Abstract: A bonded structure of aluminum and copper is formed by bonding a copper workpiece and an aluminum workpiece together along a joint via an arc welding process. The copper workpiece has a first coating, having a lower melting point than copper, applied to at least a portion of it. The first coating allows the copper workpiece to be wetted and brazed, while the aluminum workpiece is melted and fused along the joint. The arc welding process involves the cyclic alternating of a first stage, in which an electric current is supplied to a welding wire as it is moved toward the workpieces, and a second stage, in which the electric current is reduced and the welding wire is moved away from the workpieces, to generate and detach a plurality of molten droplets along the joint. Each molten droplet is formed from the welding wire in the first stage.

Abstract: A modular sunroof frame assembly and method for a vehicle having a body structure is provided. The modular sunroof frame assembly is attachable to the body structure and includes right and left side rails, front and rear cross beams, and a plurality of corner attachment couplings. The right and left side rails have respective cross-sections throughout their length, front rail ends, and rear rail ends. The front and rear cross beams have respective cross-sections throughout their length, right beam ends, and left beam ends. The corner attachment couplings are fixed to the respective side rail end and to the respective cross beam end.

Abstract: A method of controlling a downhill rolling shift sequence (DRSS) of a vehicle having an engine and a dual-clutch transmission (DCT) includes initiating a DRSS upon detecting a rolling downhill condition of the vehicle in an initial gear state, identifying an exit gear state corresponding to the initial gear state, shifting the DCT to a rolling neutral state when a speed of an initial gear input shaft is equal to an idle speed of the engine, initiating synchronization of the engine speed with the speed of an exit gear input shaft when the shaft speed is equal to the engine idle speed, and shifting the DCT from the rolling neutral state to the exit gear state when the synchronized speed of the engine and the exit gear input shaft is equal to a calibrated exit speed defined by the exit gear state. A system for controlling the DRSS is provided.

Abstract: A vehicle includes an internal combustion engine, brake actuators configured to slow the vehicle in response to braking commands, and a transmission. The transmission includes a plurality of gear sets each having a plurality of nodes, an input member that is continuously connected to the engine and to a node of one of the gear sets, a reverse clutch, a binary clutch assembly, and a controller. The binary clutch assembly is connected at least to the same gear set as the input member, and is applied with the reverse clutch when entering a reverse gear state. The controller executes a method to transmit the braking commands to the brake actuators in response to a requested garage shift into a reverse gear state when the vehicle is rolling above a calibrated speed threshold, and thereby slows the vehicle until a calibrated target slip is achieved across the binary clutch assembly.

Abstract: A method for controlling a turbocharger is provided. The turbocharger has a turbine operatively connected to an exhaust of an internal combustion engine, and a compressor operatively connected to an intake of the engine. The method includes determining a boost pressure command for the compressor. The boost pressure command is configured to provide sufficient combustion reactant for the engine. The method includes calculating a compressor power from the determined boost pressure command, and calculating a turbine flow from the calculated compressor power. The method commands the turbocharger to operate at the calculated turbine flow.

Abstract: An apparatus for providing a coolant to a stator and a rotor of an electric motor in a vehicle having a coolant pump is provided. The apparatus includes a base defining a plurality of first openings through at least one of which the coolant is flowable to the stator. The apparatus also includes at least one wall extending from the base to define a cavity configured to receive the coolant from the coolant pump. The apparatus further includes at least one first raised member within the cavity that extends from the base. The at least one first raised member defines at least one second opening substantially aligned with one of the first openings to form a first passageway through which the coolant is flowable to the rotor. The apparatus may be located above the electric motor such that the coolant is flowable by gravity to the stator and/or the rotor.

Abstract: A method is provided for estimating vehicle velocity for a vehicle using a single-antenna global positioning system (GPS). An absolute speed and a course angle of the vehicle is measured using the single-antenna GPS. The yaw rates of the vehicle are measured independently of the GPS. An integrated yaw rate of the vehicle is calculated as a function of the measured yaw rates over a period of time. A yaw angle is determined as a function of a reference yaw angle and the integrated yaw rate. Aside slip angle is calculated as a function of the estimated yaw angle and the course angle provided by the GPS. The vehicle velocity is determined as a function of the absolute speed and the side slip angle. The vehicle velocity is provided to a vehicle dynamic control application.

Abstract: In one exemplary embodiment, a method for active fuel management in an engine having a plurality of cylinders is provided, the method including stopping a fuel flow into a first set of the plurality of cylinders, the stopping causing a deactivation of the first set of cylinders and continuing injection of fuel into a second set of the plurality of cylinders to provide power while the first set of cylinders are deactivated. The method also includes injecting gas into the first set of the plurality of cylinders when each of the first set of cylinders are at bottom dead center, the injected gas increasing a cylinder pressure in each of the first set of cylinders that reduces an amplitude of first order torque variations during operation of the engine while the first set of cylinders are deactivated.

Abstract: A method and system for manipulating, adjusting or otherwise controlling a state-of-charge (SOC) operating range for a high voltage vehicle battery, such as the type used for hybrid or electric vehicle propulsion. By providing a dynamic SOC operating range that changes in response to changing battery conditions, the battery performance may be improved so that the battery life is extended. Depending on the particular embodiment, the dynamic SOC operating range may have different combinations of hard and/or soft boundaries or limits.

Abstract: One embodiment includes a method of forming a hydrophilic particle containing electrode including providing a catalyst; providing hydrophilic particles suspended in a liquid to form a liquid suspension; contacting said catalyst with said liquid suspension; and, drying said liquid suspension contacting said catalyst to leave said hydrophilic particles attached to said catalyst.

Abstract: A powertrain system includes a torque machine rotatably coupled to an internal combustion engine via a pulley mechanism. The torque machine and the internal combustion engine are configured to transfer torque to a driveline and include a first sensor configured to monitor rotation of the engine and a second sensor configured to monitor rotation of the torque machine. The first sensor signally connects to a controller configured to control operation of the torque machine. A method for operating the powertrain system includes employing a signal output from the first sensor to monitor rotation of the torque machine to control operation thereof, said signal output from the first sensor adjusted for a pulley ratio of the pulley mechanism upon detecting a fault associated with the second sensor.

Abstract: A reflector is used to extend an aperture of an omni-directional, single-point remote-sensing echo-system utilizing secondary round-trip reflections of a transmitted sensor signal. The reflector is spatially displaced from a transmission element to contribute a secondary reflection whose echo from the target object provides additional information used to triangulate both azimuthal and elevation angles of the target object.

Abstract: Methods and systems are disclosed for authorizing operation of an electric vehicle that is being charged at a charging station. A computer can determine whether predefined criteria relating to the electric vehicle have been satisfied, and, if so, communicates a virtual key to the electric vehicle. The virtual key allows the electric vehicle to be operated in a limited operating mode that defines constraints on operating the vehicle. The virtual key allows the electric vehicle to be operated in the limited operating mode without a physical key or fob being present at the electric vehicle. The electric vehicle includes a processor configured to receive the virtual key and to control operation of the electric vehicle according to the constraints defined by the virtual key.

Abstract: A method for controlling a variator of a continuously variable transmission includes combining, by a controller, a periodically repeating excitation signal and a desired variator speed ratio signal. A variator ratio derivative is determined based upon the desired variator speed ratio signal combined with the excitation signal. A variator control parameter is determined based upon the variator ratio derivative. The variator control parameter is sent to the controller for controlling the variator in response thereto.

Abstract: A side spoiler arrangement for a motor-driven tailgate of a motor vehicle is provided. The side spoiler arrangement case includes at least one spoiler element arranged along a lateral edge of a rear window. The spoiler element provides a function for improving the aerodynamics of the motor vehicle. An obstruction sensor device is fastened to the spoiler element and coupled to a drive of the tailgate.

Abstract: Methods and systems are provided for alerting a driver of a vehicle having a transparent conformal display unit. In one embodiment, a method includes: detecting that an object is located in proximity to the vehicle based on sensor data; determining at least one of a time and a distance associated with the detected object based on vehicle conditions; generating an image that illustrates the at least one of time and distance based on vehicle conditions; and selectively generating a display signal to display the image on a transparent display of the vehicle through the transparent conformal display unit.

Abstract: A system according to the principles of the present disclosure includes a vibration level module and an engine operation control module. The vibration level module estimates a first level of vibration in a vehicle due to contact between tires of the vehicle and a road surface as the vehicle travels over the road surface. The vibration level module estimates a second level of vibration in the vehicle due to an engine in the vehicle. The engine operation control module selectively adjusts at least one of a speed of the engine and a load on the engine when the second vibration level is less than the first vibration level.

Abstract: A method of determining an optimal grasp pose of an object by an end-effector of a robot in the execution of a task includes receiving a set of inputs via a controller, including a descriptive parameter of the object, a task wrench having a frame of reference, and a commanded end-effector grasp force. The method includes calculating a grasp wrench in the frame of reference of the task wrench, rotating and shifting the grasp pose, and then computing a resultant new grasp wrench via the controller until the task wrench and the grasp wrench are optimally balanced. Additionally, the method includes recording the optimal grasp pose as the grasp pose at which the grasp and task wrenches are optimally balanced, and then executing a control action via the controller using the recorded optimal grasp pose. A robotic system includes the robot and a controller programmed to execute the method.

Abstract: A separator for use in a lithium ion battery to provide a physical and electrically insulative mechanical barrier between confronting inner face surfaces of a negative electrode and a positive electrode may be formed predominantly of heat-resistant particles. The heat-resistant particles, which have diameters that range from about 0.01 ?m to about 10 ?m, are held together as a thin-layered, handleable, and unified mass by a porous inert polymer material. The high content of heat-resistant particles amassed between the confronting inner face surfaces of the negative and positive electrodes provides the separator with robust thermal stability at elevated temperatures. Methods for making these types of separators by a phase-separation process are also disclosed.

Abstract: In accordance with exemplary embodiments, battery capacity of an electric vehicle can be automatically determined. In an exemplary method, an instruction is received to determine a battery capacity value and one or more vehicle accessories are activated to discharge the battery to a first charge level. When the first charge level is reached, a generator in the vehicle is started and used to charge the battery to a second charge level, after which the battery capacity value can be determined and stored. In accordance with the exemplary embodiments, the vehicle comprises a controller adapted to cause a battery to be discharged and charged to determine a capacity value of the battery. A plurality of accessories are configured to activate and deactivate responsive to the controller to discharge the battery, while a generator is responsive to the controller to charge the battery so that the controller can determine the battery capacity value.