Abstract: A cooled high-power vehicle inductor includes an inductor core including a central axis; a first series of inductor windings around the central axis of the cooled high-power vehicle inductor, the first series of inductor windings having an outer perimeter; a second series of inductor windings around the central axis of the cooled high-power vehicle inductor, the second series of inductor windings having an inner perimeter that is substantially outside the outer perimeter of the first series of inductor windings, wherein the second series of inductor windings is electrically coupled to the first series of inductor windings; and a first heat transfer insert that is disposed between the outer perimeter of the first series of inductor windings and the inner perimeter of the second series of inductor windings, the first heat transfer insert forming a heat transfer path.

Abstract: An ultracapacitor energy storage cell pack includes an ultracapacitor assembly including a plurality of parallel ultracapacitors and balancing resistors in series; an enclosure for the ultracapacitor assembly; a controller; one or more temperature sensors; a pack voltage sensor; a GFI sensor; one or more cooling fans carried by the enclosure; an on/off relay coupled to the ultracapacitor assembly and the controller, the on/off relay activated by the controller during normal operation of the ultracapacitor assembly and deactivated by the controller when the GFI sensor detects a ground fault interrupt condition, the one or more temperature sensors detect an over-temperature condition, or the pack voltage sensor detects an over-voltage condition; and a pre-charge resistor and a pre-charge relay coupled to the ultracapacitor assembly and the controller, and activated by the controller to cause the pre-charge resistor to limit pack charge current until the ultracapacitor assembly reaches a minimum voltage.

Abstract: This invention is a system and a method that uses the braking resistor, commonly used and available in electrically or hybrid-electrically propelled vehicles, to limit the precharge current during the startup of a high power ultracapacitor pack energy storage device and/or safely and rapidly discharge an ultracapacitor pack for maintenance work or storage to lengthen the life of the individual ultracapacitor cells and, correspondingly, the whole pack. The use of the braking resistor for precharging an ultracapacitor energy storage pack is an effective and less expensive method compared to other methods such as a separate DC-to-DC converter. This method includes the control logic sequence to activate and deactivate switching devices that perform the connections for the charging and discharging current paths.

Abstract: A deaeration device for deaerating coolant fluid flow in a recirculation cooling system, where the recirculation cooling system includes a cooling fluid reservoir adapted to receive the deaeration device submerged within cooling fluid therein, includes an elongated deaeration tube including a fluid outlet and a deaerating skimming shaped slot for skimming air bubbles and cooling fluid from cooling fluid flow flowing through the deaeration tube, and including a fluid inlet for allowing the same amount of fluid that is skimmed off and removed through the top fluid outlet to re-enter the deaeration tube to maintain mass balance in the cooling fluid flow.

Abstract: A method of using an externally powered HVAC system for an over-the-road motor coach includes coupling the HVAC system to an external shore power source at a temporary stop location for the over-the-road motor coach while the over-the-road motor coach is parked and vehicle engine is turned off; receiving electrical power from the electrical outlet to power the HVAC system; and using the HVAC system to circulate refrigerant for heating or cooling an interior cabin of the over-the-road motor coach and power HVAC fans to ventilate the interior cabin of the over-the-road motor coach.

Abstract: A method of using an externally powered HVAC system for an over-the-road motor coach includes coupling the HVAC system to an external shore power source at a temporary stop location for the over-the-road motor coach while the over-the-road motor coach is parked and vehicle engine is turned off; receiving electrical power from the electrical outlet to power the HVAC system; and using the HVAC system to circulate refrigerant for heating or cooling an interior cabin of the over-the-road motor coach and power HVAC fans to ventilate the interior cabin of the over-the-road motor coach.

Abstract: An energy storage device coupler for transferring heat away from ends of ultracapacitors of an ultracapacitor energy storage cell pack without shorting out terminals to cases of the ultracapacitors. The energy storage device coupler includes an ultracapacitor engagement member configured to be in thermal contact with the end of the ultracapacitor and including and holes configured to receive terminals of adjacent ultracapacitors; and a heat sink engagement member connected to the ultracapacitor engagement member and configured to be coupled to one or more heat sink devices for removing heat from the ultracapacitor.

Abstract: A cooled high-power vehicle inductor includes an inductor core including a central axis; a first series of inductor windings around the central axis of the cooled high-power vehicle inductor, the first series of inductor windings having an outer perimeter; a second series of inductor windings around the central axis of the cooled high-power vehicle inductor, the second series of inductor windings having an inner perimeter that is substantially outside the outer perimeter of the first series of inductor windings, wherein the second series of inductor windings is electrically coupled to the first series of inductor windings; and a first heat transfer insert that is disposed between the outer perimeter of the first series of inductor windings and the inner perimeter of the second series of inductor windings, the first heat transfer insert forming a heat transfer path.

Abstract: A system and method for providing power to vehicle accessories having operational power requirements in excess of 1 kilowatt. The system is employed in conjunction with a vehicle comprising a main power unit and an electric motor, the main power unit providing more than 42 volts of power to a DC power bus from which the electric motor draws power to propel the vehicle. The system comprises a vibration dampening mounting structure affixed to the vehicle. A vehicle accessory requiring operational power in excess of 1 kilowatt and an electric accessory motor are affixed to the mounting structure. The electric accessory motor is mechanically coupled to the vehicle accessory. The electric accessory motor draws electric power from the DC power bus to provide operational power to the vehicle accessory. The vehicle accessory can be a scroll type air compressor.

Abstract: An energy storage pack specially adapted for a hybrid electric vehicle, the energy storage pack having overvoltage protection and a method of protecting the same. In particular, the energy storage pack includes a robust, low-cost, parasitic circuit configured to detect overvoltage conditions within the vehicle energy storage and report it to the vehicle.

Abstract: A generator voltage stabilization system of a heavy-duty vehicle hybrid-electric drive system, which has an engine and a generator coupled with the engine for generating power that varies with rotational speed of the engine, includes one or more circuits having at least one of a DC/DC converter and an DC/AC converter configured to be coupled to the generator, and receive varying power input from the generator and provide stabilized voltage output power; and a control computer coupled to the one or more circuits to control the one or more circuits to provide stabilized voltage output power with varying power input from the generator.

Abstract: This invention is a system and a method that uses the braking resistor, commonly used and available in electrically or hybrid-electrically propelled vehicles, to limit the precharge current during the startup of a high power ultracapacitor pack energy storage device and/or safely and rapidly discharge an ultracapacitor pack for maintenance work or storage to lengthen the life of the individual ultracapacitor cells and, correspondingly, the whole pack. The use of the braking resistor for precharging an ultracapacitor energy storage pack is an effective and less expensive method compared to other methods such as a separate DC-to-DC converter. This method includes the control logic sequence to activate and deactivate switching devices that perform the connections for the charging and discharging current paths.

Abstract: A system and a method that provides fuel cell and energy storage hybrid-electric propulsion and control for a heavy-duty vehicle over 10,000 pounds GVWR. Power output is supplied from a fuel cell system to a high-power intermediate DC bus through a fuel cell DC/DC converter. Power output is supplied from an energy storage system to the high-power intermediate DC bus through a separate energy storage fuel cell DC/DC converter. The received power is combined on the high-power intermediate DC bus to create a stable voltage. The stable voltage from the high-power intermediate DC bus is supplied to one or more electric motors/generators to accelerate the heavy duty vehicle.

Abstract: A method of using an engine cooling system with a bus includes providing a horizontal rooftop engine cooling system including a radiator unit through which coolant fluid flows for removing heat from the radiator unit, a fan to assist in removing heat from the radiator unit, and a continuously variable power drive and speed control system for controlling power to and the speed of the fan; horizontally locating the rooftop engine cooling system on a rooftop of the bus; interconnecting the radiator unit of the rooftop engine cooling system to a passage of an engine of the bus to allow coolant to flow between the engine and the rooftop cooling system to cool the engine; and controlling power to and the speed of the fan with the continuously variable power drive and speed control system using pulse width modulation.

Abstract: A system and method for providing power to vehicle accessories having operational power requirements in excess of 1 kilowatt. The system is employed in conjunction with a vehicle comprising a main power unit and an electric motor, the main power unit providing more than 42 volts of power to a DC power bus from which the electric motor draws power to propel the vehicle. The system comprises a vibration dampening mounting structure affixed to the vehicle. A vehicle accessory requiring operational power in excess of 1 kilowatt and an electric accessory motor are affixed to the mounting structure. The electric accessory motor is mechanically coupled to the vehicle accessory. The electric accessory motor draws electric power from the DC power bus to provide operational power to the vehicle accessory. The vehicle accessory can be a scroll type air compressor.

Abstract: A braking regeneration and propulsion system for a passive trailer including wheels with axles includes a gear box to be operatively coupled to the axle; a motor/generator operatively coupled to the gear box; an energy storage system for storing captured energy and supplying energy; and a control computer to assist deceleration of the passive trailer by causing the axle to drive the motor/generator via the gear box and supply energy to the energy storage system during deceleration, and, assist acceleration of the passive trailer by causing the motor/generator to draw energy from the energy storage system and drive the wheels via the gear box and axle during acceleration.

Abstract: A start-stop or idle-stop method for a heavy-duty hybrid vehicle that turns off the fuel supply while maintaining the crankshaft rotation of the internal combustion engine when the vehicle stops or, optionally, when the vehicle travels downhill, travels in a noise sensitive location, travels in an exhaust emissions sensitive location, or operates in an emergency situation. The stop-start or idle-stop method automatically turns on the engine fuel supply to restart combustion when the vehicle starts accelerating, is no longer traveling downhill, is no longer traveling in a noise sensitive or exhaust sensitive location, is no longer in an emergency situation, or has dropped below the minimum energy storage restart level.

Abstract: A heavy-duty hybrid vehicle power system includes a main power unit located in an engine compartment; an electric propulsion motor; a DC bus that receives DC power from the main power unit; a vehicle accessory traditionally powered directly from an internal combustion engine of a conventional heavy-duty vehicle and requiring more than 1 kilowatt of power; an electric accessory motor, which is electrically coupled with the DC bus and mechanically coupled with the vehicle accessory, configured to supply power to the vehicle accessory, and the electric accessory motor and vehicle accessory carried by the heavy-duty vehicle either inside or outside of the engine compartment; and at least one of an ultracapacitor pack and a fly wheel coupled with the DC bus and configured to store power when the main power unit is on and supply power in place of the main power unit when the main power unit is off.