Abstract: A controller of a host system executes a method for detecting an external AC electrical device. While an AC charging inlet of the host system is electrically connected to the device via different vehicle-to-live (V2L) and jump-charge connections, the controller detects a control pilot voltage and a proximity voltage. When the control pilot voltage is 0V, the controller determines whether entry conditions are satisfied indicative of a desire to offload power from the host system to the device. When the entry conditions are satisfied, the proximity or control pilot voltage are modulated to generate a modulated voltage signal, which the controller compares to an expected voltage indicative of the device. Power is offloaded to the device when the modulated voltage signal matches the expected voltage.

Abstract: A three-state contactor for an electrical system having a battery pack and voltage bus rail includes first and second pairs of electrical terminals. The first pair of terminals is separated by a first circuit gap in a first circuit path extending between the bus rail and an electrode terminal of the battery pack. The second pair of terminals is separated by a second circuit gap in a second circuit path extending between the bus rail and electrode terminal. A contactor arm, in response to a corresponding switch activation signal, translates in an orthogonal direction with respect to its longitudinal axis between a first ON state position, an OFF position, and a second ON position to close the first circuit gap, open both circuit gaps, or close the second circuit gap, respectively. A multi-pack battery system and an electric powertrain may use the contactor.

Abstract: A method for increasing a default electric stall torque limits in a motor vehicle having an electrified powertrain inclusive of a traction power inverter module (TPIM) connected to an electric traction motor includes receiving vehicle level inputs via a controller. The controller is programmed with the default electric stall torque limits. The method includes selecting an inverter control strategy, via the controller, as a selected inverter control strategy in response to the vehicle level inputs, the strategy including temporarily increasing the default electric stall torque limits while applying a pulse width modulation (PWM) type at a corresponding PWM switching frequency. The method also includes controlling an output state of the TPIM and the electric traction motor over a calibrated duration, via the controller, using the selected inverter control strategy. A motor vehicle includes the controller, road wheels, TPIM, and traction motor.

Abstract: An induction motor includes a stator and a rotor. The stator is configured to generate a rotating magnetic field. The rotor is disposed inside the stator, separated from the stator by an air gap, and is configured to rotate around an axis in response to the rotating magnetic field. The rotor includes a rotor core, multiple end rings, and multiple collars. The end rings are attached at opposite ends of the rotor core. Each end ring has one of multiple regions disposed outside the air gap. Each region has an outer surface. The collars are attached in a prestressed condition around the outer surface of each region. The prestressed condition is configured to maintain a compressive stress in the end rings at a maximum-designed rotational speed of the rotor.

Abstract: A high heat-absorption casting core for manufacturing a cast component includes a core body. The core body has at least a portion thereof defined by metal powder. The metal powder is configured to absorb heat energy from the cast component during cooling of the component and solidification thereof. The core body may be additionally defined by a sand fraction in contact with the metal powder fraction. A system and a method for manufacturing a cast component using the high heat-absorption casting core are also envisioned.

Abstract: A sensor lens cleaning system for a cylindrical sensor having a sensor lens surface includes an extended member having a first end coupled to the cylindrical sensor and a second end opposite the first end, a nozzle coupled to the second end of the extended member, an actuator coupled to the extended member and configured to control the extended member, and a controller in electronic communication with the actuator and configured to communicate an actuator control signal to the actuator. The nozzle generates an air stream directed at the sensor lens surface.

Abstract: A battery electrode includes an electrically conductive sheet and two or more coating layers of an ion transport medium stacked thereon. Each coating layer has a respective two-dimensional array of low porosity regions formed therein, with a remainder of each coating layer that is not the two-dimensional array of low porosity regions defining a respective network of interconnected high porosity regions. Each of the high porosity regions has a feature size D, and an intralayer pitch P is defined between adjacent ones of the high porosity regions of each coating layer, with each pair of adjacent two-dimensional arrays having a respective alignment error E therebetween. A respective first electrically conductive path is formed thereacross via the networks of high porosity regions when D?E?P, with a second electrically conductive path being formed across all of the coating layers via the networks of high porosity regions.

Abstract: Presented are segmented hairpin bar conductors for electric machines, methods for making/using such segmented bar conductors, electromagnetic motors using such segmented bar conductors, and vehicles equipped with an induction motor generator unit using segmented hairpin bar conductors. An electric machine includes a stator that defines multiple circumferentially spaced, radially elongated stator slots. A rotor is located adjacent and movable with respect to the stator. One or more permanent magnets are mounted to the rotor, and one or more U-shaped hairpin windings are mounted to the stator in juxtaposed spaced relation to the magnet(s). Each hairpin winding is formed from an array of collimated, electrically conductive wires that are bundled together into a unitary bar conductor. The segmented hairpin winding has a pair of hairpin legs, each of which adjoins and projects from a respective end of a hairpin crown. Each hairpin leg inserts into a respective one the stator slots.

Abstract: A wheelhouse liner for a vehicle includes a body portion and a wheelhouse deflector positioned inside the wheelhouse. The deflector includes a deflector portion extending from a first edge of the wheelhouse liner to form a lip at an outboard edge of the wheelhouse liner. In some examples, the wheelhouse deflector includes a deflector surface defining a depression configured to direct a flow of fluid away from a vehicle sensor.

Abstract: A sound reduction assembly includes a housing and a component supported via the housing. The component is movable relative to the housing. The sound reduction assembly includes a ring coupled to the component and the housing. The ring is configured to attenuate sound inducing vibrations in response to operation of the component. The ring includes a flange fixed relative to the housing to maintain a position of the ring relative to the component which maximizes attenuation of the sound in response to operation of the component. A method of utilizing a ring to attenuate sound inducing vibrations in response to operation of a component inside of a housing. A torque is selected to be applied to the ring. A stiffness of the ring is determined based on a stiffness-torque curve utilizing the selected torque to maximize attenuation of the sound. The ring is manufactured to meet the determined stiffness.

Abstract: Methods for manufacturing a pouch-type battery cell include disposing one or more electrode pairs between a first aluminum pouch layer and a second aluminum pouch layer, sealing the first pouch layer and the second pouch layer to form a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch with an outer edge encasing the anode and the cathode, applying a photocatalytic polymer coating precursor to the outer edge of the pouch, and photo-curing the photocatalytic polymer coating precursor to form a conformal edge coating. The photocatalytic polymer coating precursor includes one or more photo-initiators, one or more acrylates, and one or more polyamines. The polyamines can include tertiary amines including ?-CH functional groups, diamines represented by the formula H2N—R—NH2, wherein R represents saturated and unsaturated aliphatic moieties, and N,N?-(2,2-dimethylpropylidene) hexamethylenediamine.

Abstract: Presented are joint active thermal management (JATM) systems with heat exchanger storage of surplus refrigerant, methods for making/operating such systems, and vehicles equipped with such systems. A JATM system includes a coolant loop that fluidly connects to a vehicle battery system for pumping thereto coolant, an oil loop thermally coupled to the coolant loop and fluidly connected to a vehicle powertrain system for pumping thereto oil, and a refrigerant loop thermally coupled to the coolant loop and operable to circulate refrigerant for heating/cooling a passenger compartment. An electronic controller determines if a current amount of refrigerant in the refrigerant loop exceeds a calibrated threshold for the current operating mode of the JATM system. If so, the controller determines if one of the refrigerant loop's heat exchangers is available to store excess refrigerant. If the heat exchanger is available, the refrigerant loop stores excess refrigerant in the available refrigerant heat exchanger.

Abstract: A hybrid part includes a base structure and a plurality of layers of additive manufacturing material disposed on and attached to the base structure. The base structure may includes a plurality of sheets of base material, and/or a base formed by any non-additive manufacturing method. A method of forming a hybrid part includes providing a base structure that includes either or both of: a) a plurality of sheets of base material, and b) a base formed by a non-additive method. The method further includes disposing a plurality of layers of additive manufacturing material, layer by layer, onto the base structure.

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. The fibers of each structural reinforcement layer are localized to a discrete region within the composite panel's plan-view profile.