duty cycle and the final second duty cycle, respectively.

Abstract: A workpiece is described, and includes a substrate, a cable, and a cover piece. A portion of the cable is joined to the substrate employing a vibration welding tool, and the cover piece is interposed between the portion of the cable and the vibration welding tool during the joining.

Abstract: A push to release fuel filler door assembly for a motor vehicle includes a door on the exterior of the vehicle having a latch that cooperates with a spring biased plunger which rotates and translates axially. The plunger includes radially extending pins which are received in complementary helical tracks on the inner surface of an inner housing. The tracks define a closed path having a first segment, in which the pins travel while the fuel door is being closed, a second segment in which they travel while the fuel door is opening and a latching recess between the first and second segments in which the pins reside when the door is closed. The inner housing typically includes three segments or sections and is, in turn, received and retained within an outer housing which mounts on a fuel door inlet assembly.

Abstract: A stator assembly includes a plurality of stator slots having multiple respective slot layers and a plurality of hairpins. The plurality of hairpins have a respective first leg positioned in one of the multiple respective slot layers and a respective second leg positioned in another of the multiple respective slot layers. A first set of n adjacent slots of the plurality of stator slots is configured to accommodate the plurality of hairpins carrying a current in a first phase, n being an integer. The plurality of hairpins is configured in respective conductor layers (L1, L2 . . . ) having a plurality of respective turn locations defining n respective turn positions. The plurality of hairpins is configured to occupy the n respective turn positions an equal number of times such that the respective conductor layers (L1, L2 . . . ) are electrically balanced.