Abstract: A hybrid lithium-ion battery/capacitor cell comprising at least a pair of graphite anodes assembled with a lithium compound cathode and an activated carbon capacitor electrode can provide useful power performance properties and low temperature properties required for many power utilizing applications. The graphite anodes are formed of porous layers of graphite particles bonded to at least one side of current collector foils which face opposite sides of the activated carbon capacitor. The porous graphite particles are pre-lithiated to form a solid electrolyte interface on the anode particles before the anodes are assembled in the hybrid cell. The pre-lithiation step is conducted to circumvent the irreversible reactions in the formation of a solid electrolyte interface (SEI) and preserve the lithium content of the electrolyte and lithium cathode during formation cycling of the assembled hybrid cell. The pre-lithiation step is also applicable to other anode materials that benefit from such pre-lithiation.

Abstract: A battery control system includes first and second batteries each including first and second terminals configured to output a first voltage, third and fourth terminals configured to output a second voltage, a plurality of individually housed batteries, and a plurality of switches configured to connect ones of the individually housed batteries to and from ones of the first, second, third, and fourth terminals. A control module is configured to selectively provide the first voltage from either one of the first battery and the second battery to a first set of loads and selectively provide the second voltage from either one of the first battery and the second battery to a second set of loads.

Abstract: A method for multi-speed electric vehicle shift control for damping an acceleration oscillation of the electric vehicle. The method includes determining a percentage of accelerator pedal travel and then retrieving a clutch calibration, a first electric motor calibration, and a second electric motor calibration correlating with the determined percentage of accelerator pedal travel. The method then applies the clutch calibration in actuating a clutch-to-clutch gear ratio change, thereby generating a vibration fluctuation in a first axle, and applies the first electric motor calibration in modulating a first electric motor to dampen the vibration fluctuation. The clutch actuation and first electric motor modulation together produces a first axle torque oscillation.

Abstract: A composite article has an interior layer comprising a natural fiber and an exterior layer injection molded onto the interior layer. The exterior layer forms an outer surface over the interior layer. A method of forming the composite article includes providing a base layer comprising a natural fiber and providing a first tool and a second tool. The first and second tools are configured to cooperate to form a cavity therebetween. The first tool has an injection molding channel formed therein. The base layer is inserted into the cavity between the first and second tools and pressed into a desired shape. A liquid polymeric material is inserted through the injection molding channel of the first tool and onto a surface of the base layer to form an injection molded layer of the polymeric material on the base layer.

Abstract: A gearbox having a power take-off for an electrically propelled vehicle. The gearbox includes a housing; at least one planetary gear set; an input shaft in continuous connection with at least one sun gear; a first output shaft in continuous connection with a carrier; a second output shaft in continuous connection with a ring gear; and a plurality of brake clutches grounded to the housing and are selectively engageable in combinations to transfer a torque from the input shaft to at least one of the first output shaft and the second output shaft.

Abstract: A method for joining together metal workpiece (12,14 or 12,150, 14) includes forming a laser weld joint (66) in a workpiece stack-up (10) that fusion welds two or more overlapping metal workpiece (12,14 or 12,150 or 14) together. The laser weld joint (66) has an initial top surface (76). Once the laser weld joint (66) is formed, the method calls for impinging the laser weld joint (66) with a laser beam (24) and moving the laser beam (24) along the initial joint (66) including the initial top surface (76). The laser beam (24) is eventually removed from the laser weld joint (66) to allow the melted upper portion (78) of the joint (66) to resolidify and provide the laser weld joint (66) with a modified top surface (84) that is smoother than the initial top surface (76). By providing the laser weld joint with a smoother modified top surface, residual stress concentration points are removed and the laser weld joint is less liable to damage seal strips.

Abstract: A composite electrode for use in an all-solid-state electrochemical cell that cycles lithium ions is provided. The composite electrode comprises a solid-state electroactive material that undergoes volumetric expansion and contraction during cycling of the electrochemical cell and a solid-state electrolyte. The solid-state electroactive material is in the form of a plurality of particles and each particle has a plurality of internal pores formed therewithin. Each particle has an average porosity ranging from about 10% to about 75%, and the composite electrode has an interparticle porosity between the solid-state electroactive material and solid-state electrolyte particles ranging from about 5% to about 40%.

Abstract: A charging system of an electrical automobile vehicle includes a converter unit and a first energy storage system of within a first automobile vehicle. A charging cable is releasably connected from the first energy storage system to a charging station or is releasably connected to a second energy storage system of a second automobile vehicle. A vehicle charging controller is connected to the converter unit and programmed to communicate with the charging station and to the second energy storage system. A plurality of low-loss switching devices of the converter unit are selectively operated by signals from the vehicle charging controller to position the plurality of low-loss switching devices in an on-state (ON) or an off-state (OFF) to control charging the first energy storage system from the charging station or charging the second energy storage system from the first energy storage system.

Abstract: A seatbelt system for automatically detecting damage to a seatbelt webbing includes a strip of seatbelt webbing, a sensor, and processing circuitry. The strip of seatbelt webbing includes an embedded conductive material that extends through the strip of seatbelt webbing. The sensor is connected to the seatbelt webbing and is configured to measure electrical flow through the embedded conductive material. The processing circuitry is configured to receive the measurement of electrical flow from the sensor and to generate an alert based on the measurement.

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 radar system includes a signal generator to generate a linear frequency modulated continuous wave signal as a base chirp, and one or more frequency shifters to generate respective one or more additional chirps from the base chirp. The radar system also includes two or more switches. One of the two or more switches obtains a portion of the base chirp as a base transmit signal, and remaining ones of the two or more switches respectively obtain a portion of each of the one or more additional chirps as one or more additional transmit signals for transmission by the radar system. At least a portion of the base transmit signal and the one or more additional transmit signals overlaps in time.

Abstract: A drive torque transfer case is provided. The transfer case includes an input shaft, an output shaft, a gear assembly coupled to the input shaft, and a range clutch assembly coupled to the output shaft. The range clutch assembly includes a clutch member and a multi-piston actuator configured to receive a pressurized transmission fluid for selectively axially translating the clutch member to engage a component of the gear assembly for transmitting a drive torque from the input shaft to the output shaft. The multi-piston actuator includes an internal piston having a first annular surface area A1 and a third annular surface area A3, and an external piston having a second annular surface area A2 and a fourth annular surface area A4. The A1 and A2 are in hydraulic communication with a first hydraulic chamber, and A3 and A4 are in hydraulic communication with a second hydraulic chamber.

Abstract: A battery includes: a first terminal; a second terminal; a plurality of individually housed batteries; a plurality of switches configured to connect ones of the individually housed batteries to and from ones of the first and second terminals; and a switch control module configured to: at a frequency, vary a voltage applied to a gate of one of the switches, the one of the switches configured to connect at least one of the individually housed batteries to one of the first and second terminals; and diagnose whether a fault is present in the one of the switches based on a voltage across the one of the switches.

Abstract: A plug having a longitudinal axis includes a plug body having a generally flat sealing surface on an axial end thereof, and a protuberance extending from the axial end generally concentric with the longitudinal axis. The protuberance has a first section contiguous with the plug body, and a second section having a hub portion contiguous with the first section and a plurality of generally evenly spaced arms extending outward from the hub portion. An underside surface of each arm faces the sealing surface of the plug body and has a generally flat portion and a ramped nub thereon projecting toward the sealing surface. The plug may be inserted into a compatible socket having tabs and rotated about the longitudinal axis for sealable engagement with the socket.

Abstract: A close-out assembly includes a housing and an inlet. The housing includes a wall that surrounds an opening. The wall includes an outer edge adjacent to the face plate and an inner edge. The inlet is coupled to the wall, and the inlet is accessible through the opening. The assembly includes a door coupled to the housing that is movable relative to the housing. The assembly includes a seal formed to the wall at the outer edge of the wall and the inner edge of the wall. The door engages one part of the seal when the door is in a closed position, and the inlet engages another part of the seal regardless of the position of the door. A method of manufacturing the assembly includes positioning a housing relative to a mold, and molding an elastomeric material to the housing using the mold to form a seal.

Abstract: A method for manufacturing a ferrous rotational member including the steps of turning a first portion of the friction surface at a sufficient feed rate to provide a first deformed layer on the first portion of the friction surface; fine turning a second portion of the friction surface at a sufficient feed rate to provide a second deformed layer on the second portion of the friction surface; burnishing the first and second portions of the friction surface to achieve a predetermined roughness; and nitrocarburizing the rotational member at a time and temperature sufficient for the diffusion of nitrogen atoms and carbon atoms through the deformed layer to form hardened casings having variable thickness. The ferrous rotational member may be that of a brake rotor having a hub surface and a friction surface, where the hub surface and friction surface have a variable thickness hardened casing.

Abstract: A motor vehicle drive-axle includes a drive-axle housing defining a gear-set cavity and a shaft bore having first and second bearing pockets and an oil cavity arranged between the first and second bearing pockets. The housing also defines a supply channel and a return passage configured to respectively supply oil from the gear-set cavity to the oil cavity and return oil from the oil cavity to the gear-set cavity. The housing also includes an input shaft extending through the shaft bore into the differential gear-set cavity. The housing additionally includes first and second bearings arranged within respective first and second bearing pockets for supporting the input shaft. The housing additionally includes a lubrication regulating insert arranged inside the oil cavity. The insert defines first and second lubrication channels configured to direct oil from the supply passage to respective first and second bearings.

Abstract: The concepts described herein provide for a method, apparatus and system to monitor and control a fuel vapor capture system that is disposed in an air intake system of an internal combustion engine for evaporative emission control. This includes an air intake system for an internal combustion engine that includes a fuel vapor capture system disposed in an interior portion of the air intake system, the fuel vapor capture system including a Metal Organic Framework (MOF) material that is configured to adsorb and desorb hydrocarbon vapor and a controllable device that is integrated into the fuel vapor capture system. In one embodiment, the MOF material is a flexible MOF material.

Abstract: Presented are hybrid electric vehicle (HEV) powertrains and control logic for optimized regenerative braking (regen), methods for making/using such systems, and HEVs with increased regen through reduced engine and transmission friction. A method of operating an HEV includes determining if an REV operating state or fault prevents engagement of a regen control operation and, if not, responsively determining if a torque request for the REV's powertrain is less than a road load on the HEV. The regen control operation is executed responsive to the torque request being less than the road load. The regen control operation includes the power transmission drivingly disconnecting the engine from the road wheels, and the engine operating at a target engine speed. A negative torque offset to maintain a vehicle deceleration rate after disconnecting the engine from the road wheels is calculated; the traction motor outputs a negative torque based on this negative torque offset.

Abstract: Methods and apparatus are provided for determining a trailer dimension including a radar for generating a depth map wherein the depth map includes a detection of a first trailer surface, a camera for generating an image of the first trailer surface, a processor operative to determine a first dimension of the first trailer surface in response to the depth map and a second dimension of the first trailer surface in response to the first dimension and the image, and a vehicle controller controlling a vehicle in response to the first dimension and the second dimension.