Abstract: A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.

Abstract: An alignment device includes a first body and a second body, at least one retention member flexibly coupled to the first body, and a locking member coupled to the first body. The second body has an outer surface and an inner surface defining a cylindrical wall, the cylindrical wall defining a cylindrical opening, a first retention opening extending through the cylindrical wall and a second retention opening extending through the cylindrical wall. The first body translates within the cylindrical opening of the second body and the locking member engages with the first retention opening to position the alignment device in a first position and the locking member engages with the second retention opening to position the alignment device in a second position.

Abstract: A capacitor-assisted, solid-state lithium-ion battery is formed by replacing at least one of the electrodes of the battery with a capacitor electrode of suitable particulate composition for the replaced battery particulate anode or cathode material. The solid-state electrodes typically contain quasi-solid-state electrode material and are separated with a layer of quasi-solid-state electrolyte material. In another embodiment the capacitor anode or cathode particles may be mixed with lithium-ion battery anode or cathode particles respectively. Preferably, the battery comprises at least two positively-charged electrodes and two negatively-charged electrodes, and the location, number and compositions of the capacitor material electrode(s) may be selected to provide a desired combination of energy and power.

Abstract: A method of forming batteries includes feeding a foil through a coating machine. The movement of the foil defines a foil direction. The method applies a first coating band and a second coating band to the foil. The second coating band is spaced from the first coating band by a first tab gap. The foil is cut substantially perpendicular to the foil direction to separate a first coated blank. The first coated blank is cut separate the first coating band and a first portion of the first tab gap, and to separate the second coating band and a second portion of the first tab gap. A first electrode is formed from the first coating band and the first portion of the first tab gap, and a second electrode is formed from the second coating band and the second portion of the first tab gap.

Abstract: A clamp system and method for measurement and control of welding a first substrate to a second substrate is provided. The system comprises a squeeze clamp having to a first end and a second end. The system further comprises a motor connected to the squeeze clamp such that the first and second ends are movable to clamp the first substrate to the second substrate. The system further comprises at least one of an electromagnetic flux sensor, a current sensor, a position sensor, and a gap sensor disposed on one of the first and second ends for determining a first measured variable between the first and second substrates. The system further comprises a controller to control the motor to clamp the first substrate to the second substrate based on the first measured variable. The controller is in communication with the electromagnetic flux sensor, the current sensor, and the gap sensor.

Abstract: A hybrid electric powertrain for a vehicle includes an engine, electric machine, torque converter having a pump, turbine, and torque converter clutch (“TCC”) configured, when applied, to lock the pump to the turbine, a one-way engine disconnect clutch connected to the turbine, a transmission, and a controller. A transmission input shaft directly couples to the electric machine, and is selectively coupled to the engine via the disconnect clutch. An output shaft is connectable to road wheels of the vehicle. The controller, in response to an engine-off request, determines turbine and pump speeds of the turbine and pump, respectively, registers that the engine is in an engine-off state when the pump speed is less than the turbine speed, and executes an electric vehicle (“EV”) mode shift using machine torque from the electric machine when the pump speed is zero during the engine-off state.

Abstract: A method of determining a noise or vibration response of a vehicle subassembly may include transmitting, via a controller, an input torque control signal to a first motor of a test apparatus. The first motor is mountable on a test fixture of the test apparatus and is configured to be coupled to the vehicle subassembly. The input torque control signal causes the first motor to provide an input torque characterized as a third derivative Gaussian function. The method further includes receiving a response of the vehicle subassembly to the input torque, and executing a control action with respect to the vehicle subassembly, via the controller, based on the response.

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 battery includes a first mono cell formed from a first electrode foil having a first body and a first tab, and a first coating. The first body has long edges and short edges, and a length-to-width ratio of the first body is at least five. The first tab extends from one of the long edges of the first body entirely between one of the short edges a midpoint of the long edge. A second electrode foil has similar structure to the first electrode foil and coating, but a second tab is aligned opposite the first tab along the short edges. A second mono cell has similar structure. A third tab and a fourth tab of the second mono cell are on an opposing side of the midpoint of the long edges from the first tab and the second tab.

Abstract: An automatic fault isolation and diagnosis system includes a cloud-based data system having multiple machine-readable troubleshooting procedures stored therein. A vehicle fault code is generated by one of multiple vehicle control devices of a vehicle platform. The fault code defines an issue with at least one system or component of the vehicle platform. A data transfer device within the vehicle platform receives the fault code and forwards the fault code to the cloud-based data system. The fault code is received and analyzed in the cloud-based data system to initially determine if the fault code is directed to and can be automatically corrected by one of the stored machine-readable troubleshooting procedures.

Abstract: A vehicle including an advanced driver-assistance system (ADAS) and operator-adjustable devices is described. Controlling the vehicle includes identifying a vehicle operator, and capturing a plurality of operator-selectable settings associated with the plurality of operator-adjustable devices for the vehicle operator. A base profile and a second profile are determined for the vehicle operator based upon the first subset associated with non-autonomous operation of the vehicle and the second subset associated with ADAS, respectively. The plurality of operator-adjustable devices are controlled to the operator-selectable settings associated with the base profile when the vehicle is operating in the non-autonomous mode, and the plurality of operator-adjustable devices are controlled to the operator-selectable settings associated with the second profile when the vehicle is being controlled at least in part by one or more of the subsystems of the ADAS.

Abstract: Composite cathode-separator laminations (CSL) include a current collector with sulfur-based host material applied thereto, a coated separator comprising an electrolyte membrane separator with a carbonaceous coating, and a porous, polymer-based interfacial layer (PBIL) forming a binding interface between the carbonaceous coating and the host material. The host material includes less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds. The PBIL can have a thickness of less than about 5 ?m and a porosity of about 5% to about 40%. The host material can comprise less than about 40% conductive carbon (e.g., graphene) and have a porosity of less than about 40%. The carbonaceous coating (e.g., graphene) can have a thickness of about 1 ?m to about 5 ?m. The CSL can be disposed with an anode within an electrolyte to form a lithium-sulfur battery cell.

Abstract: A process for correcting longitudinal roll from an offset load using active roll control within a vehicle is provided. The process includes, within a computerized controller using axle-based control to control a suspension system, operating programming to control pneumatic pressure supplied to each of a plurality of air spring devices within the suspension system to execute a vehicle leveling event including one of adjusting a height of the vehicle or maintaining the height of the vehicle. The process further includes operating programming to, simultaneously with the controlling the pneumatic pressure, utilize a plurality of active sway bars to provide an offset torque to the vehicle body. Each of the plurality of active sway bars is associated with one of a plurality of axles. Providing the offset torque is based upon a number of moles of air in each of the plurality of air spring devices and reducing the longitudinal roll.

Abstract: A real-time control system for a vehicle, and a method of executing control of the vehicle via the real-time control system includes at least one primary controller that is configured to control slave controllers. The primary controller is configured to queue a task requested by respective vehicle systems, and determine which of the slave controllers is available to execute the task. The primary controller is configured to assign the task to a selected one of the slave controllers to execute the task. The primary controller is configured to re-queue the assigned task if the selected one of the slave controllers does not completely execute the assigned task. The primary controller is configured to assign that re-queued task to another one of the slave controllers to execute the re-queued task. The respective vehicle systems perform the requested task when the selected one of the slave controllers completely executes the assigned task.

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 structural arrangement for a vehicle includes a vehicle frame including an upper front rail, a frame rail, and a front hinge pillar, the frame rail extending parallel to a vehicle body axis and the front hinge pillar extending perpendicular to the vehicle body axis, the frame rail including a pulley, a load deflection system including a load member coupled to the upper front rail at a first attachment point, coupled to the frame rail at a detachable attachment point, and coupled to the front hinge pillar at a non-detachable attachment point such that the cable member extends generally longitudinally along the frame rail. The load member passes around the pulley from the first attachment point to the detachable attachment point and defines a load path between the upper front rail and the front hinge pillar utilizing the strength the frame rail.

Abstract: System and method for controlling operation of a vehicle in real-time with a supervisory control module. A fault detection module is configured to receive respective sensor data from one or more sensors in communication with the vehicle and generate fault data. The supervisory control module includes at least one fault-tolerant controller configured to respond to a plurality of faults. The supervisory control module is configured to receive the fault data. When at least one fault is detected from the plurality of faults, the supervisory control module is configured to employ the fault-tolerant controller to generate at least one selected command. The selected command is transmitted to one or more device controllers for delivery to at least one of the respective components of the vehicle. Operation of the vehicle is controlled based in part on the selected command.

Abstract: A control system includes a knock sensor and a controller. The knock sensor is configured to generate a notification signal by sensing a plurality of engine cylinder events in an engine. The controller is electrically coupled to the knock sensor and configured to detect a plurality of stochastic pre-ignition events in response to the plurality of engine cylinder events, calculate a real-time rate of the plurality of stochastic pre-ignition events, calculate a ratio of the real-time rate to an allowable rate of the engine, and adjust a current allowable torque of the engine in response to the ratio and a rotational speed of the engine.

Abstract: A system and method for managing thermal energy of a vehicle having a battery and an electric propulsion system are provided. The system monitors a current battery temperature, calculates an actual average battery temperature, and compares the calculated actual average battery temperature to a target lifetime battery temperature. If the actual average battery temperature is greater than the target lifetime battery temperature, and the current battery temperature is greater than the target lifetime battery temperature, the system cools the battery to below the current battery temperature. However, if the actual average battery temperature is less than the target lifetime battery temperature, and the current battery temperature is greater than the target lifetime battery temperature, the system delays cooling the battery. Therefore, the system may avoid expending energy to cool the battery in certain conditions.

Abstract: An automotive vehicle includes a body having a passenger compartment and a pedal assembly disposed within the passenger compartment. The pedal assembly includes a brake pedal emulator housing and at least one pedal interface coupled to the housing. The vehicle also includes an actuator operably coupled to the brake pedal emulator housing. The actuator is configured to selectively move the housing and the pedal interface between a first position and a second position with respect to the passenger compartment. The vehicle further includes at least one controller in communication with the actuator. The controller is configured to, in response to satisfaction of a first operating condition, control the actuator to move the housing and the pedal interface to the first position, and, in response to satisfaction of a second operating condition, control the actuator to move the housing and the pedal interface to the second position.