Abstract: A vehicle that includes an engine, an exhaust system, and a controller, and a method are disclosed herein. The exhaust system includes a passage for directing the exhaust gas stream from the engine through the series of exhaust after-treatment devices, including a selective-catalytic reduction device and a diesel particulate filter (DPF). The exhaust after-treatment devices are employed to reduce various exhaust emissions of the engine. The exhaust system, may however, prematurely return failing emissions results due to the amount of contaminants that have flowed through the exhaust system since the last regeneration even of the particulate filter. Therefore, the controller may, via the present method, alter the threshold of the SCR efficiency diagnostic due to contaminants accumulated on the DPF and selectively enable or disable the diagnostic based on a set of recorded instructions, to improve the robustness of the SCR efficiency diagnostic and prevent inaccurate failing emissions results.

Abstract: A system and method for reconfigurable inter-processor communications in a controller. The system and method include providing multiple processors in the controller and generating a send buffer and a receive buffer for each of the processors. The system and method further include generating a send table and a receive table for each of the processors where the send table stores identifying information about messages being sent and where the receive table stores identifying information about messages being received, and providing infrastructure services that include protocols for sending and receiving messages between multiple processors in the controller.

Abstract: Methods, systems, and vehicles are provided that provide for thermal conditioning of a vehicle rechargeable energy storage system (RESS). A thermal conditioning system is coupled to the RESS, and is configured to thermally condition the RESS. A control system is coupled to the thermal conditioning system, and is configured to estimate a state of charge for the RESS and provide instructions for the thermal conditioning system to thermally conditioning the RESS based on the state of charge.

Abstract: A torque requesting module generates a first torque request for a spark ignition engine based on driver input. A torque conversion module converts the first torque request into a second torque request. A setpoint control module, based on the second torque request, generates a mass of air per cylinder (APC) setpoint, an exhaust gas recirculation (EGR) setpoint, an intake valve phasing setpoint, and an exhaust valve phasing setpoint. A model predictive control (MPC) module: identifies sets of possible target values based on the APC, EGR, intake valve phasing, and exhaust valve phasing setpoints; generates predicted parameters based on a model of the spark ignition engine and the sets of possible target values, respectively; selects one of the sets of possible target values based on the predicted parameters; and sets target values based on the possible target values of the selected one of the sets.

Abstract: A sensor includes a magnetic piece with a magnetic array, a conductive coil and ferromagnetic object. The magnetic array provides a spatially modulated magnetic field that is concentrated in the near-field. A processor calculates the ferromagnetic object's speed based on voltage induced in the conductive coil. The ferromagnetic object's movement through the magnetic field causes a change in the magnetic flux, and the rate of change is proportional to the induced voltage.

Abstract: A seat belt system for a vehicle having a vehicle structure and a seat operatively connected to the vehicle structure includes a lap belt having a first end and a second end. The first end of the lap belt includes a buckle element and the second end of the lap belt includes a belt link. The seat belt system also includes a cable having a first end and a second end. The first end of the cable is connected to an anchor and the second end of the cable includes a ferrule. The seat belt system additionally includes a hinge operatively connecting the belt link to the ferrule. The hinge operates to pivot the belt link relative to the ferrule when an occupant of the vehicle is positioned in the seat and restrained by the seatbelt system.

Abstract: A stator assembly includes a plurality of stator slots defining a plurality of slot layers. The assembly includes a plurality of hairpins each having respective first and second legs positioned in respective ones of the slot layers. Each of the hairpins is one of a short-pitched coil, a long-pitched coil and a full-pitched coil. The short-pitched, long-pitched and full-pitched coils are configured to extend over a first, second and third number of the stator slots, respectively. The hairpins may be divided into first, second, third, fourth, fifth and sixth hairpin layers. One of the hairpin layers includes at least one short-pitched coil, and another of the hairpin layers includes at least one long-pitched coil. The first, third and fifth hairpin layers each may include at least two short-pitched coils while the second, fourth and sixth hairpin layers each may include at least two long-pitched coils.

Abstract: A vehicle includes an engine, a transmission, and an electrical system. The electrical system has an auxiliary starter motor connected to a crankshaft of the engine, a high-voltage motor generator unit (MGU) connected to the crankshaft, and a controller. Execution of instructions by a processor causes the controller to determine a set of powertrain conditions in response to a requested autostart of the engine, e.g., state of charge and/or power limits of a high-voltage energy storage system (HV-ESS), torque limits of the MGU, and/or a crank angle of the engine. The controller determines whether the requested autostart may not succeed relative to a time or noise standard using the set of powertrain conditions, and transmits an autostart command to the MGU when the requested autostart may succeed. The controller transmits the autostart command to the auxiliary starter motor when the requested autostart will not succeed.

Abstract: A high-voltage relay system for a vehicle. The system includes a high-voltage bus, a parallel relay set and a controller. The parallel relay set includes two or more relays wired in parallel and that are electrically coupled to the high-voltage bus. The controller is programmed to adjust the power flowing through the parallel relay set when a malfunction is detected in one of the relays in the set. The system can include a high-voltage power source electrically coupled to the high voltage bus through the parallel relay set, where the controller reduces the power flowing through the parallel relay by reducing output of the high-voltage power source. The system can include a high-voltage motor electrically coupled to the high voltage bus through the parallel relay set, where the controller reduces the power flowing through the parallel relay set by reducing the motor's power demands.

Abstract: A model predictive control (MPC) module: identifies sets of possible target values based on an engine torque request; determines predicted operating parameters for the sets of possible target values, respectively; determines cost values for the sets of possible target values, respectively; selects one of the sets of possible target values based on the cost values; and sets target values based on the possible target values of the selected one of the sets. An actuator module controls an engine actuator based on one of the target values. A fault diagnostic module selectively diagnoses a fault in the MPC module.

Abstract: A fuel cell system is provided which includes a compression retention enclosure with upper and lower compression shells and side sheet components coupled by interlocking hem joints. Methods for manufacturing compression retention enclosures with hem joints such that the enclosure remains sealed upon operational swelling of the fuel stack are also provided. A compression shell may be formed from a light weight composite structure having a polymeric layer interposed between steel skins, and an extension of the top steel skin may form a hemmed edge or may form a side sheet having a hemmed edge. Side sheet panels may be coupled to the end plates by interlocking two opposing hemmed edges to form the hem joint, or by sliding an opposing C-linking element between two hemmed edges held under compression force in an interlocking position.

Abstract: An engine control system for a vehicle includes a timer module, a stochastic pre-ignition (SPI) mitigation module, and a boost control module. The timer module tracks a period of operation of an engine where vacuum within an intake manifold is less than a first predetermined vacuum. The SPI mitigation module generates an SPI signal when the period is greater than a predetermined period and the vacuum is less than a second predetermined vacuum. The second predetermined vacuum is less than the first predetermined vacuum. The boost control module reduces output of a turbocharger in response to the generation of the SPI signal.

Abstract: A curved sandwich impact structure for a vehicle having a micro-truss core. In one embodiment, the sandwich impact structure includes a micro-truss layer sandwiched between two facesheets, a micro-truss layer designed for energy absorption on the outside of one of the facesheets, and a fascia panel in contact with the energy absorbing micro-truss layer.

Abstract: A battery state estimator which combines an electrochemical solid-state concentration model with an empirical equivalent-circuit model. The battery state estimator uses a reduced-order physics-based electrochemical solid-state concentration model to calculate open circuit voltage of a battery cell, and uses the calculated open circuit voltage in an equivalent-circuit model to evaluate a diffusion voltage drop and other battery cell parameters. The battery state estimator is implemented in an online estimator framework using an extended Kalman filter, with a measured terminal voltage and measured current as inputs. A state of charge of the battery cell can be determined from the calculated open circuit voltage, and the state of charge along with the other parameters from the equivalent-circuit model are used to evaluate battery pack performance and to control battery pack charging and discharging.

Abstract: Methods and apparatus are provided for determining when a task may be performed on a vehicle that is moving. The method includes generating a driver workload value based on at least one task parameter describing a predetermined attribute of the task and preventing a user from performing the task if the driver workload value exceeds a predetermined driver workload threshold and the vehicle is moving.

Abstract: A cylinder control system of a vehicle, includes a cylinder control module and a volumetric efficiency (VE) module. The cylinder control module determines a desired cylinder activation/deactivation sequence. The cylinder control module also activates and deactivates valves of cylinders of an engine based on the desired cylinder activation/deactivation sequence. The VE module determines a volumetric efficiency based on a cylinder activation/deactivation sequence of the last Q cylinders in the firing order. Q is an integer greater than one.

Abstract: An infrared energy reflecting lens system for a lamp subjectable to sunlight is provided. The lens system includes a lens having an exterior surface and a dichroic coating on the exterior surface of the lens so that at least a portion of the infrared energy content of sunlight is reflected from entering the lens.

Abstract: A support frame assembly for holding a plurality of battery cells includes a first end frame having a first plurality of protruding strips, a second end frame having a second plurality of protruding strips, and a structural frame having a plurality of grooves for receiving the first plurality of protruding strips and the second plurality of protruding strips. The first end frame and the second end frame attach to the structural frame to hold a first battery cell, a second battery cell and a foam pad positioned between the first battery cell and the second battery cell. The structural frame has curved features therein for receiving a cooling assembly and a chamfered slot for receiving a cooling fin from the cooling assembly. The support frame assembly also includes interlocking features that mate to another support frame with a gap defined between adjacent support frames.

Abstract: Friction-weld assemblies and methods of spin-welding are provided, where the components being joined are polymeric components. Designs provided for the polymeric components enable the use of relatively low speeds and pressures to achieve superior friction weld joints between the components. Further, large surface area polymeric components can be successfully friction welded with such designs. In certain variations, at least one polymeric component has a weld surface with a plurality of surface features that are concave (e.g., grooves) or convex. In other variations, the first component in the weld region has a distinct non-complementary shape from the second component, thus creating a progressive advancing weld line that avoids high temperatures that might incur damage to the polymeric component and weld joint. Such component designs additionally provide for improved flash management at the weld joint.

Abstract: A one-piece interior trim panel for a motor vehicle and method of manufacture is disclosed which includes a trim section configured to face the vehicle interior and a handle section that is arranged on the trim section such that a handle cavity is formed in the interior trim panel. The handle section features a recess that points in the vertical direction and through which a person can reach behind the rear side of a segment of the trim section. The present disclosure furthermore concerns a method for manufacturing such an interior trim panel.