Abstract: Systems and methods of making a cast steel alloy crankshaft for an internal combustion engine are provided. The method comprises providing a mold of the crankshaft. The mold has cavities to form the crankshaft. The method further comprises melting a first metallic material at between 1400 degrees Celsius (° C.) and 1600° C. to define a molten metallic material. In addition, the method further comprises feeding the molten metallic material at a riser connection angle of between 30° and 75° in the cavities of the negative sand cast mold. The method further comprises cooling the molten metallic material at a solidification time of between 5 seconds (sec) and 20 sec in the negative sand cast mold with at least one chill member to define a solidified metallic material having dimensions of the cast steel alloy crankshaft. Furthermore, the method comprises separating the solidified metallic material from the negative sand cast mold to define the cast steel alloy crankshaft.

Abstract: A vehicular communication controller includes a microcontroller (MCU) located within a vehicle to publish a newly defined protocol data unit (PDU) including a header and a payload portion to a destination device. The destination device may utilize a first protocol or a second protocol. If the destination device utilizes the first protocol that includes an automotive/embedded communication protocol then the MCU serializes the payload portion of the PDU and binds the PDU to the first protocol. The destination device may then receive the PDU using the first protocol, deserialize the payload portion, and remove the header leaving the payload portion unchanged and recreate, based on the deserialized payload portion, the PDU.

Abstract: A protective cover for a camera includes a housing configured for attachment to one of the camera and a support structure which supports the camera, a lens attached to the housing and configured for alignment with an imaging axis of the camera, a light source attached to the housing and configured for providing light to a field of view of the camera, and an electrical connector carried by the housing and configured for receiving power and/or signal commands and for conveying the power and/or signal commands to the light source. The lens may be a meniscus-shaped macro lens, and a lightguide may be attached to or incorporated into at least one of the housing and the light source. The protective cover may be used to protect a camera mounted in a wheel well or anywhere along an outer surface of an automotive vehicle.

Abstract: An electrical contactor module includes a pair of contactor assemblies each having an input contact, an output contact spaced apart from the input contact, and a linear solenoid disposed proximate the input and output contacts. Each linear solenoid has a housing, a plunger disposed within the housing so as to permit axial displacement of the plunger between an open position in which an end of the plunger is spaced apart from the input and output contacts and a closed position in which the end mechanically contacts and electrically couples the input and output contacts, a spring for biasing the plunger in the open position, and a coil within the housing for urging the plunger from the open position to the closed position along a linear direction. The contactor assemblies are fastened and arranged within an enclosure, with the linear directions for the contactor assemblies pointing in generally opposite directions.

Abstract: A battery system includes a rechargeable energy storage system (RESS) having battery cells, and a battery controller network configured to execute two-level logic to detect a thermal runaway condition. The network includes RESS-embedded cell monitoring units (CMUs) electrically connected to a respective cell group, and measuring and wirelessly transmitting cell data. A battery control module (BCM) is in communication with the CMUs. Thermal runaway sensors are mounted on the CMUs and/or the BCM. A master controller connected to the BCM includes a thermal runaway detection algorithm configured to detect a thermal runaway condition occurring within the RESS. The BCM uses data from the CMUs and thermal runaway sensors to execute first logic level which determines when to wake up the master controller. The master controller, in response to receipt of a wakeup signal, executes a second logic level to execute the algorithm.

Abstract: Presented are intelligent charging systems for transferring energy to and from motor vehicles, methods for making/operating such systems, and vehicles with V2V and V2G energy transfer capabilities. A method for operating an intelligent charging system includes a system controller receiving, from a user interface of a user, a request to schedule a transfer of electricity to the user. The system controller broadcasts to a crowdsourced set of service providers a solicitation for energy transfer bids for completing the user's transfer request. After receiving multiple bid submissions for completing the transfer request from multiple service providers, the system controller selects an optimized one of the bid submissions using a multi-criteria selection strategy. The multi-criteria selection strategy includes a joint utility maximization function and/or a trade-off Pareto solution.

Abstract: An anode-free solid-state battery includes a cathode layer having transient anode elements and a bare current collector devoid of non-transitory anode material and configured to accept thereon the transient anode elements. The battery also includes a solid-state electrolyte layer defining voids and arranged between the current collector and the cathode layer. The battery additionally includes a gel situated within the solid-state electrolyte and cathode layers, to permeate the electrolyte voids and form a gelled solid-state electrolyte layer, coat the cathode layer, and facilitate ionic conduction of the anode elements between the cathode layer, the solid-state electrolyte layer, and the current collector. Charging the battery diffuses the anode elements from the cathode layer, via the gelled solid-state electrolyte layer, onto the current collector. Discharging the battery returns the anode elements, via the gelled solid-state electrolyte layer, to the cathode layer.

Abstract: A method of controlling a vehicle includes determining a first projected path of the vehicle, receiving sensor data corresponding to a steering input, determining a first blended vehicle path resulting from a first blended steering command based on the first projected path and the sensor data, and determining when the first blended vehicle path satisfies a first criteria. When the controller determines that the first blended vehicle path satisfies the first criteria, the controller relinquishes control of the vehicle to an operator and when the controller determines that the first blended vehicle path does not satisfy the first criteria, the controller generates a second blended vehicle path resulting from a second blended steering command based on the first projected path and the sensor data.

Abstract: A system and method for processing an audio input signal includes a microphone, a controller, and a communication link that may be coupled to a remote speaker. The microphone captures the audio input signal and communicates the audio input signal to the controller, and the controller is coupled to the communication link. The controller includes executable code to generate, via a linear noise reduction filtering algorithm, a first resultant based upon the audio input signal, and generate, via non-linear post filtering algorithm, a second resultant based upon the first resultant. An audio output signal is generated based upon the second resultant employing a feature restoration algorithm. The audio output signal is communicated, via the communication link, to a speaker that may be at a remote location.

Abstract: A system for a power take-off mechanism for a powertrain system is provided. The system includes an electrically powered torque generating device including a torque generating device output shaft and a transmission output shaft receiving mechanical power from the torque generating device output shaft. The system further includes a clutch selectively disengaging the transmission output shaft from the torque generating device output shaft and a power take-off module receiving mechanical power from the torque generating device.

Abstract: A vibration monitoring system includes a plurality of encoders and an analyzer. The encoders are configured to generate multiple pulse train signals for multiple wheels. Each encoder is coupled to a respective one of the multiple wheels and generates a single one of the pulse train signals. The analyzer is coupled to the encoders and is configured to generate multiple pulse per revolution signals and multiple angular velocity signals for the wheels in response to the pulse train signals. Each pulse per revolution signal conveys a single pulse per rotation of the respective wheel. The analyzer is further configured to generate an input phasor array representative of the pulse per revolution signals, generate a response phasor array in response to the angular velocity signals for the wheels, and generate a report that identifies at least one vibrating wheel in response to the input phasor array and the response phasor array.

Abstract: Presented are oleophobic surface treatments for electric machines, methods for making/using such electric machines, and vehicles employing traction motors having oleophobic treatments on select “non-target” surfaces. An electric machine includes a direct-cooling thermal management system that circulates a coolant fluid to the electric machine's outer housing. A stator assembly, which is attached to the housing, includes a stator core with one or more electromagnetic windings mounted to the stator core. A rotor assembly is rotatably mounted to the hosing adjacent the stator assembly. The rotor assembly includes a rotor core with one or more magnets mounted to the rotor core and spaced across an air gap from the winding(s). Select components of the outer housing, rotor assembly, and/or stator assembly have a target surface with an oleophobic surface treatment that reduces the non-target surface's wetted area and decreases the mass of coolant fluid contacting the non-target surface.