Abstract: A method for laminating a lithium metal anode is provided. The method includes procuring a current collector, including a portion of the current collector to be covered with a lithium foil lamination, and procuring a plurality of lithium foil portions. The plurality of lithium foil portions each include a length configured for matching one of a length of the portion of the current collector to be covered with the lithium foil lamination or a width of the portion of the current collector to be covered with the lithium foil lamination. The method further includes disposing the plurality of lithium foil portions upon the portion of the current collector to be covered with the lithium foil lamination, wherein the plurality of lithium foil portions is arranged side-by-side, and applying heat and pressure to join the plurality of lithium foil portions to the current collector.

Abstract: A draw bar stowage apparatus includes an opening through the bed floor of the cargo box of a pickup truck for receiving the insertion end of a draw bar. The stowage apparatus may include an additional bracket beneath the bed floor, bed protection, a plug and adjustable tether for securing a stowed draw bar.

Abstract: A motor control system includes: a voltage command module configured to determine a target d-axis voltage for an electric motor and a target q-axis voltage for the electric motor; a target frequency module configured to: selectively set a target switching frequency to a first predetermined switching frequency; and selectively set the target switching frequency to a second predetermined switching frequency that is at least 2 kilohertz (kHz) greater than the first predetermined switching frequency; and a switching module configured to: based on the target d-axis voltage and the target q-axis voltage, determine target pulse width modulation (PWM) duty cycles for phases, respectively, of the electric motor; and switch switches of legs of an inverter module connected to the phases of the electric motor at the target PWM duty cycles, respectively, and the target switching frequency.

Abstract: The present disclosure relates to electrolyte systems and/or separators for electrochemical cells that cycle lithium ions and which may have lithium metal electrodes. The electrochemical cell includes a liquid electrolyte system that fills voids and pores within the electrochemical cell. The electrolyte system includes two or more lithium salts and two or more solvents. The two or more lithium salts include bis(fluorosulfonyl)imide (LiN(FSO2)2) (LIFSI) and lithium perchlorate (LiClO4). The two or more solvents include a first solvent and a second solvent. The first solvent may be a fluorinated cyclic carbonate. The second solvent may be a linear carbonate. A volumetric ratio of the first solvent to the second solvent may be 1:4. The electrochemical cell may include a surface-modified separator that has one or more coatings or fillers.

Abstract: A vehicle control system for automated driver-assistance includes a low-resolution color camera that captures a color image of a field of view at a first resolution. The vehicle control system further includes a high-resolution scanning camera that captures a plurality of grayscale images, each of the grayscale images at a second resolution. The second resolution is higher than the first resolution. The grayscale images encompass the same field of view as the color image. The vehicle control system further includes one or more processors that perform a method that includes overlaying the plurality of grayscale images over the color image. The method further includes correcting motion distortion of one or more objects in the grayscale images. The method further includes generating a high-resolution output image by assigning color values to one or more pixels in the grayscale images based on the color image using a trained neural network.

Abstract: A method of making a calendered electrode for a battery cell comprises introducing a coated electrode having a first surface extending thereover. The coated electrode has a predetermined density of active materials for ion transport. The method further comprises selectively modifying the coated electrode by patterning the first surface to define a patterned electrode having a first portion and a second portion. After the step of selectively modifying, the method further comprises compressing the patterned electrode by calendering the first surface to provide the first portion having a first density of active materials and the second portion having a second density of active materials. The second density is greater than the first density to define the calendered electrode having a spatial variation of active material density.

Abstract: A control system includes a refrigerant recovery module and at least one of a valve control module and a compressor control module. The refrigerant recovery module is configured to generate a refrigerant recovery signal to initiate a recovery of refrigerant from a first heat exchanger of a thermal system for an electric vehicle, and to stop the refrigerant recovery based on a temperature of refrigerant circulating through the first heat exchanger. The valve control module is configured to open a first valve to allow refrigerant to flow through the first heat exchanger in response to the refrigerant recovery signal. The compressor control module is configured to increase a speed of a compressor disposed upstream from the first heat exchanger in response to the refrigerant recovery signal.

Abstract: A system in a vehicle includes a current regulator to obtain current commands from a controller based on a torque input and provide voltage commands and an inverter to use the voltage commands from the current regulator and direct current (DC) supplied by a battery to provide alternating current (AC). The system also includes an electric traction motor to provide drive power to a transmission of the vehicle based on injection of the AC from the inverter. The current regulator adjusts parameters of a transfer function implemented by the current regulator, based on feedback of an input to and an output from the electric traction motor to achieve the AC corresponding with the torque input in no more than two control cycles.

Abstract: A multi-module battery pack includes a battery tray defining multiple battery tray compartments, battery modules each disposed within a corresponding one of the compartments, and a thermal barrier arranged in a predefined heat transfer path through the tray between an adjacent pair of the battery modules. The thermal barrier has a thickness of at least about 1 mm and a thermal conductivity of less than about 4 W/m-K, such that the thermal barrier blocks the heat transfer path to mitigate a thermal runaway event of one of the adjacent pair of battery modules. An electric powertrain system includes a rotary electric machine having phase leads and an output member, a driven load coupled to the output member, and the multi-module battery pack. A method includes providing the tray, identifying the heat transfer path, and arranging the thermal barrier in the heat transfer path.

Abstract: A composite panel for a vehicle includes a plurality of layers bonded together by resin. A sensing assembly is arranged between at least two of the plurality of layers. The sensing assembly includes at least one of a piezoelectric layer to sense vibration of the composite panel when installed on the vehicle and a thermopile configured to sense changes in temperature of the composite panel when installed on the vehicle. The sensing assembly further includes a transmitter configured to transmit data to the vehicle based on an output of the at least one of the piezoelectric layer and the thermopile.

Abstract: An axial flux electric motor for an automobile includes a stator assembly, and a rotor assembly, the rotor assembly including a plurality of lamination blocks arranged in an annular pattern, a plurality of conductive wedges, one conductive wedge being positioned between each adjacent pair of lamination blocks, the plurality of lamination blocks and the plurality of conductive wedges defining a rotor core disk having an inner diameter and outer diameter and opposing axial faces, and a plurality of permanent magnets attached to one of the opposing axial faces of the rotor core disk.

Abstract: A method of operating a vehicle includes a vehicle controller receiving a driver acceleration/deceleration command for the vehicle's powertrain and determining a torque request corresponding to the driver's acceleration command. The controller shapes the torque request and determines compensated and uncompensated accelerations from the shaped torque request. The compensated acceleration is based on an estimated road grade and an estimated vehicle mass, whereas the uncompensated acceleration is based on a zero road grade and a nominal vehicle mass. A final speed horizon profile is calculated as: a speed-control speed profile based on the uncompensated acceleration if the vehicle's speed is below a preset low vehicle speed; or a torque-control speed profile based on a blend of the compensated and uncompensated accelerations if the vehicle speed exceeds the preset low vehicle speed. The controller commands the powertrain to output a requested axle torque based on the final speed horizon profile.

Abstract: An autonomous vehicle and a system and method of operating the autonomous vehicle. The system includes a sensor and a processor. The processor determines an effective observation area of the sensor, the effective observation area being affected by an extrinsic condition. The processor determines an available time for performing a lane change based on the effective observation area and performs the lane change based on the available time.

Abstract: A current source inverter includes a first phase leg including a plurality of switching devices, a second phase leg including a plurality of switching devices, and a third phase leg including a plurality of switching devices. The current source inverter also includes a zero-state phase leg including at least one switching device, wherein the zero-state phase leg is configured to transition from an open state to prevent current flow to a closed state to allow current flow between a positive and negative terminal during a dead-band time.

Abstract: A rechargeable energy storage system (RESS) includes a battery controller and battery modules, each respective module having battery cells, a cell sense board, and a semiconductor switch. The switch is connected in parallel with the cells within the respective module, and configured to conduct an electrical current during a thermal runaway propagation (TRP) event in which one or more cells is in an open-circuit state. This action bypasses the module and enables electrical components to be powered by the RESS during the TRP event. A battery electric system includes a direct current (“DC”) voltage bus, an electrical component connected thereto, the battery controller, and the RESS. A method for constructing the RESS includes connecting a respective semiconductor switch in parallel with the at least one battery cell of each respective one of the multiple battery modules, and electrically connecting the multiple battery modules together to construct the RESS.

Abstract: An adhesive-reinforced rotor for a rotary electric machine includes rotor lamination layers (“rotor lams”) having axial inner surfaces collectively defining rotor openings through the rotor lams. The rotor also includes reinforcement blocks disposed within a respective one of the rotor openings. A polymer primer/adhesive layer of the rotor having a bond line thickness of less than 1 mm is disposed between the one or more reinforcement blocks and the axial inner surfaces of the rotor lams. The reinforcement blocks and the primer/adhesive layer each have a tensile strength of at least 50 MPa. A modulus of elasticity of the reinforcement blocks is at least three times greater than that of the materials of the polymer primer/adhesive layer. A method of constructing an adhesive-reinforced rotor is also described herein.

Abstract: Presented are high-voltage electrical systems, control logic, and electric-drive vehicles with optimized motor torque output. A method of operating an electric-drive vehicle includes a controller identifying the vehicle's operating mode and determining calibration settings corresponding to this operating mode. These calibration settings include low and high coolant temperature (CoolTemp) thresholds, and motor-calibrated torque limits as a function of CoolTemp. The controller determines if the present CoolTemp of the power inverter's coolant is greater than the low CoolTemp threshold and less than the high CoolTemp threshold. If so, the controller sets a motor torque limit of the vehicle's electric motor to a torque limit value selected from a fixed torque limit region within the torque limits data between the low and high CoolTemp thresholds.

Abstract: Presented are control systems for operating rechargeable electrochemical devices, methods for making/using such systems, and vehicles with intelligent battery charging and charging behavior feedback capabilities. A method of operating a rechargeable battery includes an electronic controller receiving battery data from a battery sensing device indicative of a battery state of charge (SOC). Using this battery data, the controller determines a number of low SOC excursions at which the battery SOC is below a predefined low SOC threshold and a number of high SOC excursions at which the battery SOC exceeds a predefined high SOC threshold. The controller then determines if the number of low SOC excursions exceeds a predefined maximum allowable low excursions and/or the number of high SOC excursions exceeds a predefined maximum allowable high excursions. If so, the controller responsively commands a resident subsystem to execute a control operation that mitigates degradation of the rechargeable battery.

Abstract: The concepts herein provide for a rechargeable lithium-ion battery cell having an anode with improved properties, including a capability to suppress formation of lithium dendrites after cell formation and in-use. This includes an anode for a rechargeable battery that includes a current collector having an indium nitride layer, wherein the indium nitride layer includes indium nitride, an electrically conductive material, and a polymeric binder.

Abstract: An electrical connection unit for a battery pack includes a busbar having a first hole therein, a top surface and a bottom surface, an annular bushing having a top end abutting the bottom surface, a bottom end opposed to the top end and a bore hole therein registered with the first hole, a busbar cage secured to the busbar and retaining the annular bushing in abutment with the busbar, the busbar cage having a cavity therein above the top surface, and a fastener having a head portion captured within the cavity and a shank portion extending through the first hole. The annular bushing may include one or more indents formed on an outer surface thereof, and the busbar cage may include a plurality of fingers extending along the outer surface and interfacing with the one or more indents. Each finger may include a protrusion configured to rest within an indent.