Abstract: An access assembly for a high voltage box or inverter which reduces the associated risk of exposure to charged components, such as high voltage power electronics, where an interlock is required. The access is limited so that the system may deactivate some functionality, and/or internal devices are discharged to allow safe access. The access assembly includes a wireless detection method using a sensor circuit paired with a magnet that detects if a cover or connector is removed. The magnet is mounted to the cover or connector. This detection may be made through walls of non-magnetic material, which avoids the incorporation of extra components such as PCBs or a pigtail harness, enables a much simpler EMC shielding by avoiding unwanted openings, and simplifies assembly by reducing required operations and processes. The access assembly may be used for applications where controlled access is required for installation or service of power electronic products.

Abstract: An AC carrier assembly, which includes a housing, a receptacle integrally formed as part of the housing, a plurality of busbars extending through the housing, a core at least partially disposed in the receptacle, the core surrounding the busbars to dampen electromagnetic interference. A plurality of sub-housings are integrally formed as part of the housing, and each of a plurality of flux concentrators, is disposed in a corresponding one of the sub-housings. The AC carrier assembly also includes a cover attached to the housing, and a plurality of conductors. Each of the conductors is connected one of the busbars, and each of the flux concentrators surrounds a corresponding one of the busbars. Each sub-housing includes a cavity, and one of the flux concentrators is at least partially disposed in the cavity of the sub-housing. Each sub-housing may be overmolded around the flux concentrators.

Abstract: A smart actuator assembly having an overmolded electronics assembly, where the overmolded electronics assembly includes a printed circuit board (PCB), at least one terminal mounted to the PCB, a housing at least partially surrounding the PCB, the terminal protruding out of the housing, and at least one bearing holder integrally formed as part of the housing. The smart actuator assembly includes a motor subassembly, where the motor subassembly has a motor housing, a shaft at least partially extending into the motor housing, a rotor mounted to the shaft, and at least one bearing assembly mounted to the shaft adjacent the rotor. The overmolded electronics assembly is connected to the motor subassembly such that the bearing is at least partially disposed in the bearing holder.

Abstract: A battery management system having at least one optical pathway including a plurality of optical communication devices connected to one of a plurality of batteries. Each optical communication device emits optical signals, the optical signals include data about the batteries. Each of the optical communication devices includes an optical emitter operable for emitting the optical signals, an optical sensor operable for receiving the optical signals, a controlling circuit for processing the optical signals, and a printed circuit board (PCB). The optical emitter, the optical sensor, and the controlling circuit are mounted to the PCB. The optical pathway includes a layer of transparent film, and a layer of reflective film is connected to the layer of transparent film. The optical signals which pass through the layer of transparent film and reflect off of the layer of reflective film are received by the optical sensor of one of the optical communication devices.

Abstract: A cooling system for a belt starter generator, which has at least one housing portion, a plurality of flow apertures integrally formed as part of the housing portion, a heat sink connected to the housing portion, the heat sink cooled by liquid cooling, and a plurality of fins integrally formed as part of the heat sink. A rotor having a shaft is at least partially disposed in the housing portion, and a plurality of slots are integrally formed as part of the rotor. An impeller having a plurality of blades is mounted on the shaft. As the shaft rotates, the rotor and the impeller also rotate, and the blades generate air flow to create a flow path such that air flows between each of the fins, through the flow apertures, and through the slots of the rotor, and through the blades, achieving air cooling of the belt starter generator.

Abstract: A control unit having a connection structure for connecting components of the control unit to a base plate which is cost effective, and facilitates heat transfer from a printed circuit board (PCB) to the base plate. The control unit includes circuitry mounted to a PCB, and the PCB is mounted to a base plate. The circuitry is over molded with epoxy material during manufacturing. The epoxy material flows between the PCB and the base plate, such that a layer of the epoxy is disposed between the PCB and the base plate. This layer of epoxy functions as a heat transfer layer, and a connection structure to connect the PCB to the base plate. The epoxy material transfers heat from the surface of the PCB in contact with the layer of epoxy to the surface of the base plate in contact with the layer of epoxy.

Abstract: A seal assembly which includes a combination of an outer sleeve and an inner sleeve, which has a low friction sliding interface, such that the seal assembly provides desired sealing force and frictional force characteristics. When assembled, the seal assembly surrounds a rotor, such that the seal assembly is disposed between the outer surface of the rotor and the inner surface of a housing. The inner sleeve includes one or more ribs which are in contact with the outer surface of the rotor, which concentrates the sealing in the area of the ribs. The concentration of the sealing reduces the total friction between the rotor and the inner sleeve, while maintaining proper sealing force. The ribs formed as part of the inner sleeve are spaced apart such that the openings of the rotor are positioned relative to the ribs in a desired manner, regardless of the orientation of the rotor.

Abstract: A cooling system having several cooling features for a high-voltage (HV) inverter, which provide more desirable cooling of multiple power modules, and reduce the pressure drop from the inlet to the outlet. The HV inverter includes a separator disposed in the cavity of a housing, where the separator includes several flow apertures which shorten the flow path of at least a portion of coolant fluid from the inlet to the outlet. The combination of the diameter of the flow apertures and location of the flow apertures between the inlet and the heat object location (i.e., one or more power modules), improves/reduces the temperature difference between a first of the power modules and one or more of the power modules which are located further away from the inlet. Also, the location of the flow apertures achieves a shorter distance terminal between the inlet and the outlet, improving the overall pressure drop.

Abstract: A method of operating a DC-DC converter circuit to maintain an output current to charge a battery is disclosed. The method includes receiving an output voltage of the DC-DC converter circuit and receiving a desired charging current to charge a battery. When the output voltage is greater or equal to the predefined output voltage, the method includes adjusting an operational frequency to a synchronous second gate signal that is synchronous with a first gate signal, where the first gate signal and the second gate signal are each operating at 50% duty cycle and causing the output current to be adjusted to the desired output charging current. When the output voltage is less than the predefined output voltage, the method includes applying an operational time shift to a second gate signal (operating at 50% duty cycle and ƒo) producing the second voltage waveform in the bridge circuit.

Abstract: A system and method for determining gains of a Proportional-Integral-Derivative (PID) controller is disclosed. The method includes receiving actuator data from an actuator and determining a load torque of the actuator based on the received actuator data and a data model stored on memory hardware. The method also includes determining a gain based on the load torque and the actuator data and applying the gain to the actuator.

Abstract: An electronics assembly which includes a grounding connection, having a housing, a connector, a portion of the connector formed around the housing, a recess portion integrally formed as part of the connector, a substrate located in proximity to the connector, and circuitry mounted to the substrate such that the circuitry is at least partially disposed in a cavity formed as part of the connector. A conductor is mounted to the connector such that the conductor is located in the recess, and the conductor is in contact with the housing and the substrate. A grounding connection is formed between the circuitry and the housing when the conductor is in contact with the housing and the substrate. The conductor may be made of an elastomeric material, and the conductor deforms when the substrate is placed in proximity to the connector.

Abstract: A heat dissipation structure for a belt starter generator (BSG) which reduces the temperature of one or more ground screws used to connect a printed circuit board (PCB) to a cooling device of the BSG. The PCB is part of an inverter, and the inverter of the BSG is grounded using two ground screws that fix the PCB to the cooling device. A heat dissipation bridge is connected to the two ground screws, the PCB, and the cooling device. The heat dissipation bridge is connected to the grounds screws such that the heat dissipation bridge is located and in contact with an area of the cooling device where the coolant is flowing through a flow cavity. The heat dissipation bridge absorbs the colder temperature from the cooling device therefore lowers the temperatures of the ground screws to a safe level for the components of the PCB.

Abstract: A clamping mechanism used for connecting one or more conduits or hoses to a housing. The clamping mechanism uses bolt tension and a wedge interface, where the perpendicular movement of the wedge interface reduces the interface distance and creates compression in the desired direction. At least one clamping component is assembled from one axis perpendicular from the clamping to achieve desired sealing. The interface of the clamp, a tube flange, and a housing create a progressive clamping force based on several wedge-shaped features. A portion of the interface may be molded into a separate part such that there are multiple connections using a single clamping mechanism.

Abstract: A high-voltage electronic box assembly, having a high-voltage electronic box and a multi-directional connector assembly inside the high-voltage electronic box, and a junction box housing is connected to the high-voltage electronic box differently in each of a plurality of configurations. A negative terminal is connected to the first negative bus bar in a first of the plurality of configurations and a second of the plurality of configurations, and the negative terminal is connected to the second negative bus bar in a third of the plurality of configurations and a fourth of the plurality of configurations, a positive terminal is connected to the first positive bus bar in the first of the plurality of configurations and the second of the plurality of configurations, and the positive terminal is connected to the second positive bus bar in the third of the plurality of configurations and the fourth of the plurality of configurations.

Abstract: A progressive stopper for a pressure sensing element is able to redistribute and reduce the stress of a diaphragm exposed to high pressure via multi-step contacts, such as at least dual contacts, where the diaphragm (designed for detecting pressure within a defined pressure range) is enabled to withstand much higher pressures above of the defined pressure range, such that the progressive stopper prevents catastrophic failure of the diaphragm. The progressive stopper is created to redistribute and reduce stress on the diaphragm significantly and effectively. The progressive stopper does not limit the output of the pressure sensing element such that the pressure sensing element is able to maintain the output voltage above the maximum output voltage of the defined pressure range when the diaphragm is exposed to high pressures with reduced stresses and strains.

Abstract: A spring retention system for securing a motor in a desired position. The spring retention system includes a captive feature, which includes a plurality of recesses formed as a motor support spring having a circular opening, which are engaged with a motor bearing housing. The spring retention system reduces motor displacement in multiple directions when the motor is exposed to vibrations, which reduces the cantilever bending on the motor shaft and the motor housing, also improving motor pinion run out. The spring retention system also includes a formed opening feature, which allows for the spring retention system to fit with motor bearings having different sizes. The spring retention system also includes a plurality of spring leg retention features formed as part of the motor support spring, which support the motor bearing housing on an axis, and the module housing supports the motor support spring.

Abstract: A progressive stopper for a pressure sensing element is able to redistribute and reduce the stress of a diaphragm exposed to high pressure via multi-step contacts, such as at least dual contacts, where the diaphragm (designed for detecting pressure within a defined pressure range) is enabled to withstand much higher pressures above of the defined pressure range, such that the progressive stopper prevents catastrophic failure of the diaphragm. The progressive stopper is created to redistribute and reduce stress on the diaphragm significantly and effectively. The progressive stopper does not limit the output of the pressure sensing element such that the pressure sensing element is able to maintain the output voltage above the maximum output voltage of the defined pressure range when the diaphragm is exposed to high pressures with reduced stresses and strains.

Abstract: A multi-port valve assembly, including a housing, a plurality of ports formed as part of the housing, and a rotor disposed in the housing, the rotor selectively in fluid communication with the ports. A first channel is integrally formed as part of the rotor, and a circumferential wall is part of the first channel, the circumferential wall at least partially surrounding a circular aperture which is also part of the first channel. The multi-port valve assembly also includes a second channel integrally formed as part of the rotor, the second channel fluidically isolated from the first channel, and at least two flow paths formed by the orientation of the rotor relative to the housing and the ports. The rotor is placed in one of a plurality of configurations relative to the ports and the housing such that each of the plurality of configurations includes the flow paths.

Abstract: A control unit having a connection structure for connecting components of the control unit to a base plate which eliminates the need for separate fasteners. The control unit includes circuitry mounted to a PCB, and the PCB is pre-assembled to a base plate, to form a pre-assembly. During assembly, the PCB and the base plate are aligned when placed in a tooling device which clamps and holds the pre-assembly in place during the over molding process. The circuitry is over molded with an epoxy material, such that the epoxy material flows from a top side of the PCB to underneath the base plate, and the PCB is fixed to the base plate without the use of fasteners such as screws, or adhesive materials.

Abstract: A heat dissipation structure for a casting block assembly, which includes a tube extending through a casting block, and the tube has at least one turbulence generating device to promote turbulence inside the tube and reduce boundary layer thickness, and therefore increase the heat transfer coefficient. The turbulence generating device is one or more ribs or dimples integrally formed as part of the tube, before forming the casting block around a portion of the tube. The ribs or dimples promote turbulence to reduce boundary layer thickness, and therefore increase the heat transfer coefficient. The turbulence generating devices promote higher turbulence intensity, a thinner boundary layer thickness, increased heat transfer coefficient, and a stronger bond between the tube and the casting block. The tube may have an elliptical cross-section, which allows for increased spacing between various portions of the tube while maintaining the same cross-sectional flow area, enhancing heat transfer.