Abstract: A circuit is provided for detecting peaks of a sinusoidal input signal includes circuitry for generating first and second sinusoidal output signals that are out of phase with one another and with the sinusoidal input signal. A comparator block compares the sinusoidal output signals to determine instances where the amplitudes of the first and second sinusoidal output signals cross over each other. The sinusoidal output signals may lead the sinusoidal input signal somewhat so that, after taking into account processing delay, the indicated crossover instances substantially coincide with peaks in the sinusoidal input signal such that a trigger signal generated by the circuit accurately indicates the timing of the peaks.

Abstract: A thermal management system is provided for a vehicle having an electric traction motor. The system includes a coolant system configured to convey coolant through a first thermal load, a refrigerant circuit including a condenser and a compressor configured to compress a refrigerant, a control system and a sensor. The refrigerant circuit is configured to cool at least one second thermal load. The sensor is configured to send signals to the control system that are indicative of a temperature of the first thermal load. The control system is configured to control an outlet pressure of the compressor based on the signals.

Abstract: A phase-change material is used as part of the thermal management system to assist in maintaining a thermal load, such as a battery pack, within a selected temperature range, thereby reducing the consumption of battery power. The phase-change material may be conditioned to an initial state when the vehicle is on-plug and may be used to heat or cool the battery pack directly or indirectly, thereby reducing the use of an electric battery heater. The phase-change material may be used to heat coolant that flows to the thermal load. In another embodiment the phase-change material may be directly within the battery pack in contact with the cells. The phase-change material may be conditioned via the battery circuit heater when the vehicle is on-plug. The phase-change material may also be recharged during vehicle use off-plug using waste heat from the motor circuit thermal load.

Abstract: In one aspect, a set of male and female bus bars is provided. The male bus bar includes first and second conductors and an insulation layer therebetween. The male bus bar has a male connecting portion with one or more fingers. The female bus bar third and fourth conductors and an insulation layer therebetween. The female bus bar has a female connecting portion with one or more receptacles, each having contact surfaces that are free of insulation and that are positioned to contact contact surfaces on an associated finger which are free of insulation so as to connect the first conductor and the third conductor and to connect the second conductor and the fourth conductor. Each finger has a width. A gap exists between the contact surfaces of an associated receptacle. The width and gap are sized to provide a press fit between the fingers and the receptacles.

Abstract: A circuit is provided for detecting peaks of a sinusoidal input signal includes circuitry for generating first and second sinusoidal output signals that are out of phase with one another and with the sinusoidal input signal. A comparator block compares the sinusoidal output signals to determine instances where the amplitudes of the first and second sinusoidal output signals cross over each other. The sinusoidal output signals may lead the sinusoidal input signal somewhat so that, after taking into account processing delay, the indicated crossover instances substantially coincide with peaks in the sinusoidal input signal such that a trigger signal generated by the circuit accurately indicates the timing of the peaks.

Abstract: An electric drive module for use in electric vehicles includes an electric traction motor, a geared reduction unit driven by the electric motor, a differential unit interconnecting a pair of axleshafts to a pair of wheels, and a disconnect mechanism for selectively coupling and uncoupling the geared reduction unit and the differential unit. The disconnect mechanism is configured to normally couple the geared reduction unit to the differential unit. The disconnect mechanism uncouples the geared reduction unit from the differential unit to prevent peak torque transients and torque reversals between the electric motor and the wheels.

Abstract: An electric drive module for use in electric vehicles includes a first electric motor, a second electric motor, a continuously-variable gearbox assembly interconnecting the first and second electric traction motors to a pair of wheels, and a third electric motor for controlling a direction and rotary speed of a component of the gearbox assembly so as to continuously vary a speed ratio between the wheels.

Abstract: In one aspect, a set of male and female bus bars is provided. The male bus bar includes first and second conductors and an insulation layer therebetween. The male bus bar has a male connecting portion with one or more fingers. The female bus bar third and fourth conductors and an insulation layer therebetween. The female bus bar has a female connecting portion with one or more receptacles, each having contact surfaces that are free of insulation and that are positioned to contact contact surfaces on an associated finger which are free of insulation so as to connect the first conductor and the third conductor and to connect the second conductor and the fourth conductor. Each finger has a width. A gap exists between the contact surfaces of an associated receptacle. The width and gap are sized to provide a press fit between the fingers and the receptacles.

Abstract: A battery management system for a vehicle having an electrically powered motor that is powered by a plurality of battery cells includes an electrical system for providing voltage and current from the battery cells to an electrical motor. A control is operable to at least one of (a) cause fuses of the electrical system to be the weakest link in the electrical system only during a failure event, (b) disconnect the battery cells from the battery management system only during a failure event, (c) separate the driving of balancing resistors into first and second stages, with the first stage comprising cell balancing control and the second stage comprising cell balancing with reverse voltage protection and (d) provide single stage reverse voltage protection to limit or effectively eliminate an electrical conduction path through a low impedance balancing circuit.

Abstract: An electric drive module for use in electric vehicles includes a first electric motor, a second electric motor, a continuously-variable gearbox assembly interconnecting the first and second electric traction motors to a pair of wheels, and a third electric motor for controlling a direction and rotary speed of a component of the gearbox assembly so as to continuously vary a speed ratio between the wheels.

Abstract: An electric drive module for use in electric vehicles includes an electric traction motor, a geared reduction unit driven by the electric motor, a differential unit interconnecting a pair of axleshafts to a pair of wheels, and a disconnect mechanism for selectively coupling and uncoupling the geared reduction unit and the differential unit. The disconnect mechanism is configured to normally couple the geared reduction unit to the differential unit. The disconnect mechanism uncouples the geared reduction unit from the differential unit to prevent peak torque transients and torque reversals between the electric motor and the wheels.

Abstract: A control system for a multiphase electric motor includes inputs for a desired torque output of the motor, a measured torque output of the motor, a signal representative of optimal motor efficiency; a signal representative of a measured efficiency of the motor. The output is a two-dimensional DQ control voltage. A torque feedback control loop minimizes error between the desired and measured torque outputs by controlling an angle of the DQ control voltage, and a motor efficiency feedback control loop minimizes error between the optimal and measured motor efficiencies by controlling a magnitude of the DQ control voltage.