Abstract: A charging system and method that improves utilization of available AC power during onboard charging of energy storage systems of electric vehicles. An onboard charging method for an energy storage system of an electric vehicle, the method using an AC power source, includes a) establishing a maximum DC charging current for the energy storage system responsive to a control signal indicating real-time available current/power from the AC source; and b) controlling a charging system to provide an actual DC charging current, up to the maximum DC charging current, to the energy storage system.

Abstract: A management system for a battery cell pack, the management system including a controller determining an adjustable charge profile for the battery cell pack wherein the adjustable charge profile includes an operational parameter identifying a next operation drive range mode from a set of drive range modes for the battery cell pack wherein each the drive range mode includes a state of charge (SOC) window between a charge SOC and a discharge SOC, with the set of drive range modes including a first drive range mode having a first SOC window and including a second drive range mode having a second SOC window less than the first SOC window; and one or more energy transfer stages to produce the charge SOC of the next operation drive range mode in the battery cell pack.

Abstract: A fuel delivery system and method of use are provided that may be used to open the door covering the charge port of an electric vehicle, or the door covering the fuel filler port of a conventional vehicle. The system includes a fuel coupler (e.g., a charging connector or a gas nozzle) designed to transfer fuel from the source to the vehicle via the vehicle's fuel port. The fuel coupler includes a switch that when toggled, causes a control signal to be wirelessly transmitted over a short distance. Upon receipt of the control signal by a receiver integrated into a vehicle that is in close proximity to the fuel port, an unlatching actuator within the vehicle unlatches the port door, thereby allowing it to open and provide port access.

Abstract: A contamination cleaner for a socket of a charging connector used with a charging station for an electric vehicle wherein the charging connector mates to a charging coupler of the electric vehicle during charging includes a housing mechanically configured generally similarly to the charging coupler enabling the housing to mechanically mate to the charging connector; and a cleaning contact, coupled to the housing and complementary to the socket, for engaging the socket and removing surface contaminants from the socket whenever the housing mechanically mates to the charging connector.

Abstract: A system and method for charging a metal-air battery pack at the maximum possible rate while maintaining an ambient oxygen concentration below a preset concentration is provided, thereby minimizing the risks associated with generating oxygen during the charging cycle.

Abstract: A controller identifies a condition of a hazardous internal short by comparing patterns of series element voltages to the last known balance condition of the series elements. If the loaded or resting voltage of one or more contiguous series elements uniformly drop from the previously known condition by an amount consistent with an over-current condition, an over-current internal short circuit fault is registered. The desired response is to prevent the affected series elements from heating to a hazardous temperature by summoning the maximum heat rejection capability of the system until the short ceases and the affected elements cool, the cooling function is no longer able to operate due to low voltage, or the affected series string has drained all of its energy through the short. Also includes are responses that allow the battery pack to continue to power the cooling system even though it may enter an over-discharged state.

Abstract: A system and method for a shielded coaxial cable including a collar including a cylindrical housing having a cylindrical inner bore, the inner bore having top and bottom openings the top opening having a diameter about equal to an outer diameter of an outer insulating layer of the cable and the bottom opening having a diameter about equal to an outer diameter of a shield layer of the cable with a terminating portion of the shield layer exposed and returned over an exterior portion of said collar near the bottom opening with the terminating portion overlapping said exterior portion; and a termination ferrule joined to the terminating portion that overlaps the exterior portion to simultaneously provide an electrical communication between the shield layer and the collar and provide a strain relief for the shielded cable disposed within the inner bore.

Abstract: An impact protection structure for a vehicle impacting a blunt-object barrier includes a support structure of the vehicle, an energy absorbing rail coupled to the support structure, and a localized energy dissipation structure. The energy absorbing rail extends an energy absorbing rail length and includes a plurality of lumens. The localized energy dissipation structure extends a localized energy dissipation structure length less than the energy absorbing rail length.

Abstract: A method for charging a metal-air battery pack at the maximum possible rate while maintaining an ambient oxygen concentration below a preset concentration is provided, thereby minimizing the risks associated with generating oxygen during the charging cycle.

Abstract: An apparatus, including a sealed housing defining a manifold having an inlet port for receiving an input fluid stream into the manifold and an outlet port for exiting an output fluid stream from the manifold; and a bleed structure having a proximal end, a distal end, and a hollow channel communicating a first opening at the proximal end to a second opening at the distal end, the distal end disposed within the manifold and the proximal end disposed in the outlet port outside of the manifold.

Abstract: A charging method using a multiphase line voltage for charging an energy storage system (ESS) using a polyphase motor drive circuit communicated to a polyphase motor, the polyphase motor drive circuit including a plurality M of driver stages, one driver stage for each phase of the polyphase motor with each driver stage coupled across the energy storage system.

Abstract: A system and method for providing energy management and maintenance of a high energy battery pack through use self-discharge features and processes. A battery pack is configured with self-discharger enabled-components that selectively discharge energy from the battery pack without the battery pack providing operational power.

Abstract: A charging system for a battery pack, including a charging station transferring energy to the battery pack at a maximum fast charge rate in a first operational mode and transferring energy to the battery pack at a slower charge rate in a second operational mode; a data collection system acquiring data indicating a state of charge of the battery pack and one or more desired charge optimization parameters; and a station control, responsive to the data and to the desired charge optimization parameters, automatically establishing a charging profile for the battery pack to assert a control signal and operate the charging station in the second operational mode whenever the charging station is able to transfer sufficient energy to the battery pack at the slower charge rate to meet an SOC target and a charge completion time target.

Abstract: A system and method for providing energy management and maintenance of a high energy battery pack that does not require installation of the battery pack into an operational EV. A battery service unit has multiple access mechanisms to charge or discharge a high energy battery pack through a primary or secondary high voltage port of the pack, irrespective of whether the battery pack is installed into an operating environment by adding a capability of providing a signature duplicating installation of the pack in the operating environment when necessary.

Abstract: A system and method for providing energy management and maintenance of a high energy battery pack that does not require installation of the battery pack into an operational EV. A secondary service port is provided to enable certain maintenance operations while by-passing battery pack interlocks and protection mechanisms used when the battery pack is installed into an operating environment.

Abstract: A rear structure for a vehicle is provided, the structure including (i) a pair of single piece rear torque boxes; (ii) a pair of rocker panels mechanically coupled to the rear torque boxes; (iii) a pair of rear rails mechanically coupled to the rear torque boxes; and (iv) at least one cross-member interposed between and mechanically coupled to the rear torque boxes.

Abstract: A vehicle charge inlet integrated into a port assembly surface is provided. The charge inlet includes an inlet housing with a perimeter that is curvilinear, non-cylindrical and shaped so that only a single orientation of a complementary sized and shaped electrical connector may be inserted into the inlet. A plurality of electrical contacts, a latching mechanism and a divider are also integrated into the charge inlet housing, the divider extending from the bottom surface of the inlet housing and configured to fit within a complementary slot of the charge connector, the divider providing further electrical isolation between the electrical contacts. A funneling surface connects the open end of the inlet housing to the port assembly surface.

Abstract: A system and method for low-cost, fault tolerant, EMI robust data communications, particularly for an EV environment. A data communications method, including a) enabling a transmission of a wake signal from a host to a remote client through an isolator disposed at the remote client when the wake signal is asserted from the host at a host-portion of the isolator concurrent with a periodic enablement of a client-portion of the isolator by the remote client; and thereafter b) transmitting the wake signal from the host to the remote client through the isolator; c) controlling enablement of the client-portion responsive to the wake signal transmitted through the isolator; and thereafter d) disabling the transmission by deassertion of the wake signal at the host.

Abstract: A system and method for low-cost, fault tolerant, EMI robust data communications, particularly for an EV environment.