Abstract: A fuel cell system includes a fuel cell generator, a rechargeable energy storage circuit, an auxiliary load, a converter circuit, and a switch circuit. The fuel cell generator is operable to generate electrical power in a stack output signal. The auxiliary load is powered by the rechargeable energy storage circuit while in a first mode, and powered by a local signal while in a second mode. The converter circuit is operable to convert the stack output signal into a plurality of recharge signals while in the first mode and in the second mode, and convert the stack output signal into the local signal while in the second mode. The switch circuit is operable switch the plurality of recharge signals to one or more electric vehicles, and switch the local signal to the auxiliary load while in the second mode.

Abstract: Presented are electric machines with optimized stator tooth geometries and multi-gauge stator conductors, methods for making/using such electric machines, and motor vehicles equipped with such electric machines. An electric machine includes a housing, a rotor assembly rotatably attached to the housing, and a stator assembly coaxial with and separated by an airgap from the rotor assembly. The rotor assembly includes one or more magnets mounted to a rotor core. The stator assembly includes a stator core with multiple axially elongated, circumferentially spaced stator slots, multiple radially aligned stator teeth interleaved between and separating the slots, and multiple electromagnetic windings wound through the slots. Each stator tooth has an elongated tooth body with a tooth head at a radial end of a tooth root, which attaches to a cylindrical hub of the stator core. The tooth head has an axial cross-section with a trapezoidal crown integral with a rectangular tip.

Abstract: An example method includes receiving a wakeup request from a device from a vehicle. The wakeup request indicates that the device desires to perform a task that consumes electrical power from a battery of the vehicle. The method further includes assigning a priority to the wakeup request. The method further includes queuing the wakeup request according to a wakeup schedule. The method further includes, responsive to a current time satisfying the wakeup schedule, performing the task based at least in part on the priority.

Abstract: A method for controlling transient operation of a variable flux machine (VFM) includes, during a shunt angle transition, receiving a commanded and measured shunt angle when operating in a predetermined operating region, e.g., maximum torque per ampere or field weakening. The method includes calculating d-axis and q-axis delta current terms (?Id and ?Iq) required to maintain an output torque level of the VFM through a duration of the shunt angle transition, then applying the required ?Id and ?Id terms as feed-forward terms to adjust a d-axis current (Id) term and a q-axis current (Iq) term from a respective lookup table. In this manner the controller maintains the output torque level of the VFM during the shunt angle transition. An electric powertrain includes the VFM, a TPIM, and the controller. A PM machine may be controlled by substituting temperature for shunt angle.

Abstract: An emblem installation system for installing emblems on a work piece includes an end effector for a robotic arm. The end effector has a base and multiple vacuum gripper modules repositionable along the base in different configurations. The vacuum gripper modules are configured to simultaneously grip multiple emblems and individually release the emblems. An emblem installation method includes applying a force within a first range of forces to the multiple emblems individually and in succession via vacuum gripper modules of an end effector on a robotic arm, with the emblems disposed at a first location, applying a vacuum to the vacuum gripper modules to grip the emblems with the vacuum gripper modules, and moving the robotic arm from the first location to a second location adjacent a workpiece with the emblems gripped by the vacuum gripper modules.

Abstract: A method to manage thermal propagation in an energy storage device of a battery electric vehicle is provided. The method includes operating the battery electric vehicle with a plurality of distinct battery cell module groups each separately providing electrical power to the battery electric vehicle. The method further includes, within a computerized battery cell module groups controller, monitoring conditions within the distinct battery cell module groups, determining occurrence of an abnormal event within one of a plurality of the distinct battery cell module groups based upon the monitored conditions, and controlling operation of the battery electric vehicle based upon the determined occurrence of the abnormal event.

Abstract: Presented are multilayer composite panels for motor vehicles, methods for making/using such panels, and motor vehicles with transparent composite roof panels having localized reinforcement features. A sandwich-type multilayer composite panel contains one or more exterior layers each including a transparent rigid material, one or more bonding layers each including a transparent adhesive material, and one or more structural reinforcement layers each including a fiber-reinforced polymer material. Each structural reinforcement layer may be attached directly to a bonding layer and/or exterior layer. The composite panel may also include one or more IR-reflective layers, one or more light-absorbing sunshade layers, and one or more insulating low-k layers.

Abstract: A multi-cell rechargeable energy storage system (RESS) includes a plurality of battery cells organized into battery modules and a first enclosure configured to house the battery modules. The RESS also includes a first vent arranged on the first enclosure and configured to direct air from inside the first enclosure to an environment external to the first enclosure. The RESS additionally includes a second vent arranged on the first enclosure and configured to direct air into the first enclosure from the environment external to the first enclosure. The RESS further includes a phase-change material (PCM) device arranged on the second vent and configured to melt in response to at least one of the battery modules experiencing a thermal runaway event. In combination with the first vent, the PCM generates crossflow ventilation through the first enclosure to cool the battery modules therein and mitigate thermal runaway.