Abstract: Presented are electronic power module assemblies with direct-cooling heat pipe systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A sidewall of the module's housing defines therethrough multiple coolant windows that fluidly connect to the coolant chamber. A power semiconductor switching device is mounted to the module housing, fluidly sealed to a first coolant window with the power device's inboard surface exposed to the coolant fluid. The power device is operable to modify electric current transmitted between a power source and an electrical load. A heat pipe with an outer casing has a first casing segment thereof mounted to an outboard surface of the power device, and a second casing segment fluidly sealed to a second coolant window and exposed to the coolant fluid.

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: 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 resolver disposed to monitor a rotatable member is described, along with an associated method for evaluating an output signal therefrom. The method for monitoring the resolver includes supplying an excitation signal to the resolver, and monitoring, at an oversampling rate, first and second output signals from the resolver. An oversampling routine is executed to determine averages of the first and second output signals from the resolver. A demodulation angle error is determined based upon the first and second output signals from the resolver, and provided as feedback. A position of the resolver is also determined based upon the first and second output signals from the resolver.

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 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 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: System and method of controlling power distribution from a charging source to an electric vehicle having a battery. The system includes a plurality of switches selectively connectable between the charging source, the battery and a thermal circuit. A controller is configured to control operation of the plurality of switches to provide multiple settings for the electric vehicle. The controller is configured to select from the multiple settings based on part on a trigger signal from a mobile application. The multiple settings include an external power mode, a charging mode, a discharging mode and a mixed charging and conditioning mode. The mixed charging and conditioning mode allows charging of the battery concurrently with thermal conditioning of at least one of the battery and a cabin of the vehicle. The mixed charging and conditioning mode enables a power split between a thermal conditioning power (PT) and a charging power (PC).

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.

Abstract: A torque transmission device (100) includes a variator of a continuously variable unit (CVU) (20) arranged in parallel with a layshaft gearset (30). The CVU (20) includes a first pulley (22) rotatably coupled to a second pulley (24), and the layshaft gearset (30) includes a first gear element (32) meshingly engaged with an intermediate gear element (34) meshingly engaged with a second gear element (36). A transmission input member (12) is rotatably coupled to the first pulley (22) of the CVU (20), and is selectively rotatably coupled to the first gear element (32) of the layshaft gearset (30) by activation of a first clutch (37). A transmission output member (14) is rotatably coupled to the second pulley (24) of the CVU (20) and rotatably coupled to the second gear element (36) of the layshaft gearset (30). The transmission is disposed to operate in a continuously variable mode when the first clutch (37) is disengaged, and to operate in a fixed gear mode when the first clutch (37) is engaged.

Abstract: An on-vehicle radar system is described, and includes a phased array antenna including a plurality of transmit antennas, and a corresponding plurality of transmitters, wherein each of the transmitters is in communication with a respective one of the transmit antennas. A controller is operatively connected to each of the plurality of transmitters. The controller includes an instruction set that is executable to generate a plurality of Non-Linear Frequency Modulated (NLFM) radar signals corresponding to individual ones of the plurality of transmitters. Each of the NLFM radar signals that is generated for a respective one of the transmitters is determined based upon a desired beam steering angle and a position of the respective one of the transmit antennas of the phased array antenna.

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: Systems and methods are provided for interpreting traffic information by a vehicle. In one embodiment, a method includes: receiving, by a processor, sensor data from one or more sensing devices of the vehicle, where the sensor data depicts a traffic device in an environment of the vehicle; receiving, by the processor, map data associated with the environment of the vehicle, where the map data includes traffic devices; matching, by the processor, the traffic device of the sensor data with a traffic device of the map data; determining, by the processor, a probability distribution of a traffic signal associated with the matched traffic devices based on a Hidden Markov model (HMM); and planning, by the processor, control of the vehicle based on the probability distribution.

Abstract: A vehicle particulate matter contamination recovery system includes a particulate matter filter receiving exhaust gas from an engine. A particulate matter sensor is positioned downstream of the particulate matter filter, the particulate matter sensor collecting a non-combustible contaminant on a circuit of the particulate matter sensor and generating a current indicating presence of the non-combustible contaminant. A total volume of water collected during multiple cold start operations of the engine is passed onto the sensor acting to at least partially dissolve the non-combustible contaminant. The particulate matter sensor is operated in a remedial action mode of operation having no voltage applied to the circuit of the particulate matter sensor until a quantity of the cold start operations corresponding to the total volume of water is reached.

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 method and system for monitoring a charge capacity of a battery includes determining a predicted charge capacity and a first uncertainty parameter based upon the current, voltage, and temperature of the battery, wherein the predicted charge capacity is determined by executing a charge capacity degradation model. A measured charge capacity and an associated second uncertainty parameter of the battery are also determined, by executing a charge capacity update routine. A charge capacity estimate for the battery is determined based upon the predicted charge capacity and the measured charge capacity, and an updated uncertainty parameter for the charge capacity estimate is determined based upon the first and the second uncertainty parameters. An estimated covariance parameter, and a covariance ratio are determined based upon the updated uncertainty parameter and the estimated covariance parameter.