Abstract: A method for constructing a lamination for a rotary electric machine includes forming an annular lamination from a ferrous core material having a first relative magnetic permeability. The lamination defines through-openings, e.g., for permanent magnets or conductors. Peripheral bridges of the core material extend between the through-openings and an outer or inner diameter surface of the lamination. The method includes diffusing an alloy material having a second relative magnetic permeability into the bridges to form austenitic bridges, with the second relative magnetic permeability being less than the first relative magnetic permeability. A rotary electric machine includes a stator and rotor. A vehicle includes a rotary electric machine connected to the battery pack and to road wheels, and having a rotor and/or a stator constructed in accordance with the method.

Abstract: A planar power module includes a second substrate arranged parallel to a first substrate, with the substrates respectively having a dielectric layer interposed between two conductive layers, such that one of the conductive layers of each substrate together forms parallel external conductive surfaces of the power module. The power module includes direct current (DC) bus bars, alternating current (AC) bus bars, and semiconductor switching dies arranged between the substrates. The dies are electrically connected to the bus bars, with each respective die electrically connected to a conductive layers of the first or second substrates. A polymer molding material partially surrounds the substrates and the switching dies. An electric powertrain system includes an electric machine, a propulsion battery pack, and a traction power inverter module (TPIM) having the power module. The power module is a three-phase full-bridge inverter circuit. An electric powertrain and motor vehicle use the power module.

Abstract: A rechargeable energy storage includes a battery pack having a plurality of battery modules between a negative terminal and a positive terminal. A backup network is electrically connected between the negative terminal and the positive terminal. The backup network includes a first diode and a second diode. A bypass junction located between a first portion of the battery pack and a second portion of the battery pack. The bypass junction electrically connects the battery pack and the backup network. The backup network is configured such that current flow is directed along a first pathway when open circuit state occurs in the first portion of the battery pack, and the current flow is directed along a second pathway when the open circuit state occurs in the second portion of the battery pack. The backup network enables powering of a designated load and/or a designated function during the open circuit state.

Abstract: A door for an entryway includes an exterior-facing surface, an inner structure, and a latch mechanism. The latch mechanism is connected to the inner structure and configured to be fastened or released for controlling access to the entryway. The door also includes a key-cylinder accessible from the exterior-facing surface and configured to selectively lock and unlock the latch mechanism. The door additionally includes a pawl configured to be rotated by the key-cylinder about a pivot axis, connected to the latch mechanism, and defining a pass-through aperture distal from the pivot axis. The door also includes a shield defining a shield attachment aperture and connected to the inner structure. The door further includes a security fastener to fix the shield relative to the key-cylinder at the shield attachment aperture and extending through the pass-through aperture without impeding the pawl's rotation or contacting the pawl as the pawl operates the latch mechanism.

Abstract: A method for brand identification of an electric vehicle to a charging station includes connecting a plug of the charging station to a socket of the electric vehicle, receiving a control pilot signal at the socket from the charging station, terminating the control pilot signal in a variable resistance in the electric vehicle, and toggling the variable resistance in a vehicle pattern that transitions between two charging state resistances. The charging station detects the vehicle pattern and maps the vehicle pattern to a vehicle brand of the electric vehicle. The method includes receiving electrical current to recharge the electric vehicle at the socket.

Abstract: A test system for detecting impairment aboard a motor vehicle includes an electronic control unit (ECU) and sensors in communication therewith. The sensors are positioned within a vehicle interior, and include at least a touch screen and a microphone, and possibly an eye-tracking camera. In response to receiving a start request indicative of a requested start event of the motor vehicle, the ECU executes instructions to initiate a cognitive response test via the sensors. The ECU determines a test score of a driver during the test while the motor vehicle remains off, compares the test score to baseline scores to determine a passing or failing test result, and executes a control action aboard the motor vehicle in response to the passing or failing test result. The ECU may disable or immobilize the motor vehicle in response to the failing test result.

Abstract: Presented are metalworking systems for joining metallic workpieces, methods for forming and welding such workpieces, and lithium-ion battery pouch cells with anodized aluminum tabs joined via knurling and laser welding. A method for laser welding abutting sections of a workpiece or stackup of workpieces includes receiving, via a workpiece support frame, one or more metallic workpieces each with a surface having applied thereto a treatment layer. This treatment layer releases a gas during welding. A metalworking device forms a knurl pattern into the workpiece surface with the treatment layer. The knurl pattern includes a network of channels, such as one or more series of mutually parallel, rectilinear vent channels, designed to exhaust therethrough the gas released from a welded section of the treatment layer. A laser welding device thereafter welds a joint region of the surface(s) of the one or more metallic workpiece with the knurl pattern.

Abstract: Presented are metalworking systems for forming metallic workpieces, methods for making/operating such metalworking systems, and battery module cell tabs bent by a multistage cluster-and-bend press. A metalworking system includes a grouping tool and a contouring tool that both align adjacent a workpiece support structure, such as a base plate of a battery module housing buttressing a stack of battery pouch cells. The grouping tool, which may include a first reciprocating plunger or plunger head, presses together a stack of metallic workpieces to thereby form a workpiece set having a first bend profile and a first length. The contouring tool, which may include a second reciprocating plunger or a pair of plunger fingers mounted on the plunger head, is attached to the grouping tool and bends the workpiece set to a second bend profile, distinct from the first bend profile, and a second set length, shorter than the first set length.

Abstract: A battery system includes first and second battery packs connected to positive and negative DC voltage bus rails, a contactor switch connected between the battery packs, a solid-state switch in series with the contactor switch, and a controller. The controller determines characteristic values of the switches, including a respective temperature, voltage, and current value for each. The controller also detects a predetermined electrical fault condition of the contactor switch using the characteristic values, and executes a control action in response to the electrical fault condition. The control action includes opening the semi-conductor switch to thereby interrupt a flow of current between the first and second battery packs. A mobile platform includes road wheels connected to a body, a rotary electric machine configured to power the road wheels and thereby propel the mobile platform, and the battery pack, switches, and controller.

Abstract: A vehicle configured to execute one or more methods for detecting function of a charging receptacle during a charging cycle. The methods include supplying a charging current through the pins; monitoring a pin temperature of the pins during the charging current; and applying a first step function to the charging current. The methods may also include monitoring a first step change in the pin temperature during the first step function; comparing the first step change in the pin temperature to a first expected temperature change to create a first deviation; and comparing the first deviation to a predetermined threshold. If the first deviation exceeds the predetermined threshold, signaling a maintenance alert, and if the first deviation is less than the predetermined threshold, logging the first deviation.

Abstract: A cathode configured for use within a fuel cell system is provided. The cathode includes a cathode substrate. The cathode further includes a coating disposed upon the cathode substrate and including a fluorocarbon polymer additive configured for sintering at a temperature of less than 200° C. The fluorocarbon polymer additive may be mixed with a catalyst ink coating or may be applied separately as a topcoat layer.

Abstract: An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.

Abstract: An electric powertrain system includes an electric machine having a rotor and stator. The stator has multiple phase legs, each respective one of which includes a single phase lead connected to two or more parallel stator windings. The stator thus has multiple phase leads collectively conducting phase currents. A rotary output member is connected to the rotor and connectable to a load. A traction power inverter module (TPIM) is electrically connected to the phase legs. Current sensors collectively measure the phase currents. Each respective current sensor is connected to a different phase lead. A controller in communication with the current sensors and the TPIM, in response to a commanded current and the measured phase currents, detects a threshold variation in the measured phase currents indicative of a phase current imbalance fault, and selectively changes a thermodynamic state of the electrified powertrain in response to the fault.

Abstract: An apparatus including a light detection and ranging (LiDAR) antenna of an optical phased array includes a silicon-on-insulator substrate including a silicon wire waveguide embedded within the substrate and a grating layer disposed over the substrate. The grating layer includes a silicon nitride layer coating the silicon-on-insulator substrate and including a plurality of etchings formed in a direction perpendicular to a longitudinal axis of the optical phased array and a silicon oxynitride layer coating the silicon nitride layer and filling the etchings. The etchings are relatively thin in the direction of the longitudinal axis of the optical phased array at a first end of the optical antenna and are relatively thick in the direction of the longitudinal axis at a second end. The etchings gradually increase in thickness between the first end of the optical phased array and the second end of the optical antenna.

Abstract: The concepts described herein provide a method, system, and apparatus for joining, via welding, first and second members fabricated from an aluminum alloy including aluminum, zinc, and manganese, such as 7000-series aluminum alloys, and a resultant workpiece. A junction is formed by a first member being disposed contiguously to a second member. A welding machine generates a weld pool at the junction that includes liquified aluminum alloy. An ultrasonic transducer directs ultrasonic energy in proximity to the weld pool. In some embodiments, an electro-magnetic transducer directs electro-magnetic energy in proximity to the weld pool. The first member is fused to the second member at the junction upon solidification of the weld pool.

Abstract: A battery electric device includes a battery cell, e.g., a pouch, prismatic, or cylindrical cell, connectable to an electric load, and a direct-to-air thermoelectric assembly (TEA) or another heat pump connected to a surface of the cell. A pressure control device maintains constant pressure on the cell surface when the cell is connected to the load. Connection to the load causes the TEA/heat pump to pump heat from the cell. A sensor, e.g., thermocouple(s) and/or heat flux sensor(s), generate an output voltage signal indicative of the quantity of heat. A battery system includes the device and a processor in communication with the cell, the load, and the power supply. The processor generates an electronic control signal in response to the quantity of heat.