Abstract: An electric vehicle (EV), and systems and methods are introduced in aspects of the disclosure that use a battery management system (BMS) for one or more Lithium ion (Li+) battery cells. The BMS includes an apparatus coupled with outer terminals of the one or more Li+ battery cells and configured to estimate an open circuit voltage (VOC) across the Li+ battery cells. The apparatus further includes a memory, at least one processor coupled with the memory. The at least one processor is configured, when executing code stored in the memory, to produce a state of charge (SOC) observer, the SOC observer including a hysteresis model to account for hysteresis in the one or more Li+ battery cells.

Abstract: Presented are separately excited motor (SEM) drive systems, methods for making/using such systems, and vehicles equipped with such systems. A motor drive system includes a rechargeable battery unit and a multilevel power factor correction (PFC) device interposed between and electrically connecting the battery unit and an electric power source. The battery unit and PFC device are electrically connected via a traction inverter module (TIM) device and a multilevel power transfer circuit (PTC) device. The TIM contains multiple pairs of TIM switches, and the PTC device contains multiple PTC switches. An SEM unit contains a rotor assembly, which includes a rotor core bearing a rotor winding, and a stator assembly, which includes a stator core bearing multiple stator windings electromagnetically paired with the rotor winding. Each stator winding is electrically connected to a respective pair of TIM switches, whereas the rotor winding is electrically connected to the PTC switches.

Abstract: A functionalized polymeric separator membrane, including a polymer backbone chosen from an aramid-based polymer, a polyamide-based polymer, or a polyimide-based polymer, or combinations thereof; and further comprising one or more functional side groups (-FSG) capable of trapping transition metal ions and acidic species. The functionalized polymeric separator membrane may be a sulfonated polyaramid separator membrane. Sulfonation of polyaramid separators add functional groups that trap both acidic species and TM ions, thereby suppressing anode damage caused by TM deposition onto the anode by a two-step process. The functionalized polymer separator membranes may be used with Li-ion, Li-metal, or Sodium-ion batteries.

Abstract: A slew rate controllable system for powering an electric machine. The system may include a plurality of power switches operable for converting a direct current (DC) input into an alternating current (AC) output suitable for electrically powering the electric machine. The system may include a gate drive system operable for controlling a slew rate associated with transitioning the switches between opened and closed states.

Abstract: Methods, systems, and vehicles are provided for determining a stator resistance value of an electric motor. The systems may include the electric motor including a stator and a rotor; a sensor system including configured to generate sensor data indicative of sensed operating conditions of the electric motor including a current magnitude, a current angle, a motor speed, a temperature of the stator, and a temperature of the rotor; and a controller operably coupled with the sensor system and the electric motor. The controller is configured to: determine an initial stator resistance value based on a stator reference temperature and either estimated data sensor data received from the sensor system; determine a stator temperature coefficient based on the sensor data and a stator nonlinear resistance ratio curve; and determine the stator resistance value based on the initial stator resistance value and the stator temperature coefficient.

Abstract: A power transfer system may include a rotating magnetic core; a rotating high index core winding within the rotating magnetic core; a stationary high index core winding within the rotating high index core winding; and a stator referenced magnetic core within the stationary high index core winding. The power transfer system may include a rotor rectifier mounting plate, operatively attached to the rotating magnetic core, and/or a first and a second stationary high index core winding; and/or the stationary high index core winding and the stator referenced magnetic core do not rotate and/or the rotor rectifier mounting plate includes rectifiers to convert AC to DC; and/or the rotor rectifier mounting plate is further configured as a heat sink; and/or the rotor rectifier mounting plate is operatively attached to the rotating magnetic core via adhesive; and/or cooling fluid is allowed to pass through the power transfer system.

Abstract: Methods, vehicle systems, and vehicles are provided that are capable of managing communication between a vehicle and a portable energy source (PES) coupled to the vehicle. The vehicle systems include a vehicle battery configured to provide electrical power to a propulsion system of the vehicle and a vehicle controller that is configured to establish two-way data communication between the vehicle controller and a PES controller of the PES, determine an energy transfer mode for transferring electrical power between the vehicle battery and a PES battery of the PES, initiate electrical power transfer between the vehicle battery and the PES battery in accordance with the energy transfer mode while the vehicle is being propelled by the propulsion system, receive a status of the PES battery from the PES controller, and adjust the electrical power transfer between the vehicle battery and the PES battery based on the status.

Abstract: A telematics system for a vehicle includes a vehicle processor for storing data including vehicle location, vehicle data, and environmental data. The telematics system also includes a server communicatively coupled to the vehicle processor and configured to determine a range remaining for the vehicle. In some examples, the range remaining is based on vehicle data and environmental conditions.

Abstract: A method for capturing trapped powder from a part during an additive manufacturing process, the method comprising defining parameters for a part, the part defining an interior passageway defined by interior sidewalls, defining parameters for a powder removal cap, the powder removal cap comprising a body portion and a thin radial membrane connected to the interior sidewalls of the part, simultaneously creating the part and the powder removal cap via additive manufacturing, wherein the powder removal cap is created within the interior passageway and, upon completion of the creation of the part and the powder removal cap, the powder removal cap traps excess powder within the interior passageway, removing the powder removal cap from the interior passageway by breaking the radial membrane from the interior sidewalls to permit access to the interior passageway, and capturing the excess powder within the interior passageway.

Abstract: In an embodiment, a method is provided for controlling a plurality of converters that are coupled to a plurality of cells of a rechargeable energy storage system (RESS) and configured to supply electric current to other systems that require the electric current, the method including obtaining, via one or more sensors, cell data as to the plurality of cells, the cell data including a state-of-charge for each of the plurality of cells; obtaining other system data as to the other systems, including an amount of electric current required by the other systems; and controlling the plurality of converters, in accordance with instructions provided by a processor, based on both: the cell data, including the state-of-charge for each of the plurality of cells; and the other system data, including the amount of electric current by the other systems.

Abstract: A rotor for mounting on a rotational axis in an axial flux electric motor includes a ferromagnetic rotor core. The rotor also includes a plurality of alternating south and north pole permanent magnets (PMs) arranged on the ferromagnetic rotor core symmetrically around the rotational axis and facing the stator. The ferromagnetic rotor core includes a plurality of core saliencies extending to the rotor exterior surface. Each of the core saliencies is arranged between one south pole PM and one north pole PM. The plurality of core saliencies is phase-angle shifted relative to the plurality of alternating south and north pole PMs to thereby alter magnetic reluctance of the electric motor. An axial flux electric motor employing the above-described rotor is also contemplated.

Abstract: A method for control of an alternating current (AC) electric motor through a voltage inverter having a plurality of electric switches with on-off states that collectively define a plurality of non-zero vectors angularly disposed about a common origin includes through one or more controllers, calculating a rotating voltage reference vector to apply to the AC electric motor through the voltage inverter. The method also includes through one or more controllers, calculating voltage inverter switching times using a first subset of the plurality of non-zero vectors, the first subset including fewer than all of the plurality of non-zero vectors and including no adjacent non-zero vectors, to synthesize the rotating voltage reference vector. Additionally, the method includes through the voltage inverter, applying the rotating voltage reference vector to the AC electric motor.

Abstract: A dual inverter open winding machine for a vehicle. The machine may include an electric motor, a first energy source, a first inverter, a second energy source, and a second inverter. The first inverter may include a plurality of first switches independently operable between an opened position and a closed position to selectively connect and disconnect a first direct current (DC) port and a first alternating current (AC) port with one or more of the first energy source, the first inverter, and the motor. The second inverter may include a plurality of second switches independently operable between an opened position and a closed position to selectively connect and disconnect a second DC port and a second AC port with one or more of the second energy source, the second inverter, and the motor.

Abstract: A radar signal processing method for improved occupant vital monitoring includes a method for detecting vital signs using at least one radar sensor mounted to a vehicle. The method includes detecting a plurality of target candidates using the at least one radar sensor, analyzing the plurality of target candidates to generate a list of targets, steering the at least one radar sensor towards the target using the angle of arrival to the target, and detecting a vital signal of the target based on the range using the at least one radar sensor.

Abstract: A method of extending connectivity of a recipient vehicle may be executed by a non-transitory computer-readable medium. During an ignition off state of the recipient vehicle, the method includes disabling a recipient cellular network access device (NAD) of the recipient vehicle and connecting to a low power communications source. The method includes communicating with a centralized location over the low power communications source. The low power communications source may be a recipient Bluetooth® low energy (BLE) within the recipient vehicle. The method may include connecting to a donor vehicle proximate the recipient vehicle. The donor vehicle includes a donor NAD and a donor BLE, such that the donor NAD of the donor vehicle communicates with the centralized location on behalf of the recipient vehicle.

Abstract: A hybrid material housing for a battery reduces or minimizes thermal runaway propagation. The housing includes a composite structure for the battery and optionally includes a polymeric matrix selected from the group consisting of: epoxy, phenolic resin, polyester, vinyl ester, and combinations thereof and a reinforcing material selected from the group consisting of: glass fibers, carbon fibers, basalt fibers, aromatic polyamide KEVLAR® fibers, and combinations thereof. A metal layer is disposed along an exterior surface of the composite structure that comprises aluminum, steel, stainless steel, alloys, and combinations thereof. In a first mode, the metal layer contacts the composite structure and in a second mode after exposure to a thermal load of greater than or equal to about 500° C., the metal layer at least partially delaminates from the exterior surface and forms insulating air gaps to define a thermal barrier. Methods of forming the hybrid material housings are also provided.

Abstract: A collaborative dual robot hinge mounting system includes: a first robot including an end effector that moves a pair of bolts in position to be run through a pair of hinges and into a BIW, where the end effector includes a first bolt runner and a second bolt runner; and first and second cameras that detect locations or orientations of hinge mounting holes on the BIW for the pair of hinges. A control module sends to a second robot the locations or orientations of the hinge mounting holes to signal the second robot to position the pair of hinges relative to the BIW and, in response to detecting the pair of hinges being placed relative to the BIW, drives the pair of bolts via the first bolt runner and the second bolt runner through the pair of hinges and into the hinge mounting holes in the BIW.

Abstract: A system for a high-performance prismatic lithium-ion battery cell is provided. The system includes a battery cell stack including an electrode sub-assembly including a plurality of pairs of anode electrodes and cathode electrodes and including a planar side. The battery cell stack further includes a polymeric shell disposed around the electrode sub-assembly and configured for providing mechanical protection and electrical insulation to the electrode sub-assembly. The battery cell stack further includes a metal foil sheet attached to the polymeric shell and disposed next to and in contact with the planar side of the electrode sub-assembly, wherein the metal foil sheet is configured for exchanging heat with the electrode sub-assembly.