Abstract: Presented are thermal management systems with passive quenching sacks for cooling battery assemblies, methods for making/using such systems, and vehicles equipped with such systems. A passive thermal management (PTM) system is presented for cooling a battery assembly, such as a traction battery pack with a battery case containing stacked battery cells. The PTM system includes a fluid container that mounts inside the battery assembly, interposed between the battery case and battery cells. The fluid container stows therein a dielectric coolant fluid and has multiple fluid ports that fluidly connect to the battery cells to dispense thereto the coolant fluid. Thermomechanical plugs, such as wax, film, or smart-material barriers, seal the fluid container ports and passively open (e.g., melt, bend, disintegrate, expand, etc.) at a predefined temperature to thereby unseal the fluid ports such that the coolant fluid is fed from the fluid container into the battery cells.

Abstract: A system for detection and reporting of data signal interference includes a plurality of vehicles. Each vehicle includes a global navigation satellite system (GNSS) receiver receiving a GNSS signal, a cellular modem configured for sending and receiving data over a wireless communication network, and a computerized detection and reporting controller. The controller includes programming to monitor the GNSS signal, analyze the GNSS signal to identify a presence of radio frequency (RF) interference, and generate a report of an RF interference event to a remote server device based upon the presence of the interference. The system further includes the server device including programming to monitor the report of the interference event from each of the vehicles, identify a threshold RF interference event based upon the report of the RF interference event from each of the plurality of vehicles, and command a remedial action based upon the threshold RF interference event.

Abstract: The concepts described herein provide a method, apparatus, and system for controlling an inverter by modifying duty cycles of the PWM control signals in a manner that achieves a minimum duration between consecutive switching events in the inverter, which serves to reduce common mode current in the bearing(s) of an attached rotary electric machine. To minimize the effect of additional current and voltage ripple into the system, the minimum switching duration is defined in relation to a modulation index and geometric location near the sector boundaries of the respective inverter voltage space vector diagram.

Abstract: A monitoring assembly for an electrochemical cell of a secondary lithium battery includes a porous sensory structure and a transducer. The porous sensory structure includes a sensory layer disposed on a major surface of a porous separator and a buffer layer disposed between the sensory layer and a facing surface of a negative electrode layer. The buffer layer electrically isolates the sensory layer from the facing surface of the negative electrode layer. The sensory layer includes an electrically conductive material and is configured to produce a response to an input signal or to a physical stimulus received within the electrochemical cell. The transducer is configured to process the response produced by the sensory layer to generate an output signal indicative of a diagnostic condition within the electrochemical cell.

Abstract: A battery system includes a multi-cell rechargeable energy storage system (RESS) and an electronic controller configured to process RESS cell data. The controller is programmed with a battery cell open circuit voltage (OCV) versus state of charge (SOC) data table used to calculate a peak OCV movement for a representative battery cell at predetermined capacity and maximum discharge/charge rate. The controller is configured to acquire voltage data for one of the cells during active RESS cycling. The controller is also configured to pass the acquired voltage data through a first-order lag filter algorithm to generate an overpredicted OCV for the subject cell. The controller is additionally configured to determine an overpredicted SOC value for the subject cell in the data table using an OCV value from the overpredicted OCV. Furthermore, the controller is configured to regulate the RESS using the determined overpredicted SOC value for the subject cell.

Abstract: A system for implementing a secure boot event includes a system on a chip (SoC). The SoC includes key hashes stored within one-time programmable memory. Each of the key hashes is configured for use with one of a plurality of candidate authentication key sets. The SoC further includes firmware stored within RAM. The firmware includes a secondary bootloader, a plurality of public keys, and corresponding signatures. The public keys and corresponding signatures are configured for use with one of the key sets. The SoC further includes a primary bootloader utilizing fuses stored within the programmable memory. The fuses activate a selected key hash based upon an ecosystem in which the system is to operate. The selected hash and a corresponding public key and signature define an active authentication key set. During the event, the primary bootloader utilizes the active authentication key set to authenticate a downloaded update to the firmware.

Abstract: A system comprises an engine, a torque converter connected to the engine, a transmission connected to the torque converter via an input shaft, a particulate filter connected to the engine, an engine control module connected to the engine, the transmission, and the particulate filter, the engine control module being configured to perform service regeneration operations to lock the input shaft to the transmission and elevate the engine speed to retard the spark in the engine and increase the temperature in the particulate filter.

Abstract: A method for manufacturing a battery cell having electrode foils protruding from a cell pouch includes positioning the cell pouch in a fixture such that distal end sections of the foils extend outward from the fixture. The method includes clamping the distal end sections in a curvilinear guide clamp to cause the distal end sections to taper into an electrode foil stack, and then translating the clamp a predetermined distance toward the fixture to displace the distal end sections by the predetermined distance. The method also includes trimming the distal end sections using a trim tool, positioning a sonotrode and an anvil adjacent opposite surfaces of the stack, and ultrasonically welding the stack to a conductive lead tab using the sonotrode to thereby form a welded joint within the battery cell. The sonotrode may be multi-sided with different knurl patterns for performing different welding processes.

Abstract: A system for managing communication between a vehicle and a broker module includes a telematics unit connected to the vehicle. The telematics unit is configured to carry out wireless data communications according to a publish-subscribe messaging protocol. A command unit is in communication with the telematics unit, the command unit having a processor and tangible, non-transitory memory on which instructions are recorded. The telematics unit is configured to establish a network connection with the broker module. The command unit is adapted to create a dynamic retry delay process for the network connection by varying a connection retry delay time based on a plurality of failure categories and an operation mode of the vehicle. The plurality of failure categories each corresponds to a respective failure in the network connection.

Abstract: A method for coordinating a discharge session in which direct current power is offloaded from a power supply, e.g., of an electric vehicle (EV), to a bidirectional offboard charging station includes, in response to connection of the power supply to the charging station via a charging cord set, exchanging charging data between the EV and charging station. This occurs over a low-voltage communication line, with charging data including power and current limits of the EV and charging station. In response to the limits being indicative of negative limits, with the negative limits representing a request for the discharge session, the method includes transmitting the EV power and current limits to the charging station to confirm the request. The discharge session is initiated in response to confirming the request through an exchange of a unique identifier indicating support for the discharge session.

Abstract: A hairpin conductor includes two wire segments each having respective first and second ends and a respective middle region. The segments are disposed in a side-by-side orientation such that their first ends are proximate each other and their second ends are proximate each other. The first ends are welded to each other and the second ends are welded to each other, or the middle regions are welded to each other, thereby providing a welded wire assembly, which is bent such that the two wire segments are bent equally to form the hairpin conductor. The hairpin conductor has a primary bend in the middle regions to form an apex thereat and first and second secondary bends in the two wire segments nearer to the apex than to the first and second ends to form respective first and second shoulders thereat. A method of forming the hairpin conductor is also presented.

Abstract: A method for adjusting state of charge (SOC) limits aboard a motor vehicle having a propulsion battery pack includes receiving a pre-drive information set via a host computer and identifying, from the pre-drive information set, a probability that the motor vehicle is about to embark on a road trip. The road trip is a drive event in which the motor vehicle will travel outside of a predetermined area. The method further includes expanding the SOC limits of the propulsion battery pack when the motor vehicle is about to embark on the road trip, such that a total SOC window of the propulsion battery pack is increased for a duration of the road trip.

Abstract: Presented are metal-coated, polymer-encapsulated power semiconductor modules, methods for making/using such power modules, and vehicles with traction power inverters containing such power modules. A power electronics assembly includes one or more power semiconductor modules packaged inside an assembly housing. Each power module includes a substrate, a semiconductor device mounted on the substrate, a polymeric encapsulant encasing therein the substrate and semiconductor device, and an electrical lead connected to the semiconductor device and projecting from the polymeric encapsulant. A metallic or ceramic coating is applied to select sections of the polymeric encapsulant's exposed exterior surface. The metallic/ceramic coating may be a single metallic layer that covers substantially all of the exposed surface area of the polymeric encapsulant's exterior surface. An optional hydrophobic polymer layer, passivated layer, and/or oxidized layer may cover the exterior surface of this metallic layer.

Abstract: A multi-directional viewing camera system for a motor vehicle including a vehicle body defining an interior compartment and a body panel having an exterior surface and an interior surface facing the interior compartment. The camera system includes a mirror module for mounting to the body panel exterior surface. The mirror module is configured to capture and transmit incident light from at least one field of view (FOV) and has a polarizing beam splitter configured to reflect an s-polarized component and transmit a p-polarized component of the incident light in a visible spectral range. The camera system also includes a camera module having a video camera for mounting to the body panel interior surface. The camera module is configured to receive from the mirror module the s-polarized or the p-polarized component of the incident light and selectively display at least one FOV within the interior compartment.

Abstract: A method and system for authenticating soft part updates to an electronic control unit (ECU) or other processing device is contemplated. The authenticating may include a back office providing authentication data to a programming tool whereupon the ECU interacts with the programming tool to authenticate the soft part updates. The authenticating may optionally include the ECU identifying whether the soft part update is to be authenticated according to different types of authentications.

Abstract: A method for controlling a motor vehicle having an electronic control unit (ECU), includes enabling an initial set of vehicle performance limits of the motor vehicle via the ECU in response to a request signal from a computer device. The method includes detecting a current vehicle state of the motor vehicle, including one or more of a location of the motor vehicle, an occupancy state of the motor vehicle, and/or an experience level of a driver thereof, and dynamically adjusting at least one of the performance limits in response to the current vehicle state. A motor vehicle includes one or more road wheels and vehicle components connected to a vehicle body. The ECU includes non-transitory memory on which is recorded instructions for performing the method.

Abstract: A motor stator includes a plurality of stacked annular stator laminates defining a stator core having an inner circumference, an outer circumference, a plurality of stator teeth on the inner circumference, and a plurality of ears extending outward from the outer circumference with a respective bolt hole defined in each ear. A first set of the stator laminates includes a plurality of coolant openings therethrough, wherein the coolant openings of adjacent stator laminates communicate with one another in order to define cooling channels inside the stator core. A second set of the stator laminates each include one or more generally radially extending first openings therethrough, wherein the first openings of adjacent stator laminates communicate with one another to define one or more first radial channel segments inside the stator core for providing radial coolant flow between one or more bolt holes and one or more cooling channels.

Abstract: A system for obtaining vehicle status data includes a location sensor configured to obtain location data for one or more connected devices in or around the vehicle. The vehicle has a plurality of seats, including at least one seat without an occupant sensor. The location data is obtained based at least partially on radiofrequency waves. A command unit is adapted to receive the location data. The command unit has a processor and tangible, non-transitory memory on which instructions are recorded. The command unit is adapted to obtain the vehicle status data in real time based in part on the location data of the one or more connected devices, the vehicle status data including a total number of occupants in the vehicle.

Abstract: Presented are control systems for operating dual-independent drive unit (DIDU) powertrains, methods for making/operating such systems, and electric-drive vehicles with fault management and mitigation for DIDU axles. A method of operating a motor vehicle with a DIDU axle includes monitoring first and second drive units (DU) that are independently operable to drive respective road wheels via respective axle shafts of the DIDU axle. A vehicle controller receives an indication of a fault condition in the first DU from a fault sensing module and responsively determines a fault type for the fault condition. The controller ascertains the vehicle's current speed and determines a respective torque limit for each of the DIDU drive units based on the fault type and current vehicle speed. Torque output of the first DU is concomitantly constrained to a first torque limit while torque output of the second DU is constrained to a second torque limit.

Abstract: A microLED lighting module is disclosed. The microLED lighting module includes a micromodule having one or more transparent polymer layers thereon. Additionally, the one or more transparent polymer lavers are configured to maintain a temperature of the microLED lighting module below approximately 220° C.