Abstract: A light bar for an exterior lighting assembly of an automotive vehicle includes a body portion and an ornamental element. The body portion is made of a substantially transparent material and has a generally slab-like shape with an average height H in a z-direction, an average width W in a y-direction and an average thickness T in an x-direction, wherein the x-, y- and z-directions are mutually orthogonal and H>W>T. The ornamental element is disposed within the body portion and has an outer surface, wherein at least a portion of the outer surface contains a light-scattering material.

Abstract: Methods of controlling axle torque distribution of a vehicle during steering through a curve include collecting, via a controller: input data which is representative of a plurality of vehicle inputs; vehicle data which is representative of axle torque of the front axle and axle torque of the rear axle; and constraint data which is representative of real-time constraints of the vehicle. The collected input data, vehicle data and constraint data are communicated to a predictive model. Determining, using the predictive model, whether torque adjustments are necessary. The distribution of the axle torque of the front axle and the axle torque of the rear axle is controlled, via the controller, when the torque adjustments are necessary as determined via the predictive model.

Abstract: A method of manufacturing an interconnect board (ICB) assembly for a battery module, the ICB assembly having a printed circuit board assembly (PCBA) and a carrier frame, includes depositing solder paste onto a printed circuit board (PCB) and/or a flexible printed circuit (flex circuit). The flex circuit has a conductive foil substrate coated with insulating material, and defines tabular flying leads radially-projecting from the flex circuit's periphery. The method may include positioning the PCB adjacent to the flex circuit such that the PCB and flex circuit are in direct contact along a flex interface surface of the PCB, and integrally joining the PCB and flex circuit along the interface surface to form the PCBA. The PCBA connects to the carrier frame to construct the ICB assembly. The battery module may be manufactured by connecting the ICB assembly to battery cells of the battery module.

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.

Abstract: A method and system for controlling and regulating operation of a multi-phase rotary electric machine in a manner that minimizes power loss under partial load conditions is described. This includes an instruction set that is executable to determine a torque command and a rotational speed of the electric machine, determine a peak torque per loss parameter for the electric machine based upon the rotational speed, and determine a second torque parameter for the electric machine based upon the rotational speed. A modulated torque command for controlling the electric machine is determined based upon the peak torque per loss parameter and the second torque parameter, wherein the electric machine generates an average torque that is equivalent to the torque command when operating in response to the modulated torque command. The inverter is controlled to operate the electric machine based upon the modulated torque command.

Abstract: A machine bearing disposed on a rotatable member, such as may be present on a vehicle, is described. A method for monitoring a state of health of the machine bearing includes monitoring, via a microphone, an acoustic signal, and coincidently determining a rotational speed of the rotatable member associated with the machine bearing. The sound spectrum is correlated to the rotational speed of the rotating member, and a time-frequency analysis is executed to determine a sound spectrum. The sound spectrum is transformed to a residual spectrum. A first feature associated with a first frequency band and a second feature associated with a second frequency band are extracted from the residual spectrum. The state of health associated with the machine bearing is detected based upon the first and second features, and is communicated to a second controller.

Abstract: A cruise control method includes: receiving, by a controller of the vehicle, a set speed, a maximum allowed speed, and a minimum allowed speed, wherein each of the maximum allowed speed and the minimum allowed speed is a speed boundary of an allowed speed range; commanding, by the controller, a propulsion system to produce a commanded axle torque to maintain the set speed; monitoring a current speed of the vehicle; monitoring an elevation of a terrain at predetermined-upcoming locations of the vehicle based on upcoming elevation data from a map database; generating an elevation look-ahead table using the elevation of the terrain at the predetermined-upcoming locations of the vehicle; and determining projected speeds of the vehicle at each of the predetermined-upcoming locations of the vehicle as a function of the current speed of the vehicle and the elevation of the terrain at the predetermined-upcoming locations.

Abstract: Methods and devices for providing an even distribution of waste heat in a vehicular battery pack, including a battery pack, a cold plate, a coolant reservoir, a support structure between the battery pack and the coolant reservoir, and a conformable thermal interface material for filling the space between cells of the battery pack and the coolant reservoir so as to provide thermal contact between the cells and the coolant reservoir for distributing the waste heat. In addition, methods and devices for providing an even distribution of waste heat and structural support in any heat source to heat sink for applications such as small devices such as computer motors.

Abstract: Automated driving systems, control logic, and methods execute maneuver criticality analysis to provide intelligent vehicle operation in transient driving conditions. A method for controlling an automated driving operation includes a vehicle controller receiving path plan data with location, destination, and predicted path data for a vehicle. From the received path plan data, the controller predicts an upcoming maneuver for driving the vehicle between start and goal lane segments. The vehicle controller determines a predicted route with lane segments connecting the start and goal lane segments, and segment maneuvers for moving the vehicle between the start, goal, and route lane segments. A cost value is calculated for each segment maneuver; the controller determines if a cost values exceeds a corresponding criticality value. If so, the controller commands a resident vehicle subsystem to execute a control operation associated with taking the predicted route.

Abstract: An exemplary impact beam for a vehicle includes a body defining a longitudinal axis of the impact beam. The body has a first longitudinal surface laterally separated from a second longitudinal surface, a first end including a first extension and a second extension such that the first and second extensions form a “T”-shape with the first and second longitudinal surfaces of the body, and a second end opposite the first end, the second end including a first extended portion and a second extended portion connected to the first extended portion by a connecting surface. The first extended portion is configured to extend into a first crush space defined by a fascia of the vehicle and the second extended portion is configured to extend into a second crush space defined by the fascia of the vehicle.

Abstract: System and method of controlling operation of a device having multiple rechargeable packs configured to store energy. The multiple rechargeable packs include at least one primary pack characterized by a first capacity and at least one auxiliary pack characterized by a second capacity, the first capacity being greater than the second capacity. A controller is configured to selectively command one or more of the multiple rechargeable packs to begin at least one of discharging and charging. When an estimated end of trip time is less than or equal to a discharging time of the at least one auxiliary pack, the discharging of the at least one auxiliary pack is begun. When the estimated end of trip time is greater than the discharging time, the discharging is delayed until the respective state of charge of the at least one primary pack reaches a first threshold.

Abstract: An exemplary method for determining a remaining life expectancy of a brake component includes the steps of providing vehicle parameters that identify operating conditions of a vehicle, using the vehicle parameters to determine work done by a brake of the vehicle as brake work, using the brake work to determine brake rotor temperature, using the brake rotor temperature to determine a fatigue damage of the brake component, accumulating the fatigue damage to determine a cumulative fatigue damage of the brake component, and comparing the cumulative fatigue damage to a damage limit to provide an estimation of the remaining life expectancy of the brake component.

Abstract: A retention socket is configured to hold a non-ferrous metallic fastener and includes a socket body defining a cavity shaped to receive a head of the non-ferrous metallic fastener. The retention socket further includes a mechanical retaining feature coupled to the socket body to removably couple the non-ferrous metallic fastener to the socket body without the aid of magnetic forces.

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 method for estimation of a vehicle tire force includes: receiving, by a controller of a vehicle, a measured vehicle acceleration of the vehicle; receiving, by the controller, a measured wheel speed and a measured yaw rate of the vehicle; forming, by the controller, inertia matrices based on an inertia of rotating components of the vehicle; calculating torques at corners of the vehicle using the inertia matrices; estimating tire forces of the vehicle based on the measured vehicle acceleration, the measured wheel speed, and the inertia matrices; and controlling, by the controller, the vehicle, based on the plurality of estimated longitudinal and lateral tire forces.

Abstract: An automotive vehicle includes a body having a passenger compartment, an anchorage system for securing a child restraint disposed in the passenger compartment, the anchorage system including a latchable bar member, a child restraint installation system coupled to the anchorage system, the child restraint installation system including a trigger member, a sensor contact member, a compression member, a retaining member, and a sensor, and at least one controller in communication with the sensor, the at least one controller being configured to, in response to satisfaction of a first operating condition, generate a first notification signal and, in response to satisfaction of a second operating condition, generate a second notification signal.

Abstract: Pressure vessels having a grooved liner and methods of forming the same are described. The pressure vessel includes a liner surrounding a cavity therein, an outer surface of the liner disposed opposite the cavity, a boss disposed at a first end of the liner, a composite layer surrounding the liner, an inner surface of the composite layer disposed proximate the liner, and a plurality of longitudinal grooves configured to release gas present between the inner surface of the composite layer and the outer surface of the liner. The liner defines a longitudinal axis therethrough. The boss and the outer surface of the liner define the plurality of longitudinal grooves therein. The plurality of longitudinal grooves extends along the longitudinal axis from the boss toward a second end of the liner. The composite layer spans each of the plurality of longitudinal grooves.

Abstract: An inflatable blanket for a vehicle includes a first blanket layer, a second blanket layer coupled to the first blanket layer, and an airbag disposed between the first blanket layer and the second blanket layer. The airbag has a deflated configuration and an inflated configuration to protect a vehicle occupant when the vehicle is subjected to an external force.

Abstract: A torsional damper assembly includes a hub having an outer periphery, an annular elastomeric element disposed about the outer periphery, and an annular inertia ring disposed about the elastomeric element. The inertia ring has an inner periphery adjacent the elastomeric element. The outer periphery of the hub is provided with a first plurality of surface features and the inner periphery of the inertia ring is provided with a second plurality of surface features. The first plurality of surface features is complementary to and engaged with the second plurality of surface features.

Abstract: A torque transmission device (100) includes a variator of a continuously variable unit (CVU) (20) arranged in parallel with a layshaft gearset (30). The CVU (20) includes a first pulley (22) rotatably coupled to a second pulley (24), and the layshaft gearset (30) includes a first gear element (32) meshingly engaged with an intermediate gear element (34) meshingly engaged with a second gear element (36). A transmission input member (12) is rotatably coupled to the first pulley (22) of the CVU (20), and is selectively rotatably coupled to the first gear element (32) of the layshaft gearset (30) by activation of a first clutch (37). A transmission output member (14) is rotatably coupled to the second pulley (24) of the CVU (20) and rotatably coupled to the second gear element (36) of the layshaft gearset (30). The transmission is disposed to operate in a continuously variable mode when the first clutch (37) is disengaged, and to operate in a fixed gear mode when the first clutch (37) is engaged.