Abstract: A battery system and a method include an auxiliary power module configured to support auxiliary loads. A first contactor switch connected between first and second battery packs, and a second contactor switch is in series with the first contactor switch. A controller determines whether to open or close first and second contactor switches depending on whether the battery packs are being charged in a high voltage mode or a low voltage mode. The contactor switches are both closed when in the high voltage mode and at least one of the contactor switches is opened when in the low voltage mode. At least one of the first and second battery packs operate to power the auxiliary power module while charging at least one of the first and second battery packs regardless of whether the battery packs are in the high voltage mode or the low voltage mode.

Abstract: A battery system is electrically connected to a power bus that is arranged to supply electric power to an on-vehicle actuator such as an electric traction machine. Controlling electric power flow in the battery pack includes determining states of charge for the plurality of battery packs, identifying one of the battery packs as a weakest battery pack based upon the states of charge, and determining an internal circulating current being transferred via the wiring harness that is associated with charging of the weakest battery pack. Electric power transfer through the wiring harness and the power bus is controlled such that the internal circulating current is less than an internal circulating current limit. In one embodiment, the internal circulating current limit is determined in relation to battery temperature.

Abstract: A battery system and a method include an auxiliary power module configured to support auxiliary loads. A first contactor switch connected between first and second battery packs, and a second contactor switch is in series with the first contactor switch. A controller determines whether to open or close first and second contactor switches depending on whether the battery packs are being charged in a high voltage mode or a low voltage mode. The contactor switches are both closed when in the high voltage mode and at least one of the contactor switches is opened when in the low voltage mode. At least one of the first and second battery packs operate to power the auxiliary power module while charging at least one of the first and second battery packs regardless of whether the battery packs are in the high voltage mode or the low voltage mode.

Abstract: A battery system is electrically connected to a power bus that is arranged to supply electric power to an on-vehicle actuator such as an electric traction machine. Controlling electric power flow in the battery pack includes determining states of charge for the plurality of battery packs, identifying one of the battery packs as a weakest battery pack based upon the states of charge, and determining an internal circulating current being transferred via the wiring harness that is associated with charging of the weakest battery pack. Electric power transfer through the wiring harness and the power bus is controlled such that the internal circulating current is less than an internal circulating current limit. In one embodiment, the internal circulating current limit is determined in relation to battery temperature.

Abstract: A method and system for controlling one or more contactors of a rechargeable energy storage system (RESS) includes adjusting, via a controller, the respective actuating power provided to a respective one or more of the contactors, where adjusting of the actuating power is defined by the energized or non-energized condition of the vehicle and at least one parameter affecting holding and opening forces exerted on the respective contactor. In an example, the controller is configured to use feed forward factors defined by the at least one parameter and to adjust the dynamic actuating current by modulating the dynamic actuating current at a pulse width modulation (PWM) frequency defined by a feed forward window. The system may be configured as a plug-in electric vehicle including the rechargeable energy storage system and the controller.

Abstract: A method and system for controlling one or more contactors of a rechargeable energy storage system (RESS) includes adjusting, via a controller, the respective actuating power provided to a respective one or more of the contactors, where adjusting of the actuating power is defined by the energized or non-energized condition of the vehicle and at least one parameter affecting holding and opening forces exerted on the respective contactor. In an example, the controller is configured to use feed forward factors defined by the at least one parameter and to adjust the dynamic actuating current by modulating the dynamic actuating current at a pulse width modulation (PWM) frequency defined by a feed forward window. The system may be configured as a plug-in electric vehicle including the rechargeable energy storage system and the controller.

Abstract: An alarm system for a vehicle charge cord is provided. The alarm system has an armed state and a disarmed state. The alarm system includes a battery, a charge cord sensor, a battery state estimator (“BSE”) module, and an interface module. The battery has state of charge (“SOC”), and is rechargeable to a predetermined level of charge. The charge cord sensor is configured to detect if the vehicle charge cord is connected to or disconnected from a vehicle. The BSE module is configured to monitor the SOC of the rechargeable battery and determine if the battery is charged to the predetermined level of charge. The interface module is in communication with the charge cord sensor and the BSE module. The interface module is configured to switch the alarm system from the armed state to the disarmed state.

Abstract: A battery module for an electric vehicle includes an auxiliary power module (APM) and at least one battery pack assembly. The battery pack assembly includes a plurality of battery frames, each with at least one battery cell disposed within it, and a plurality of cooling plates, each in thermal communication with at least one battery cell. The cooling plates have an inlet and an outlet connected by at least one coolant channel through which coolant is circulated to cool the battery cells. The APM may also require cooling, in which case the battery module may further include at least one additional cooling plate in thermal communication with the APM. The APM and the battery pack assembly are held together under compression such that they may share a common cooling system, and coolant may flow through the APM and/or the battery pack assembly to the cooling plates.

Abstract: An alarm system for a vehicle charge cord is provided. The alarm system has an armed state and a disarmed state. The alarm system includes a battery, a charge cord sensor, a battery state estimator (“BSE”) module, and an interface module. The battery has state of charge (“SOC”), and is rechargeable to a predetermined level of charge. The charge cord sensor is configured to detect if the vehicle charge cord is connected to or disconnected from a vehicle. The BSE module is configured to monitor the SOC of the rechargeable battery and determine if the battery is charged to the predetermined level of charge. The interface module is in communication with the charge cord sensor and the BSE module. The interface module is configured to switch the alarm system from the armed state to the disarmed state.

Abstract: A battery module for an electric vehicle includes an auxiliary power module (APM) and at least one battery pack assembly. The battery pack assembly includes a plurality of battery frames, each with at least one battery cell disposed within it, and a plurality of cooling plates, each in thermal communication with at least one battery cell. The cooling plates have an inlet and an outlet connected by at least one coolant channel through which coolant is circulated to cool the battery cells. The APM may also require cooling, in which case the battery module may further include at least one additional cooling plate in thermal communication with the APM. The APM and the battery pack assembly are held together under compression such that they may share a common cooling system, and coolant may flow through the APM and/or the battery pack assembly to the cooling plates.

Abstract: An alarm system associated with a charge cord of a plug-in vehicle is provided. The system includes a sensor configured to evaluate a status of the charge cord, including a coupled status when the charge cord is coupled to the vehicle and a decoupled status when the charge cord is not coupled to the vehicle. The system further includes an alarm interface coupled to the sensor and configured to activate an alarm when the charge cord is in the decoupled status.

Abstract: A module for a battery pack includes a cooling frame and a spacer frame. At least one of the first and second surfaces of the cooling frame is adapted to transfer heat to a coolant flow. A first battery cell having first and second electrically conductive tabs abuts a cooling frame member first surface. A second end of the cooling frame member includes a connection terminal for electrically connecting to the first electrically conductive tab. A spacer frame member first surface abuts the first battery cell, and a second surface abuts a second battery cell. A first end of the spacer frame member includes a connection terminal for electrically connecting to the second electrically conductive tab of the first battery cell and the first electrically conductive tab of the second battery cell.

Abstract: A method of controlling a hybrid powertrain having an electric machine and an engine is provided. The method includes determining a requested power and an excess power for the hybrid powertrain. The requested power substantially meets the needs of the hybrid powertrain. The excess power is non-zero and is not included in the determined requested power. The method also includes absorbing the excess power with the electric machine.

Abstract: A method of controlling a vehicular electrical system for a hybrid electric vehicle (HEV) includes providing a high voltage electrical system having a high power electrical energy storage device (HPD) and a power inverter that cooperate to provide power to a hybrid electric vehicle propulsion system, providing a low voltage electrical system having a low voltage power source, at least one accessory power load, and a control switch, and toggling the control switch between an opened and a closed position to isolate the low voltage system from the high voltage system when the switch is opened and to charge the HPD when the control switch is closed.

Abstract: A module for a battery pack includes a cooling frame and a spacer frame. At least one of the first and second surfaces of the cooling frame is adapted to transfer heat to a coolant flow. A first battery cell having first and second electrically conductive tabs abuts a cooling frame member first surface. A second end of the cooling frame member includes a connection terminal for electrically connecting to the first electrically conductive tab. A spacer frame member first surface abuts the first battery cell, and a second surface abuts a second battery cell. A first end of the spacer frame member includes a connection terminal for electrically connecting to the second electrically conductive tab of the first battery cell and the first electrically conductive tab of the second battery cell.

Abstract: A method of controlling a vehicular electrical system for a hybrid electric vehicle (HEV) includes providing a high voltage electrical system having a high power electrical energy storage device (HPD) and a power inverter that cooperate to provide power to a hybrid electric vehicle propulsion system, providing a low voltage electrical system having a low voltage power source, at least one accessory power load, and a control switch, and toggling the control switch between an opened and a closed position to isolate the low voltage system from the high voltage system when the switch is opened and to charge the HPD when the control switch is closed.

Abstract: A vehicular electrical system for a hybrid electric vehicle provides a high voltage electrical system having a high power electrical energy storage device (HPD) and a power inverter that cooperate to provide power to a hybrid electric vehicle propulsion system; and a low voltage electrical system having a low voltage power source, at least one accessory power load, and a control switch that toggles between an opened and a closed position to control the flow of current flowing between the low voltage power source and the HPD. A method of using the vehicular electrical system provides the step of using the HPD and power inverter to provide power to the electric vehicle propulsion system; and opening a control switch to isolate the low voltage system from the high voltage system and closing a control switch to charge the HPD.

Abstract: An alarm system associated with a charge cord of a plug-in vehicle is provided. The system includes a sensor configured to evaluate a status of the charge cord, including a coupled status when the charge cord is coupled to the vehicle and a decoupled status when the charge cord is not coupled to the vehicle. The system further includes an alarm interface coupled to the sensor and configured to activate an alarm when the charge cord is in the decoupled status.

Abstract: A vehicular electrical system for a hybrid electric vehicle provides a high voltage electrical system having a high power electrical energy storage device (HPD) and a power inverter that cooperate to provide power to a hybrid electric vehicle propulsion system; and a low voltage electrical system having a low voltage power source, at least one accessory power load, and a control switch that toggles between an opened and a closed position to control the flow of current flowing between the low voltage power source and the HPD.