Abstract: Presented are multilayer, fiber-reinforced impact protection structures with honeycomb-core or corrugated-layer designs, methods for making/using such structures, and vehicles with traction battery packs supported on skid plates fabricated from such structures. A multilayer impact protection structure includes a first layer with continuous fibers embedded in a polymeric matrix, and a second layer that is attached to the first layer and includes an elastomeric polymer. A third layer, which is attached to one side of the first layer opposite that of the second layer, includes a fiber-reinforced polymer honeycomb and/or corrugated structure. An optional fracture detection circuit is attached to the first or third layer, and is configured to detect a break in the impact protection structure. The corrugated structure may include multiple reinforcement ribs that are interposed within and substantially orthogonal to a series of mutually parallel, elongated ridges.

Abstract: A method for use aboard a motor vehicle or other mobile system having a multi-core communication chipset includes scanning a radio frequency spectrum to identify candidate access points (APs) operating in a frequency band of the communication chipset, e.g., 2.4 GHz and 5 GHz. The method includes selecting one of the candidate APs as a first AP for connection to a primary station of the chipset. In response to a secondary station (STA-2) of the chipset being connected to an external AP on the same frequency band as the first AP, the method includes automatically disconnecting the secondary station (STA-2), then connecting the first AP to the primary station. Another candidate AP is connected to the secondary station as a second AP. The method may include simultaneously communicating with the first and second APs via the primary and secondary stations, respectively.

Abstract: Presented are fuel cell systems and control logic for extracting water from system exhaust, methods for making/using such systems, and electric-drive vehicles with aftertreatment systems for extracting water from fuel cell exhaust. An aftertreatment system for a fuel cell stack includes a condensate generator that fluidly connects to the fuel cell stack to receive exhaust output therefrom. The condensate generator includes an evaporator core with a refrigerant line that actively cool the exhaust via controlled circulation of refrigerant fluid. A condensate collector fluidly connected to the condensate generator includes a reservoir housing with a condensate trap that separates entrained water vapor from the cooled exhaust. The reservoir housing collects the separated water vapor as liquid water. A liquid storage container fluidly connected to the condensate collector receives and stores the collected water.

Abstract: A storage compartment system for a vehicle includes a lid, and a snap rod locker including a first hinge portion. The first hinge portion includes a support portion connected to the lid and extends from a base portion to a rod portion. The storage compartment system further includes a bin having a second hinge portion having a locking feature and a plurality of arcuate flanges. The plurality of arcuate flanges defines an arcuate slot. The locking feature and the plurality of arcuate flanges define a gap in a hollow wall of the bin. The first hinge portion and the second hinge portion are connected to rotatably connect the lid to the bin.

Abstract: An actively controlled flap system includes a bar defining a rotational axis, a first flap rotatably coupled to the bar and configured to rotate about the rotational axis, and a second flap rotatably coupled to the bar and configured to rotate about the rotational axis, the second flap including an opening extending through the second flap. The first flap is rotatable between a first position in which the opening in the second flap is covered by the first flap and a second position in which the opening in the second flap is uncovered, and the second flap is rotatable between a third position and a fourth position.

Abstract: A method of determining a volume of a fluid in a reservoir arranged in a vehicle includes assessing, via a controller, whether a first sensor operatively connected to the reservoir and configured to detect a predetermined level of the fluid in the reservoir has been triggered. The method also includes detecting, via a second sensor, a vehicle operative state indicative of inclination of a free surface of the fluid in the reservoir. The method additionally includes communicating, via the second sensor, the detected vehicle operative state to the electronic controller and determining a degree of inclination of the free surface of the fluid in response to the detected vehicle operative state. Furthermore, the method includes determining, via the controller, the volume of the fluid in the reservoir when the first sensor has been triggered in response to the determined degree of inclination of the free surface of the fluid.

Abstract: A radar circuit for use with a host system such as a vehicle includes a radio frequency (RF) signal generator configured to generate a predetermined RF waveform, an RF antenna connected to the RF signal generator, and an ECU which executes a method. As part of such a method, a signal generator transmits the RF waveform toward different radar target types, and receives return signatures reflected therefrom. The ECU receives the return signatures from the antenna, processes the return signatures via parallel constant false-alarm rate (CFAR) subdetectors each with defined cells under test to detect the target types as a set of detection events, merges the detection events into a merged set, and executes a control action aboard the host system responsive to the merged set. Each subdetector detects a corresponding one or more of the radar target types via corresponding detection parameters.

Abstract: An autonomous vehicle (AV) maintenance system engages a user of an AV to assist in maintenance tasks. A sensor interface receives data captured by a sensor of the AV. An issue detector processes the sensor data to detect an issue in the AV. A user interface module instructs a user to perform a maintenance task addressing the detected issue. A verification module verifies that the user successfully completed the maintenance task.

Abstract: A method and associated system for selecting a charging station for a subject vehicle is described, and includes determining a state of charge of an on-vehicle DC power source arranged to supply electric power to a propulsion system for the subject vehicle. A travel route to a destination point is determined, and locations of a plurality of charging stations proximal to the travel route are identified. Desired states and corresponding weighting factors for a plurality of user-selectable parameters are determined, and a sorting routine is executed to rank the plurality of charging stations proximal to the travel route based upon the desired states and corresponding weighting factors for the plurality of user-selectable parameters and the state of charge of the on-vehicle DC power source. One of the charging stations is selected based upon the ranking, and a charging reservation is scheduled.

Abstract: A capacitor-assisted, solid-state lithium-ion battery is formed by replacing at least one of the electrodes of the battery with a capacitor electrode of suitable particulate composition for the replaced battery particulate anode or cathode material. The solid-state electrodes typically contain solid-state electrode material and are separated with solid-state electrode material. In another embodiment the capacitor anode or cathode particles may be mixed with lithium-ion battery anode or cathode particles respectively. Preferably, the battery comprises at least two positively-charged electrodes and two negatively-charged electrodes, and the location and compositions of the capacitor material electrode(s) may be selected to provide a desired combination of energy and power.

Abstract: A dual-voltage charging station system for an alternating current (“AC”) power supply and a mobile platform having a charging port includes a charge coupler, an AC-to-DC conversion stage, a cable, and a controller. The charge coupler has AC pins and direct current (“DC”) pins configured to engage with respective AC and DC receptacles of the charging port. The conversion stage is connected to the charge coupler and the AC power supply, converts the supply voltage to a DC charging voltage, and relays an appropriate AC or DC accessory voltage. The cable connects to the charge coupler such that the AC pins receive the accessory voltage and the DC pins receive the DC charging voltage. The controller simultaneously delivers the accessory voltage and the DC voltage to the mobile platform via the AC pins and the DC pins, respectively.

Abstract: A device and associated method for joining, via a laser welder, a first workpiece to a second workpiece is described. This includes arranging the first and second workpieces in a stack, including overlapping a portion of the first workpiece with a portion of the second workpiece. The laser welder generates a first laser beam and coincidentally controls the laser welder to traverse a desired weld path that is disposed on the top surface of the first workpiece. The laser devices generates a second laser beam and coincidentally controls the laser welder to traverse the desired weld path. Generating, via the laser welder, the first laser beam includes operating the laser welder at a pulsed operation and at a first power level. Generating, via the laser welder, the second laser beam includes operating the laser welder at a continuous operation and at a second power level.

Abstract: A thermal interfacing assembly for use in a power module having at least one battery module and a cooling plate, and corresponding method of forming the thermal interfacing assembly. The thermal interfacing material is deposited over a first surface of the cooling plate such that the thermal interfacing material conforms to the shape of the first surface. The thermal interfacing material is configured to be electrically insulating and thermally conductive. A first embedded heater is positioned adjacent to the thermal interfacing material. The first embedded heater includes an electrically-conductive portion and a resistive portion. The battery module is installed adjacent to the first embedded heater such that the first embedded heater is directly in contact with a first face of the battery module. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.

Abstract: The present disclosure relates generally to rotors for electric motor assemblies and methods of making the same, and more specifically, to variable thickness rotors for axial flux motors. More specifically, annular-shaped rotors having interiorly disposed magnets for axial flux motors are provided in certain aspects. The variable thickness rotors may each include an annular-shaped body having a first thickness at a first radial position and a second thickness at a second radial position. The first radial position may be spaced apart from the second radial position. The first thickness may be greater than or equal to about 200% of the second thickness.

Abstract: A headlight unit includes a housing, a micro-LED device mounted in the housing, a relay lens system mounted in the housing forward of the micro-LED device, and a projection lens system mounted in the housing forward of the relay lens system. The micro-LED device has a plurality of forward-facing micro-LEDs, wherein first, second and third subsets of the micro-LEDs are arranged in respective first, second and third 2D arrays. The relay lens system includes first, second and third relay lenses configured to receive and relay respective first, second and third streams of light emitted by the first, second and third subsets of micro-LEDs. The projection lens system includes first, second and third projection lenses configured to receive and project the first, second and third streams of light in respective first, second and third projection patterns.