Abstract: A tire radius monitoring system for dynamically determining a tire effective radius for each of the wheels on a vehicle is described. The system includes a GPS sensor, a plurality of wheel speed sensors, and a controller. The controller determines, via the GPS sensor, a velocity vector related to longitudinal velocity of the vehicle. The controller determines wheel speeds for the plurality of vehicle wheels, and detects a no-wheel-slip state for the vehicle wheels and the velocity vector from the GPS sensor. The controller determines tire effective radii for the plurality of vehicle wheels based upon the velocity vector for the vehicle and the wheel speeds for the plurality of vehicle wheels during the no-wheel-slip state, and controls vehicle operation based upon the tire effective radii.

Abstract: A method to form a gear for motor vehicles includes one or more of the following: placing a blank between a first tool member and a second tool member, each of the first tool member and the second tool member having a set of teeth; and moving the first tool member and the second tool member towards the blank while rotating the first tool member and the second tool member to form a gear with a set of teeth from the blank. Each tooth of the set of teeth has a topography that varies tooth-to-tooth.

Abstract: Vehicle behavioral monitoring includes determining a measure of distraction of the operator of a target vehicle, characterizing the type or category of distraction, determining level of risk that the target vehicle poses, and invoking various responses including host vehicle notifications and evasive actions and external notification and information sharing.

Abstract: Angled, single laser weld and a method of forming an angled, single laser weld including arranging a first and second faying surfaces of a first and second component adjacently to form an interface between the components; irradiating at least one of the first and second components at the interface with a laser, wherein the first faying surface defines a plane formed at an angle alpha in the range of +/?5 degrees to 60 degrees from an axis A perpendicular to the first front surface and the second faying surface matches the first faying surface; and forming a junction at the interface with an hourglass shaped weld.

Abstract: Presented are clutch-type engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device includes a notch plate, which has multiple notches and attaches to a torque converter, and a pocket plate, which has multiple pockets and attaches to an engine's crankshaft. A pawl is movably mounted within each notch; these pawls selectively engage the notches with the pockets. A notch plate insert is nested within each notch, supporting thereon one of the pawls. A selector plate interposed between the pocket and notch plates moves from a first position, to shift the pawls out of engagement with the pockets, and a second position, to move the notch plate inserts within the notches and allow the pawls to engage the notches with the pockets to thereby lock the notch plate to the pocket plate to rotate in unison with each other.

Abstract: The subject disclosure relates to features that facilitate the automatic cleaning of optical sensors and in particular Light Detection and Ranging (LiDAR) sensors used in autonomous vehicle deployments. In some aspects, the disclosed technology includes a sensor cleaning apparatus having a housing, wherein the housing is configured to be rotatably coupled to an optical sensor, a wiper blade coupled to the housing, wherein the wiper blade is disposed at a downward angle relative to a top-surface of the optical sensor, and one or more nozzles disposed within the wiper blade, wherein the nozzles are configured to apply compressed gas to a surface of the optical sensor.

Abstract: A method of making a reference electrode assembly for an electrochemical cell according to various aspects of the present disclosure includes providing a subassembly including a separator layer and a current collector layer coupled to the separator layer. The method further includes providing an electrode ink including an electroactive material, a binder, and a solvent. The method further includes creating a reference electrode precursor by applying an electroactive precursor layer to the current collector layer. The electroactive precursor layer covers greater than or equal to about 90% of a superficial surface area of a surface of the current collector layer. The electroactive precursor layer includes the electrode ink. The method further includes creating the reference electrode assembly by drying the electroactive precursor layer to remove at least a portion of the solvent, thereby forming an electroactive layer. The electroactive layer is solid and porous.

Abstract: An electric machine includes a stator with stator slots securing therein electrically conductive windings. A rotor is rotatably mounted adjacent the stator and includes a stack of rotor laminates. Each laminate includes circumferentially spaced poles, each of which includes a magnet slot spaced from an insert slot. These laminate magnet slots cooperatively define the rotor's magnet slots. Likewise, the laminates' insert slots cooperatively define the rotor's insert slots. Magnets are mounted inside the rotor's magnet slots, and non-magnetic inserts are mounted inside the rotor's insert slots. One or more poles of each laminate includes a structural web that extends radially through the magnet and insert slots of that pole. Multiple poles of each rotor laminate lack a radially extending structural web. Each rotor laminate is rotated with respect to a neighboring rotor laminate such that each pole with a structural web axially aligns with a pole without a structural web.

Abstract: An autonomous vehicle (AV) implements a notification system that provides notifications to user devices in nearby vehicles to alert drivers of the nearby vehicles of the AV's planned behavior. The notifications are delivered wirelessly and output by the user device to the drivers. The planned behaviors of the AV may not be conveyed by existing mechanisms, such as turning signals or hazard lights. The AV or the receiving user device may determine when an AV's planned behavior may impact a particular driver, and provide relevant notifications to the driver.

Abstract: A motor stator includes a plurality of stacked annular stator laminates defining a stator core having an inner circumference, an outer circumference, a plurality of stator teeth on the inner circumference, and a plurality of ears extending outward from the outer circumference with a respective bolt hole defined in each ear. A first set of the stator laminates includes a plurality of coolant openings therethrough, wherein the coolant openings of adjacent stator laminates communicate with one another in order to define cooling channels inside the stator core. A second set of the stator laminates each include one or more generally radially extending first openings therethrough, wherein the first openings of adjacent stator laminates communicate with one another to define one or more first radial channel segments inside the stator core for providing radial coolant flow between one or more bolt holes and one or more cooling channels.

Abstract: The present disclosure provides an electrode for an electrochemical cell. The electrode includes a polymer binder network and a plurality of electroactive material particles. The polymer binder network includes a plurality of fibers defining the polymer binder network. Each of the plurality of fibers includes a plurality of beads and a plurality of filaments. The plurality of filaments extends from at least a portion of the plurality of beads, respectively. The plurality of electroactive material particles is in voids of the polymer binder network. In certain aspects, the present disclosure provides a single- or double-sided electrode component including a current collector and the electrode.

Abstract: Methods and systems are provided for a vehicle towing a trailer. In an exemplary embodiment, one or more sensors onboard a vehicle are configured to provide sensor data, and a processor onboard the vehicle is configured to at least facilitate: monitoring a trailer sway of the trailer using the sensor data, based on one or more parameters of the sensor data representing the trailer sway and application of a band-pass filter to the one or more parameters; and mitigating the trailer sway, via instructions provided by the processor to one or more braking systems of the vehicle, the trailer, or both, when it is determined that the trailer sway of the trailer is sufficient to warrant mitigation based on the one or more parameters of the sensor data representing the trailer sway and the application of the band-pass filter to the one or more parameters.

Abstract: A composite cover includes a generally rectangular main portion having four main portion edges about a perimeter of the main portion and having opposing top and bottom surfaces defining respective upward and downward directions, and four generally rectangular side portions each contiguous with and extending downward from a respective one of the main portion edges. The main portion and the four side portions generally enclose an interior space and are made of a sandwich structure comprising an interior layer of continuous fiber reinforcements and resin and an exterior layer of metallic foil bonded to the interior layer. A method of manufacturing the cover, having a desired shape generally of a five-walled open box, includes attaching a formed sheet made of metallic foil and having the desired shape onto a shaped composite preform disposed in the desired shape, wherein the shaped composite preform is made of continuous fiber reinforcements and resin.

Abstract: An interior permanent magnet (IPM) electric machine has an improved rotor configuration to manage mechanical stresses induced by electro-magnetic force acting upon permanent magnets housed therein. This includes providing magnet cavities in the rotor with sufficient clearances in the corners wherein a portion of a slot corner is formed with certain curvature shapes using a novel geometry. By doing this, more surface area is obtained to evenly distribute stress that is induced by centrifugal force acting upon the rotor during rotation, thus reducing the stress concentration. Furthermore, an expanded space is achieved between the magnet corner and the rotor lamination, thus providing robust packaging and dynamic support of the permanent magnets in the magnet cavities. Furthermore, the expanded space provides improved clearance for ease of manufacturing and assembly.

Abstract: A method of forming a shaped steel object is provided. The method includes cutting a blank from an alloy composition including 0.05-0.5 wt. % carbon, 4-12 wt. % manganese, 1-8 wt. % aluminum, 0-0.4 wt. % vanadium, and a remainder balance of iron. The method also includes heating the blank until the blank is austenitized to form a heated blank, transferring the heated blank to a press, forming the heating blank into a predetermined shape to form a stamped object, and decreasing the temperature of the stamped object to a temperature between a martensite start (Ms) temperature of the alloy composition and a martensite final (Mf) temperature of the alloy composition to form a shaped steel object comprising martensite and retained austenite.

Abstract: An electrode includes an electroactive material layer and a protective layer disposed on or adjacent to a surface of the electroactive material layer. The protective layer includes a polymerized cyclic ether and a salt dispersed therewithin. The salt includes a nitrate salt and a phosphate salt. The salt may also include a Lewis acid salt. The protective layer is formed by disposing a solution, including the salt and solvent, on or adjacent to the surface of the electroactive material layer, and polymerizing the solvent. The solvent includes the cyclic ether, and also, one or more organic phosphates.

Abstract: Negative electrodes for electrochemical cells that cycle lithium ions are provided. The negative electrodes comprise electroactive material particles that exhibit a core-shell structure defining a core made of a lithiated silicon-based material and a shell surrounding the core that is a bi-layer structure including first and second carbon coating layers. An electrical conductivity of the first carbon coating layer is greater than that of the second carbon coating layer. A method of manufacturing a negative electrode material is provided in which a first carbon coating layer is formed on an outer surface of a silicon-based precursor particle. The silicon-based precursor particle is exposed to a lithium source to form a lithiated silicon-based particle having the first carbon coating layer. A second carbon coating layer is formed on the first carbon coating layer over the lithiated silicon-based particle to form an electroactive material particle.

Abstract: Methods for resistance welding, resistance-welded assemblies, and vehicles including resistance-welded assemblies are provided. An exemplary resistance welding method includes compressing a workpiece stack-up with an interface material between first and second workpieces to squeeze a portion of the interface material to a reduced thickness. After compressing the workpiece stack-up, the first welding electrode contacts the first workpiece at an operating contact area between the first welding electrode and the first workpiece that is greater than an initial contact area. The method also includes passing an electrical current between the welding electrodes to form a molten weld pool within the workpieces, and ceasing the passing of the electrical current between the welding electrodes to allow the molten weld pool to solidify into a weld nugget that forms all or part of a weld joint between the workpieces.

Abstract: A drive system for an electric vehicle includes a housing having a first housing portion, a second housing portion connected to the first housing portion, and a third housing portion connected to the second housing portion. The third housing portion includes a torque arm connectable to a vehicle chassis. A hypoid gear set is mounted in the first housing portion, and an electric motor is mounted in the third housing portion.

Abstract: An electrified drivetrain system that maximizes power density, is readily packaged, and improves drivability is described. It includes a propulsion system having an axial-flux rotating electric machine, a torque converter having a selectable one-way clutch, and an output member that is couplable to a drivetrain. The axial-flux rotating electric machine include a first rotor coaxially arranged with a first electric stator. The torque converter includes a fluidic stator, a pump, a turbine and a torque converter clutch. The axial-flux rotating electric machine is arranged coaxially with the torque converter. The first rotor of the axial-flux rotating electric machine is coupled to the pump of the torque converter, and the turbine of the torque converter is rotatably coupled to the output member.