Abstract: A fuel cell stack assembly for a vehicle is provided which includes a first end plate, a second end plate; and a first plurality of fuel cells disposed between the first and second end plates. The first plurality of fuel cells may define a repeating pattern of a thick fuel cell adjacent to a thin fuel cell. Each fuel cell in the first plurality of fuel cells having an active area thickness. The fuel cell stack assembly of the present disclosure may further include a second plurality of nominal fuel cells.

Abstract: A moisture detection and regulation system is disclosed for a vehicle interior component having a section of material with a moisture absorbent material structure. The system includes a sensing device configured to detect a level of moisture in the section of material. The system also includes a moisture removal element configured to dissipate moisture from the section of material. The system additionally includes an electronic controller fixed to the vehicle structure and in operative communication with each of the sensing device and the moisture removal element. The controller is configured to receive a signal from the sensing device indicative of the detected level of moisture in the section of material and activate the moisture removal element when the detected level of moisture is equal to or greater than a predetermined threshold level of moisture. A vehicle having such a moisture detection and regulation system is also disclosed.

Abstract: A die set for forming a panel having a surface includes a stationary die, a moveable die, and a clamp attached to the stationary die to secure a panel blank. The moveable die includes a moveable brazing formation surface and the stationary die includes a stationary brazing formation surface for forming the surface. One of the moveable and stationary dies includes a male bead forming portion, and the other includes a female bead forming portion for forming a bead. The male and female bead forming portions extend in a continuous and uninterrupted, generally parallel relationship with the moveable and stationary brazing formation surfaces. The male and female bead forming portions are operable to engage the panel blank during movement of the moveable die to induce tensile forces in both a first direction parallel to a path of the surface and a second direction transverse to the path.

Abstract: An upholstery piping component for a vehicle seat includes an elongated anchor and an elongated projection. The elongated anchor is formed from an elastomeric material. The elongated anchor extends along a length. The elongated anchor is configured to be coupled to a first upholstery portion and a second upholstery portion and disposed between the first upholstery portion and the second upholstery portion. The elongated projection is formed from the elastomeric material. The elongated projection is integrally is formed with the elongated anchor. The elongated projection extends from the elongated anchor for at least a portion of the length. The elongated projection is configured to at least partially conceal a seam between the first upholstery portion and the second upholstery portion. The elastomeric material is flexible such that the upholstery piping component is configured to move between a neutral configuration and a modified configuration.

Abstract: A non-linear stiffness actuator for a suspension corner employed in a vehicle includes an actuator housing and an actuator shaft configured to transmit an actuator force to the road wheel. The actuator also includes a primary elastic member assembly arranged between the actuator housing and the actuator shaft and configured to exert a primary elastic member force along the actuator shaft. The actuator additionally includes a secondary elastic member assembly configured to exert a variable secondary elastic member force acting between the actuator housing and the actuator shaft. The variable secondary elastic member force is configured to selectively contribute to and subtract from the primary elastic member force to thereby facilitate the non-linear stiffness of the actuator. A vehicle having such a non-linear stiffness actuator is also provided.

Abstract: An adjustable body skirting assembly and a vehicle that includes the assembly. The assembly includes a support structure and a skirt member. The support structure includes a side surface and a bottom surface, and the skirt member is supported by the support structure. The skirt member is movable between a deployed position in which the skirt member is disposed transverse to the bottom surface of the support structure such that the skirt member and the side surface cooperate with each other to define a wall configured to redirect an airflow away from the bottom surface, and a retracted position in which the skirt member retracts relative to the side surface such that the wall is removed which allows the airflow to interact with the bottom surface. The assembly includes an actuator coupled to the skirt member and configured to move the skirt member to the deployed and retracted positions.

Abstract: Disclosed are active engine compartment venting systems, methods for making and using such systems, and vehicles equipped with an active engine compartment vent and control logic for operating the vent. A method is disclosed for regulating operation of an active venting device fluidly coupled to a vent in an engine hood of a motor vehicle. The method includes a vehicle controller determining if a calibrated vehicle venting condition exists, and determining if a calibrated vehicle speed condition exists. Responsive to determining that the calibrated vehicle venting condition exists, the controller commands the active venting device to transition to an open state and thereby unobstruct the vent and allow venting fluid flow therethrough. Conversely, in response to determining that the calibrated vehicle speed condition exists, the controller commands the active venting device to transition to a closed state to thereby obstruct the vent and restrict venting fluid flow therethrough.

Abstract: Disclosed are control algorithms and system architectures for arbitrating vehicle charging, e.g., for electric vehicles with rechargeable battery packs, wired and wireless charging capabilities, and control logic for governing such charging. A method is disclosed for managing charging of electrical storage units of motor vehicles at vehicle charging stations. The method includes determining if a wireless charging interface of the motor vehicle is available for wireless power transfer, and determining whether or not the vehicle charging station has an electrical connector coupled to a wired charging interface of the motor vehicle. Responsive to the charging station having an electrical connector coupled to the wired charging interface, the method initiates a wired (conductive) charge power mode.

Abstract: A method of joining parts of the wastegate assembly, and a wastegate assembly includes an arm defining a hole. The wastegate assembly also includes a shaft. The shaft includes a first end disposed inside the hole of the arm. The shaft includes an outer surface defining a groove disposed inside the hole of the arm. The arm and the first end of the shaft are welded together to form a joint having a joint root region disposed adjacent to the groove. A turbocharger includes a compressor, a turbine and a rotating assembly driven by exhaust gas. The rotating assembly has a turbine wheel disposed inside the turbine and a compressor wheel disposed inside the compressor. The turbocharger further includes the wastegate assembly described above, and the wastegate assembly defines an opening configured to selectively redirect at least a portion of the exhaust gas to bypass the turbine wheel.

Abstract: A portable communication device, for implementation with a host vehicle of transportation having an on-board diagnostics port and a limited-access head-unit display. The device includes an on-board diagnostics connector sized and shaped to connect to the on-board diagnostics port of the host vehicle, a hardware-based processing unit in communication with the on-board diagnostics; and a non-transitory storage device in communication with the processing unit, the storage device. The storage includes a media-options presentation module that, when executed by the processing unit: sends, by way of the on-board diagnostics connector and port, media-options data to the host vehicle for presenting user media options by way of the limited-access head-unit display; and receives user-selection data responding to the user media options.

Abstract: A system for forming an electrode for a lithium-ion battery cell includes an electrode material, a material-supply mechanism, a wetting mechanism, a debris-generating tool, and a conditioner. The material-supply mechanism is configured to deliver the electrode material. The wetting mechanism is configured to receive the electrode material from the material-supply mechanism and apply a solution to the electrode material to produce a wet precursor. The debris-generating tool is configured to remove a portion of the electrode material from the wet precursor to form a pre-electrode. The conditioner is configured to eliminate the solution from the pre-electrode and thereby form the electrode.

Abstract: A starter includes a three-phase switched reluctance electric motor including a rotor and a stator, a pinion gear, a power inverter that is connected to the stator, and a rotational position sensor. The rotor includes a quantity of rotor poles that is between 6 and 16, and the stator includes a quantity of stator poles that is between 8 and 24. An outer diameter of the electric motor is less than 85 mm. An active length of the motor is less than 50 mm. An airgap distance between the rotor and the stator is between 0.1 mm and 0.5 mm. A ratio between a rotor pole arc and a stator pole arc is at least 1.0:1. A ratio between a stator diameter and a rotor diameter is at least 2.0:1, and a ratio between a stator pole height and a rotor pole height is at least 2.5:1.

Abstract: A starter system for a powertrain comprises a brushless electric starter motor operatively connectable to an internal combustion engine. The starter system includes both an ultracapacitor power pack and a battery power pack. A nominal voltage of the ultracapacitor power pack is greater than that of the battery power pack. A DC-DC converter operatively connects the battery power pack and the ultracapacitor power pack and converts direct current at a first voltage level of the battery power pack to direct current at a greater second voltage level of the ultracapacitor power pack. An electronic control system is operable to control the brushless electric starter motor to start the engine using power provided from the ultracapacitor power pack, and to control the DC-DC converter to recharge the ultracapacitor power pack using power provided from the battery power pack through the DC-DC converter. A method of controlling the starter system is included.

Abstract: An electric starter system includes a brushless alternating current (AC) starter motor selectively coupled to an engine and having a rotor with a rotor position. A position sensor generates measured position signals indicative of rotor position. A controller is in communication with the sensor. The controller has sensorless logic, e.g., a BEMF, inductance, or high-frequency signal injection method, for generating an estimated rotor position. The controller executes a method in which, below a threshold speed of the starter motor, the controller calibrates the sensorless logic using the measured position signals and controls a torque operation of the starter motor using the measured position signals. Above the threshold speed, the torque operation is controlled solely using the estimated rotor position. A powertrain includes the engine, a transmission, a drive shaft, and a load, along with the electric starter system.

Abstract: A starter assembly includes a partial planetary gear set connected to a pinion gear slidable along a first axis. The starter also includes a motor casing housing a brushless electric motor and having a first bearing. The motor includes multi-phase stator and rotor assemblies arranged inside the casing concentrically relative to the first axis. The rotor assembly has a rotor with a shaft supported by the first bearing and connected to a sun gear engaging the gear set, and a rotor position and speed sensor target. The starter additionally includes a motor end-cap for mating with and enclosing the motor casing and having a second bearing supporting the shaft. The starter also includes an electronics cover with a power connector for mating with the end-cap and housing an electronic commutator assembly. The commutator assembly includes power electronics, and control processor electronics arranged between the end-cap and the power electronics.

Abstract: A hitch angle module determines a hitch angle based on an input from at least one of a vehicle rear camera and a hitch angle sensor. The hitch angle is an angle between a longitudinal centerline of a trailer and a longitudinal centerline of a vehicle. A trailer load sensor measures a load on a trailer hitch of the vehicle. A trailer wheel speed sensor measures a wheel speed of the trailer. A trailer dimension module determines at least one of a width of the trailer, a mass of the trailer, a drawbar length of the trailer, a height of the trailer, and a trailer hitching length of the vehicle based on at least one of the hitch angle, the trailer load, and the trailer wheel speed. The trailer hitching length is a distance from a rear axle of the vehicle to a distal end of the trailer hitch.

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 polyphase/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.

Abstract: A brushless electric motor includes a motor casing having a first bearing, a motor end-cap including a second bearing, a multi-phase stator assembly, and a rotor assembly having a rotor shaft. The shaft has a first end, a second end, and a knurled section therebetween. The shaft also has a first bearing surface proximate the first end and supported by the first bearing, a second bearing surface proximate the second end and supported by the second bearing, and a rotor position and speed sensor target. The shaft additionally has a sun gear integrated with the shaft proximate the first bearing surface for engaging a partial planetary gear set. The rotor assembly also includes a rotor lamination fixed to the shaft at the knurled section and having opposing first and second sides, and first and second end plates arranged on the respective first and second sides of the rotor lamination.

Abstract: A starter system includes a brushless electric starter motor and a battery power pack, the motor operatively connectable to an internal combustion engine of a powertrain. A power inverter converts direct current provided from the battery power pack to multi-phase alternating current to drive the motor. A pinion gear with one-way clutch is rotatably driven by the motor and movable between a disengaged position and an engaged position in which the pinion gear is meshingly engaged with a ring gear operatively connected to a crankshaft of the engine. A solenoid is operatively connected to the pinion gear. An electronic control system controls the motor to crank the engine using power provided from the battery power pack, and to separately command the solenoid to a disabled or an enabled state. A method of controlling the starter system controls the motor to crank the engine in a restart following an autostop.

Abstract: A starter assembly includes a multi-phase brushless electric motor including a stator, a rotor disposed on a rotatable shaft, and a motor endcap disposed at a first end of the stator. An electronic commutator assembly includes a sensing circuit, a control electronics subassembly, a power electronics subassembly and a heat sink. The sensing circuit is disposed adjacent to the second end of the rotatable shaft. The control electronics subassembly, the power electronics subassembly and the heat sink are disposed on disk-shaped devices arranged in a stacked configuration orthogonal to the axis defined by the rotatable shaft. The control electronics subassembly is disposed adjacent to the sensing circuit, and the power electronics subassembly is disposed adjacent to the control electronics subassembly. The control electronics subassembly is interposed between the power electronics subassembly and the sensing circuit. The heat sink is disposed adjacent to the power electronics subassembly.