Abstract: A control system for a rotary electric machine includes an inverter including a plurality of power switches, a heat exchanger, first temperature sensors arranged to monitor the power switches, a second temperature sensor arranged to monitor the heat exchanger, and a controller. An expected power loss is determined based upon electric current, switching functions, and electrical characteristics of the power switches. A plurality of power capacity terms are determined based upon the expected power loss in the inverter, the temperatures of the power switches, and the temperature of the heat exchanger. The inverter is controlled based upon the aforementioned power capacities.

Abstract: A casting die includes a first ingate defining a first annular chamber and a second ingate defining a second annular chamber and spaced from the first ingate. The die includes a first end ring gate concentric with the first ingate and defining a first end ring chamber in fluid communication with the first annular chamber, and a second end ring gate concentric with the second ingate and defining a second end ring chamber in fluid communication with the second annular chamber. The die includes runners interconnecting the first and second end ring gates. Each of the runners defines a conductor bar channel in fluid communication with the first and second end ring chambers. The die includes an overflow gate disposed between the first and second ingates, wherein the overflow gate defines an annular overflow chamber in fluid communication with the conductor.

Abstract: An electronic pallet (e-pallet) includes a superstructure mounted to a wheeled base platform. A tether device defines an articulation angle with respect to a leading edge of the superstructure, and is grasped by an operator towing the e-pallet. A motor connected to driven road wheels transmits a drive torque to the road wheels responsive to motor control signals, including a desired yaw rate and ground speed. A speed sensor, angle sensor, and length sensor are respectively configured to determine an actual ground speed of the e-pallet, the articulation angle, and a length of the tether device. An electronic controller, in response to the input signals, generates the motor control signals using proportional-integral-derivative (PID) control logic. Coupled lateral and longitudinal dynamics control loops respectively determine the desired yaw rate and ground speed to accommodate for motion of the operator.

Abstract: A vehicle includes an electric motor and a battery operable to provide electrical power to the electric motor. The battery system includes a first battery pack and a second battery pack. The first battery pack has a relatively high power density, and the second battery pack has a relatively high energy density. An electronic controller determines a remaining driving range of the first battery pack, and a remaining driving range of the second battery pack. The vehicle has a human-machine interface (HMI) operatively connected to the electronic controller and configured to indicate the remaining driving range of the first battery pack and the remaining driving range of the second battery pack. The controller executes a method of monitoring the battery system.

Abstract: A method for dynamically matching energy demand of a population of electric vehicles (EVs) with energy supply of a population of charging stations within a geofenced perimeter includes receiving, via a cloud-based server, EV information from each respective EV, and receiving charging station information from each respective charging station. The method includes generating an SoC map and a charging station power map from the EV information and the charging station information, respectively, and predicting the energy supply and demand using the maps. The server dynamically matches the EVs to at least one of the charging stations or vice versa using a reward function, the predicted energy supply, and the predicted energy demand, including generating a rank-ordered listing for each of the EVs and/or each of the charging stations in a manner that maximizes an expected discounted future reward.

Abstract: A propulsion system for a device includes an electric motor configured to generate torque to propel the device. A controller is in communication with the electric motor and is adapted to select at least one harmonic order for a harmonic current command. The controller is adapted to define a plurality of operating regions, including a first operating region, a second operating region and a third operating region, each associated with a respective objective function for generating the harmonic current command. The controller is adapted to operate the harmonic current command with four degrees of freedom by selectively varying a q-axis current magnitude, a d-axis current magnitude, a q-axis phase and a d-axis phase as a function of the torque and a motor speed.

Abstract: A process for local traffic approximation through analysis of cloud data is provided. The process includes, within a computerized traffic flow estimation controller of a host vehicle, operating programming to monitor a planned navigational route of the host vehicle, identify along the planned navigational route a road section including cross-traffic, monitor cloud data related to a mobile cellular device, analyze the cloud data to identify traffic posing a hazardous condition to the host vehicle within the road section, and generate a vehicle alert to a driver of the host vehicle based upon the identified traffic.

Abstract: A system of controlling operation of a vehicle includes one or more sensors operatively connected to the vehicle. The sensors are configured to obtain respective data of a scene and include a radar unit. A command unit is adapted to receive the respective data and includes a processor and tangible, non-transitory memory on which instructions are recorded. The command unit is configured to determine an orientation angle of a pedestrian in the scene, a Doppler frequency of the pedestrian and a distance of the pedestrian from a border of a road, based in part on the respective data. The orientation angle is based on a heading of the pedestrian relative to a direction of a road. The command unit is configured to designate a status of the pedestrian as either crossing or not crossing based on the distance, the orientation angle and the Doppler frequency of the pedestrian.

Abstract: A system for authenticating communications from a vehicle to a remote assistance unit includes a connectivity module (CM) installed in the vehicle. A security device is adapted to transmit messages when the security device is within a predefined proximity of the CM. A security cloud unit is configured to validate the security device based in part on a first pair of complementary keys, including a first factory key stored by the security device and a second factory key stored by the security cloud unit. The first pair of complementary keys is configured for asymmetric encryption such that the first factory key is solely decryptable with the second factory key. The remote assistance unit is configured to authenticate an integrity of the CM based in part on a second pair of complementary keys which are dynamically generated by the security cloud unit.

Abstract: A method and a system for a high-voltage (HV) battery pack having multiple rechargeable energy storage devices (RESSs) that are connectable to an external load via a power bus via a pre-charge circuit in parallel with a first electrical contactor. The RESSs are monitored via current sensors. The current sensors monitor current levels between the RESSs and the power bus, detect a low current level from one of the current sensors, identify one of the RESSs associated with the low current level, activate the respective pre-charge circuit, monitor the electrical current, and determine a state of the respective first electrical contactor based upon the electrical current.

Abstract: Presented are torque converters (TC) with hydraulic systems for converter feed and clutch control, methods for making/operating such TC assemblies, and vehicles equipped with such TC assemblies. A TC assembly includes a housing that drivingly connects to an electric motor, and an output member that drivingly connects to a multi-gear transmission. Rotatable within the TC housing are a turbine attached to the TC output member and an impeller juxtaposed with the turbine. A lockup clutch disposed inside the TC housing, between the turbine and housing, is operable to lock the housing to the output member. A disconnect clutch disposed inside the housing, between the impeller and housing, is operable to lock the housing to the impeller. A pump is attached to the TC housing and drivingly connected to the motor for feeding fluid into the housing to increase pressure within the TC chamber and activate the lockup and disconnect clutches.

Abstract: Presented are lithium-metal electrodes for electrochemical devices, systems and methods for manufacturing lithium-metal foils, and vehicle battery packs containing battery cells with lithium-metal anodes. A method of melt spinning lithium-metal foils includes melting lithium (Li) metal stock in an actively heated vessel to form molten Li metal. Using pressurized gas, the molten Li metal is ejected through a slotted nozzle at the base of the vessel. The ejected molten Li metal is directly impinged onto an actively cooled and spinning quench wheel or a carrier sheet that is fed across a support roller underneath the vessel. The molten Li metal is cooled and solidified on the spinning wheel/carrier sheet to form a Li-metal foil. The carrier sheet may be a polymeric carrier film or a copper current collector foil. An optional protective film may be applied onto an exposed surface of the Li-metal foil opposite the carrier sheet.

Abstract: A system for on-vehicle camera alignment monitoring includes an on-vehicle camera in communication with a controller. The controller monitors vehicle operating parameters and camera signal parameters, and captures an image file from the on-vehicle camera. A first level analysis of the image file, the vehicle operating parameters, and the camera signal parameters is executed to detect dynamic conditions and image feature parameters that affect camera alignment. An error with one of the dynamic conditions or the image feature parameters that affects the camera alignment is detected. A second level analysis of the camera signal parameters is executed to identify a root cause indicating one of the dynamic conditions or the image feature parameters that affects the camera alignment based upon the error. A camera alignment-related fault is detected based upon the root cause, and vehicle operation is controlled based upon the camera alignment-related fault.

Abstract: A system for multi-mode connectivity for group vehicle activity and for over-the-air updates via time synchronized device-to-device side-link communications is provided. The system includes a remote communication device configured to transmit data, vehicles to receive the data, and a computerized controller. The controller includes programming to analyze hardware of the vehicles to identify alpha vehicles including excellent wireless capabilities, monitor signal strength between the vehicles and the remote communication device to identify vehicles including relatively strong communication strength, and determine a portion of the plurality of vehicles including highly functioning vehicles including the capabilities and communication strength. The controller generates a series of data transfers to first transfer the data from the remote communication device a highly functioning vehicle and subsequently transfer the data from the highly functioning vehicle to a second of the vehicles and transfers the data.

Abstract: Presented are intelligent vehicle systems for thermal event mitigation during vehicle towing, methods for making/using such systems, and vehicles equipped with such intelligent control systems. A method of operating a host vehicle includes a resident or remote vehicle controller verifying the host vehicle is an incapacitated state. Responsive to the incapacitation of the host vehicle, the controller detects the host vehicle being towed by a tow vehicle and identifies a wireless-enabled portable computing device (PCD) within a predefined range of the host vehicle. Responsive to the host vehicle being towed, the controller determines if the wireless-enabled PCD is on the tow vehicle while towing the host vehicle. Upon detection of a thermal event in at least one battery cell in the host vehicle's battery system while the host vehicle is being towed, the controller responsively commands a resident vehicle subsystem to execute a control operation to mitigate the thermal event.

Abstract: A system for transmitting an audio signal in a vehicle includes a stabilizer located at a source position in the vehicle. At least one speaker is operatively connected to the stabilizer. The speaker is adapted to transmit an audio signal to a target position for at least partially supporting a spatial audio representation. The target position and the source position are independently movable. The stabilizer is adapted to direct the audio signal such that a trajectory between the target position and the source position is maintained regardless of respective motion of the target position and the source position. The trajectory includes a first segment between the source position and a deflecting surface and a second segment between the deflecting surface and the target position.

Abstract: A press-in-place reinforced seal for an interface between adjacent components, includes a cylindrical structure arranged along a longitudinal axis and characterized by a stepped-shape in a cross-sectional view. The seal is pressed into a first component and compressed by a second component when the seal is installed within the interface. The stepped-shape includes a compliant first section having a first width along the longitudinal axis and a first length orthogonal to the longitudinal axis. The first section is compressed by the second component and generates sealing pressure between the first and second components when the seal is installed. The stepped-shape also includes a rigid second section affixed to the first section along the first length for stabilizing the seal structure. The second section has a second width along the longitudinal axis and a second length orthogonal to the longitudinal axis and greater than the first length.

Abstract: A battery module includes a first pouch battery cell and a neighboring second pouch battery cell. The battery module also includes a dielectric fluid in direct contact with and in circulation over and around each of the first and second pouch cells. The battery module additionally includes an immersion barrier positioned between the first and second pouch cells and defining an opening for controlling passage of the dielectric fluid between the first and the second pouch cells. The barrier thereby facilitates localization of a thermal runaway event in the first pouch cell by minimizing transfer of high temperature gases between the first and the second pouch cells via the dielectric fluid and controls propagation of the thermal runaway event in the module. The battery module further includes an enclosure housing and retaining each of the first and second pouch cells, the dielectric fluid, and the immersion barrier.

Abstract: A vehicle control system including a spatial monitoring system includes on-vehicle cameras that capture images, from which are recovered a plurality of three-dimensional points. A left ground plane normal vector is determined for a left image, a center ground plane normal vector is determined for a front image, and a right ground plane normal vector is determined for a right image. A first angle difference between the left ground plane normal vector and the center ground plane normal vector is determined, and a second angle difference between the right ground plane normal vector and the center ground plane normal vector is determined. An uneven ground surface is determined based upon one of the first angle difference or the second angle difference, and an alignment compensation factor for the left camera or the right camera is determined. A bird's eye view image is determined based upon the alignment compensation factor.

Abstract: A method of assisting deceleration during a stop of a motor vehicle having a drivetrain including a traction motor, a road wheel operatively connected to the drivetrain, a friction brake configured to decelerate the road wheel, and an electronic controller includes detecting, via the electronic controller, a request to stop the vehicle. The method also includes commanding the traction motor to provide regenerative braking in response to the request to stop the vehicle. The method additionally includes determining a current vehicle operating state. The method also includes determining an amount of brake drag torque to be generated by the friction brake based on the current vehicle operating state. The method further includes commanding an application of the determined amount of the brake drag torque in parallel with the regenerative braking, thereby operating the friction brake as a mechanical drivetrain damper while assisting the regenerative braking to stop the motor vehicle.