Abstract: Methods and systems for creating a battery module. A battery cell can include a cooling device that cools a busbar and a power electronics package. To allow the cooling device to be attached to the busbar and allow the cooling device to cool both the power electronics and the busbar, the cooling device is mounted on the busbar with the busbar held between two portions of the cooling device and with the power electronics mounted on an opposite side of the cooling device from the busbar. The fluid or phase change material may then circulate through a cavity in the cooling device to cool both the power electronics and the busbar.

Abstract: Methods and systems are disclosed for controlling heat within a junction box. The disclosure relates to the use of phase change materials to manage heat generation in a junction box of a vehicle.

Abstract: A spring-loaded busbar has a first portion divided from a second portion by a first pair of notches and a third portion divided from the second portion by a second pair of notches. The second portion is bent relative to the first portion and the third portion is bent relative to the second portion. The busbar is configured to deform elastically when pressed against an electrical cell to ensure proper contact between the busbar and the cell before the busbar is welded to the cell.

Abstract: Systems and methods of detecting leakage and other issues with electrical battery housings are provided. By using an air compressor to alter the air pressure within a battery housing, a processor may detect an abnormal rate of change in the air pressure within the battery housing as compared to a rate of change of an ideal battery housing.

Abstract: A power module for a vehicle includes a bidirectional voltage converter to i) convert a first voltage to a second voltage and convert the second voltage back to the first voltage, and ii) convert the first voltage to a third voltage and convert the third voltage back to the first voltage. The power module includes one or more power sources coupled to the bidirectional voltage converter and to supply power to auxiliary components of the vehicle. The power module includes a controller to control the bidirectional voltage converter and the one or more power sources. The first voltage is for supplying power to a powertrain of the vehicle, and the second voltage and the third voltage are for supplying power to the one or more power sources.

Abstract: A power module for a vehicle includes a first bidirectional voltage converter to convert a first voltage to a second voltage and convert the second voltage back to the first voltage. The power module includes a second bidirectional voltage converter to convert the first voltage to a third voltage and convert the third voltage back to the first voltage. The power module includes a first battery coupled to the first bidirectional voltage converter to receive the second voltage, and a second battery coupled to the second bidirectional voltage converter to receive the third voltage. The power module includes a controller to control the first and second bidirectional voltage converters and the first and second batteries. The first voltage is for supplying power to a powertrain of the vehicle. The second voltage and the third voltage are for supplying power to the first and second batteries, respectively.

Abstract: Devices, methods, and systems are provided that incorporate and support a number of physical fusible links arranged in a terminal of a battery cell. The fusible links are configured as legs connecting a raised platform of a battery cell cap to a conductive base portion of the battery cell cap. Each of the fusible link legs is sized and shaped to function as a fusible link. The fusible link legs include a controlled cross-sectional area disposed along a length of the material making up the fusible link leg. In an overcurrent situation, the connection between an electrical system and a battery cell having the integrated fusible link legs is severed by the overcurrent melting the legs.

Abstract: Methods and systems for creating a battery module. A battery cell can include a vent in the bottom of the battery. To allow the battery to be attached to a cooling plate and allow the vent to function properly, an opening is formed in the cooling plate under the battery. The opening can vent gasses from the vent in the battery to atmosphere through a chamber in the cooling plate or a conduit in the cooling plate.

Abstract: Methods and systems for welding a terminal of a battery cell to corresponding terminal tab or busbar are described using a magnet that causes the terminal and tab/busbar to be placed in physical contact. The terminal of a battery cell is aligned in contact with the tab/busbar by the force of a magnetic field. A welder, e.g., a laser welder, can then generate a laser weld beam to weld the terminal of the battery cell to the tab/busbar. Next, the laser weld beam is narrowed, reducing the first diameter to a smaller second diameter. Without touching the tab/busbar or terminal of the battery (which could affect the welding operation), the magnetic field can cause a force that brings the tab and terminal in contact during welding.

Abstract: Embodiments of the present disclosure are directed to providing temporary, additional cooling to one or more elements of the vehicle on an as needed basis, e.g., under extreme conditions, when additional cooling is required or predicted to be needed, etc. According to one embodiment, the RC can be “overclocked” or “supercharged” to provide short-term, high output cooling performance under such conditions. For example, if the cooling system is a 10 kW system, it is increased to 15 kW for a short time period by increasing the electrical current and/or frequency to increase the torque and/or speed of the motor driving the RC. According to one embodiment, the cooling system can also be adapted to more effectively utilize the available cooling capacity, either the standard capacity to temporarily increased capacity, by directing the air or liquid coolant to one or more components in need of extra cooling.

Abstract: Embodiment include a power source module comprising one or more power cells. Each power cell can comprise a pressure vent on a side of the power cell. The pressure vent can be adapted to relieve an internal pressure of the cell when the internal pressure exceeds a threshold. A cooling plate can be disposed adjacent and substantially parallel to a side of the one or more power cells having the pressure vent. One or more spacers can be disposed between each of the one or more power cells and the cooling plate and substantially surrounding the pressure vent of one of the one or more power cells. A thermally conductive potting material can be disposed between the one or more power cells and the cooling plate. Each spacer prevents the potting material from intruding into an area around the vent of one of the one or more power cells.

Abstract: A spring-loaded busbar has a first portion divided from a second portion by a first pair of notches and a third portion divided from the second portion by a second pair of notches. The second portion is bent relative to the first portion and the third portion is bent relative to the second portion. The busbar is configured to deform elastically when pressed against an electrical cell to ensure proper contact between the busbar and the cell before the busbar is welded to the cell.

Abstract: Embodiments of the present disclosure are directed to providing temporary, additional cooling to one or more elements of the vehicle on an as needed basis, e.g., under extreme conditions, when additional cooling is required or predicted to be needed, etc. According to one embodiment, the RC can be “overclocked” or “supercharged” to provide short-term, high output cooling performance under such conditions. For example, if the cooling system is a 10 kW system, it is increased to 15 kW for a short time period by increasing the electrical current and/or frequency to increase the torque and/or speed of the motor driving the RC. According to one embodiment, the cooling system can also be adapted to more effectively utilize the available cooling capacity, either the standard capacity to temporarily increased capacity, by directing the air or liquid coolant to one or more components in need of extra cooling.

Abstract: According to one embodiment, a fully-autonomous vehicle, when properly equipped, can be used to clear snow, hail, leaves, and/or other debris from a driveway, roadway, parking lot, etc. For example, a vehicle capable of fully autonomous operation can operate in a “snow plow mode.” In such operations, the vehicle can identify, or be informed of, weather conditions such as snow that would impede travel on paved surfaces such as driveways and roads. When such conditions exist and if the vehicle is properly equipped with a plow or other snow removal equipment, the vehicle and operate in an autonomous manner to clear the user's driveway and/or one or more other driveways, roadways, parking lots, or other paved surfaces depending upon prior permission from the vehicle's owner and based on a variety of factors.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. More particularly, a vehicle including a first charging port at a first location on the vehicle and a second charging port at a second location on the vehicle is provided. The first charging port of the vehicle may be different from the second charging port of the vehicle. That is, a standard associated with a receptacle of the first charging port may be different from a standard associated with a receptacle of the second charging port.

Abstract: According to one embodiment, a fully-autonomous vehicle, when properly equipped, can be used to clear snow, hail, leaves, and/or other debris from a driveway, roadway, parking lot, etc. For example, a vehicle capable of fully autonomous operation can operate in a “snow plow mode.” In such operations, the vehicle can identify, or be informed of, weather conditions such as snow that would impede travel on paved surfaces such as driveways and roads. When such conditions exist and if the vehicle is properly equipped with a plow or other snow removal equipment, the vehicle and operate in an autonomous manner to clear the user's driveway and/or one or more other driveways, roadways, parking lots, or other paved surfaces depending upon prior permission from the vehicle's owner and based on a variety of factors.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. In particular, a vehicle is described with the ability to gather State of Charge (SOC) information as well as State of Health (SOH) information for one or more batteries in a vehicle and then display both SOC and SOH information to a driver of the vehicle as well as other interested parties. The displayed SOH information may be accompanied by suggestions to modify driving and/or charging behaviors that will improve or contribute to a slower degradation in the SOH of the batteries.

Abstract: A vehicle having a diagnostic system for a fuse is provided. The vehicle has first and second voltage sensors, a current sensor, and a microcontroller. The first and second voltage sensors generate first and second signals, respectively, indicating first and second voltage levels, respectively, at first and second ends, respectively, of the fuse. The current sensor generates a third signal indicating a current level flowing through the fuse. The microcontroller determines first and second voltage values based on the first and second signals, respectively, a current value based on the third signal, and a first resistance value utilizing the first and second voltage values and the current value. The microcontroller generates a diagnostic signal indicating degraded operation of the fuse if the first resistance value is greater than an end-of-life resistance value.

Abstract: An exemplary contactor control system and method to reduce the amount of sound during the translation of an automotive contactor from a closed state to an open state is provided. The contactor has an electrical coil and first and second electrical contacts. The control system includes a microcontroller and a high side driver circuit. The microcontroller generates a pulse width modulated signal that is applied to the high side driver circuit and decreases a duty cycle thereof to decrease a first control voltage applied to the electrical coil over a time interval. The microcontroller maintains a duty cycle for another time interval to maintain the contactor in the closed operational state. Next, the microcontroller decreases the duty cycle to reduce a speed of a contactor armature prior to contacting a stop member to reduce an amount of sound while transitioning the contactor to the open state.

Abstract: An energy storage cell pack cradle assembly for holding multiple rows of energy storage cells oriented along a dominant axis of vibration includes a first cradle member including a plurality of energy storage cell body supporting structures including respective holes; a second cradle member including a plurality of energy storage cell body supporting structures including respective holes; and one or more fasteners connecting the first cradle member and the second cradle member together. The energy storage cell body supporting structures are configured to structurally support the energy storage cells, with the energy storage cells oriented along a dominant axis of vibration, by energy storage cell bodies of the energy storage cells with respective electrically conductive terminals extending through the respective holes without structural support of the electrically conductive terminals by the cradle members.