Abstract: A composite thermal barrier coating (TBC) may be applied to a surface of components within an internal combustion engine. The composite TBC provides low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses. The composite TBC includes three layers, bonded to one another, i.e., a first (bonding) layer, a second (insulating) layer, and a third (sealing) layer. The insulating layer is disposed between the bonding layer and the sealing layer. The bonding layer is bonded to the component and to the insulating layer. The insulating layer includes hollow microspheres that are sintered together to form insulation that provides a low effective thermal conductivity and low effective heat capacity. The sealing layer is a thin film that is configured to resist the high temperatures, present within the engine. The sealing layer is impermeable to gasses and presents a smooth surface.

Abstract: A braking system for a vehicle includes devices that are configured to apply braking force to a wheel in response to a braking command. A first sensor is disposed to monitor a parameter associated with the braking force, and a spatial sensor is disposed to determine a linear range between the vehicle and a predefined locus point. A controller is operatively connected to the braking system and in communication with the first sensor and the spatial sensor. The controller detects a braking event and determines a time to stop and an applied braking force during the braking event, which is integrated over the time to stop. The braking system is evaluated based upon the total stopping distance and the integrated applied braking force during the braking event. A fault associated with the braking system is determined based upon the evaluation of the braking system.

Abstract: A method for controlling a powertrain system in response to a command to execute a multi-state shift event for the transmission includes determining an initial output torque limit and determining an initial commanded output torque based upon the initial output torque limit. The powertrain system is controlled to generate torque in response to the initial commanded output torque prior to completion of a first state transition of the multi-state shift event that includes a commanded torque reduction. After completion of the first state transition of the multi-state shift event that includes the commanded torque reduction, a torque ramp rate is determined, and the initial commanded output torque is adjusted based upon the torque ramp rate. The powertrain system is controlled to generate torque in response to the initial commanded output torque and the adjusted initial commanded output torque during a remainder of the multi-state shift event.

Abstract: Presented herein are adaptive power assist systems for manually-powered vehicles, methods for operating/constructing such systems, and motorized operator-powered vehicles with adaptive power assist systems. A method for regulating a power assist system of a manually powered vehicle includes a vehicle controller determining path plan data that includes a predicted route plan to traverse from a current vehicle location to a desired vehicle destination. A resident wireless communications device receives, from a remote computing node, an assist level power trace for operating the vehicle's tractive motor on the predicted route plan. The vehicle controller receives health level data specific to the vehicle user, determines a power assist delta based on the health level data, and modifies the assist level power trace based on this power assist delta. The vehicle controller transmits command signals to the tractive motor to output a selectively variable torque according to the modified assist level power trace.

Abstract: An interior permanent magnet electric machine includes a stator having a plurality of teeth disposed around a circumference oriented radially towards a center defining slots interposed between each of the teeth, and a conductive winding wrapped around at least one of the teeth of the stator to receive an electrical current. The electric machine also includes a rotor which is rotatable relative to the stator. The rotor defines a plurality of openings configured to hold permanent magnets near an outer portion of the rotor and a number of spokes interposed between mass reduction cutouts located closer to a center of the rotor relative to the permanent magnets. Each of the permanent magnets defines a magnetic pole and each of the spokes is circumferentially aligned with one of the magnetic poles.

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 radially slotted welding electrode is disclosed that may be used in conjunction with a companion second welding electrode to conduct resistance spot welding on a workpiece stack-up assembly that includes a steel workpiece and an overlapping adjacent aluminum workpiece, especially when an intermediate organic material layer is disposed between the workpiece faying surfaces of the steel and aluminum workpieces. The radially slotted welding electrode includes a weld face that has a central upstanding plateau and a convex dome portion that surrounds the central upstanding plateau and which includes a plurality of circumferentially spaced trapezoidal weld face sections that include transverse upstanding arcuate ridges. Together, the central upstanding plateau and the trapezoidal weld face sections of the convex dome portion define an annular channel that surrounds the central plateau and a plurality of radial slots that communicate with and extend outwards from the central channel.

Abstract: A switching circuit includes a semiconductor switch having a Gate terminal, and includes first, second, third, and fourth Gate resistors. The Gate resistors have upstream and downstream ends relative to a location of the semiconductor switch or a driven load. The downstream ends connect to the Gate terminal. First, second, third, and fourth buffer switches have Gate terminals and Source terminals, with the Source terminals connected to the upstream ends of the first, second, third, and fourth Gate resistors, respectively. An optional Gate driver integrated circuit (IC) connects to the Gate terminals of the buffer switches. A microcontroller, responsive to circuit measurements, selects switching control values and Gate resistor identities based on the measurements, and transmits switching control signals and a Gate resistor selection signal to select on/off states of the buffer switches and an optimum switching speed for the semiconductor switch.

Abstract: A catalyst temperature control system of a vehicle includes a fuel control module configured to control fuel injection based on a target air/fuel ratio that is fuel lean relative to a stoichiometric air/fuel ratio and a target fuel injection start timing. An exhaust gas recirculation (EGR) control module is configured to control an EGR valve based on a target EGR opening. An adjustment module is configured to, when a temperature of a catalyst in an exhaust system is less than a sum of a predetermined light-out temperature of the catalyst and a predetermined temperature and the target air/fuel ratio is fuel lean relative to the stoichiometric air/fuel ratio, based on a comparison of an engine speed and a predetermined engine speed, selectively adjust at least one of: a target throttle opening, a target spark timing, the target fuel injection start timing, the target air/fuel ratio, and the target EGR opening.

Abstract: A vehicle including a hybrid battery pack includes a first battery pack and a second battery pack. The first battery pack has a higher energy density than the second battery pack. The second battery pack has a higher power density than the first battery pack. A power inverter module is connected between the hybrid battery pack and a motor generator unit (MGU) that is connected to a powertrain of the vehicle. The power inverter module is configured to regulate power flow between the hybrid battery pack and the MGU. A battery management module is configured to: control switching of the power inverter module; selectively charge and discharge at least one of the first battery pack and the second battery pack; and selectively charge the first battery pack with power from the second battery pack.

Abstract: A cooling assembly includes an instrument panel. A passenger compartment for a vehicle can also utilize the cooling assembly. The instrument panel includes a first surface and a second surface opposing the first surface. The cooling assembly also includes a thermoelectric apparatus coupled to one of the first and second surfaces. The thermoelectric apparatus includes a first conductive plate and a second conductive plate spaced apart from each other. The first and second conductive plates are configured to be at different temperatures from each other during operation of the thermoelectric apparatus. The cooling assembly further includes a film secured to one of the first and second surfaces of the instrument panel and thermally connected to one of the first and second conductive plates of the thermoelectric apparatus such that operation of the thermoelectric apparatus causes the film to decrease in temperature by an amount sufficient for cooling the instrument panel.

Abstract: A method to control an internal combustion engine including exhaust gas recirculation (EGR) system and an air charging system includes the following steps: (a) determining, via an engine controller, a first EGR mass flow rate using an orifice model; (b) determining, via the engine controller, a second EGR mass flow rate using a cylinder volumetric efficiency model; (c) determining, via the engine controller, a hybrid EGR mass flow rate based on the first EGR flow rate and the second EGR flow rate; and (d) controlling the air charging system based on the hybrid EGR flow rate.

Abstract: A knitted seat trim cover for attachment to a vehicle seat includes a knitted trim panel configured to be installed over at least one foam support member of the vehicle seat and a fastener member integrally knitted in the knitted trim panel. The fastener member is configured to connect the knitted trim panel to the vehicle seat and at least a portion of the fastener member is made of a heat-activated yarn.

Abstract: An energy share system includes a first vehicle and a second vehicle. The first vehicle includes a first battery pack and a first battery management module configured to selectively charge and discharge the first battery pack. The second vehicle includes a second battery pack and a second battery management module configured to, in response to receipt of payment, selectively charge the second battery pack with power received from the first battery pack of the first vehicle.

Abstract: A knitted seat trim cover for attachment to a vehicle seat includes a knitted trim panel configured to be installed over one or more support members of the vehicle seat and at least one fastener tube integrally knitted to the trim panel. The fastener tube is positioned on a back side of the trim panel facing the one or more support members. The knitted seat trim cover also includes an elongated fastener member positioned inside the at least one fastener tube. The elongated fastener member is configured to releasably connect to a complimentary fastener member on the vehicle seat.

Abstract: A thermal management device for dissipating heat from an electrical component includes a volume of working fluid configured to change from a liquid state to a vapor state in response to being heated by the electrical component. The thermal management device also includes a working fluid chamber configured to move the working fluid. The working fluid chamber includes an impermeable outer portion and a porous inner portion integrally formed with and connected to the impermeable outer portion. The inner portion is configured to move the working fluid when in the liquid state toward the electrical component. The impermeable outer portion is made of a first material and the porous inner portion is made of a second material. The first material is different from the second material.

Abstract: A method for exhaust aftertreatment includes determining a diagnostic condition with respect to a threshold diagnostic condition, determining an SCR efficiency as a ratio of a readout of a first NOx sensor at a first NOx sensing position with respect to a readout of a second NOx sensor at a second NOx sensing position, the first NOx sensing position located about an engine out area within an exhaust stream before a DOC and the second NOx sensing position located about an output of an SCR device within the exhaust stream; and comparing the SCR efficiency to a threshold SCR efficiency range. If the SCR efficiency is less than the threshold SCR efficiency range, then trigger DOC failure for NO oxidation, and if the SCR efficiency is greater than or equal to the threshold SCR efficiency range, then DOC is determined to be operating within specifications.

Abstract: A method for controlling a vehicle transmission includes electrically connecting a Transmission or Powertrain Control Unit (TCU or PCU) to the vehicle transmission, the TCU or PCU controlling operation of the transmission and having switchable power on a high side, and switchable ground on a low side of a plurality of solenoids in a shared functional grouping configuration, proportionally controlling an amount of current through a load such as a solenoid via controlling an amount of time current is being sunk through the solenoid to ground and controlling an amount of time current is provided via an adaptable recirculation path in the TCU or PCU, the recirculation path minimizing current decay when the solenoid is driven in an OFF state. The TCU or PCU having a single hardware layout, but being electronically adaptable to control a plurality of transmission types and solenoid architectures based on any desired functional solenoid grouping.

Abstract: A method of manufacturing a workpiece includes heating a pre-formed blank of a first fiber reinforced thermoplastic material in an oven. A second fiber reinforced thermoplastic material is heated in an extruder. The second fiber reinforced thermoplastic material is extruded from the extruder, within the oven, to form an extrudate. The extrudate is positioned on the pre-formed blank of the first fiber reinforced thermoplastic material, within the oven, to form a composite blank. The extrudate may be formed into a shape before being positioned onto the pre-formed blank, after being positioned onto the pre-formed blank. The composite blank may then be transferred to a final shaping station.

Abstract: The present disclosure provides a fuel cell stack having a plurality of bipolar plates aligned between a pair of end plates. Each of the bipolar plates further includes a first bead and a second bead. The first bead defines a first bead height, and the second bead defines a second bead height wherein the second bead height is less than the first bead height.