Abstract: An electrical system connectable to an offboard power supply includes a battery pack, parallel DC-coupled conductive and inductive charging systems, and a controller. The controller initiates charging of the battery pack using analog low-voltage signals. A charging preference may prioritize charging via a designated one of the charging systems. Another electrical system includes a battery pack connected to a DC voltage bus, a charge coupler connectable to the offboard power supply to establish a plug-in charging connection, parallel DC-coupled conductive and inductive charging systems, and a controller. The controller commands charging using the analog low-voltage control signals, doing so via the conductive charging system when the charge coupler is plugged into the power supply and via the wireless charger when the charge coupler is not plugged into the power supply and the controller detects proximity of the system to the primary induction coil.

Abstract: A sensor for detecting leaked cooling fluid in a battery pack or container. The sensor is part of a sensor wire, where one end of the wire is electrically coupled to the positive terminal or the negative terminal of the battery pack and the other end of the wire is positioned at a location where the leaked cooling fluid may accumulate. A fault isolation detection circuit monitors a voltage output from the sensor and determines that there is a cooling fluid leak if the measured voltage potential is greater than a predetermined voltage threshold.

Abstract: An electrical system includes a contactor having a pair of contacts and a coil configured to electrically close and open the contacts. The electrical system also includes a high voltage (“HV”) circuit including a power supply electrically connected to at least one of the contacts of the contactor. The electrical system further includes a low voltage (“LV”) circuit electrically connected to the coil and configured to selectively energize the coil of the contactor. A disconnect mechanism is coupled with the LV electrical circuit and operable to electrically open the LV electrical circuit to actuate electrical opening of the contacts of the contactor.

Abstract: Systems and methods disclosed herein provide for a distributed high-voltage bus for a battery system included in a vehicle. In certain embodiments, the systems and methods disclosed herein provide for a scalable high-voltage bus architecture utilizing a common high-voltage rail for powering vehicle systems and/or modules. Independent contactors may be utilized on the opposite rail to selective power high-voltage branches. In further embodiments, a common rail pre-charge circuit may be utilized allowing for independent pre-charging of HV branches and systems and/or modules coupled to the HV bus.

Abstract: A power inverter includes a multi-phase inverter circuit electrically connected to positive and negative conductors of the high-voltage bus. A bi-stable switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus, and a capacitor is electrically connected between the positive and negative conductors of the high-voltage bus. First and second trigger circuits are in communication with a gate of the bi-stable switch, and first and second contactors are controllable to electrically connect a respective one of the positive and negative conductors of the high-voltage bus to the high-voltage DC power source. The bi-stable switch is controllable to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal from one of the first and second high-voltage DC contactor circuits.

Abstract: A power inverter including a multi-phase inverter circuit is electrically connected to a high-voltage DC power source, and includes a capacitor electrically connected between positive and negative conductors of a high-voltage bus. A normally-ON discharge switch is electrically connected in series with a discharge resistor between the positive and negative conductors of the high-voltage bus. The discharge switch includes a control gate, wherein the control gate of the discharge switch is in communication with an ignition switch. The discharge switch is controllable to an open state between the positive and negative conductors of the high-voltage bus when the ignition switch is in an ON state. The discharge switch achieves a closed state to provide a low-impedance electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus when the ignition switch is in an OFF state.

Abstract: A discharge circuit for a high-voltage bus that is electrically connected to a high-voltage DC power source is described. The discharge circuit includes a discharge switch electrically connected in series with a discharge resistor between positive and negative conductors of the high-voltage bus, and the discharge switch includes a gate. A bi-stable switch includes a control gate, an input line that is electrically connected to the high-voltage bus and an output line that is electrically connected to the gate of the discharge switch. A trigger device is in communication with the control gate of the bi-stable switch. The input line of the bi-stable switch is electrically connected to the high-voltage bus, and the discharge switch is controllable to a closed state to provide an electric current flow path through the discharge resistor between the positive and negative conductors of the high-voltage bus in response to an activation signal.

Abstract: A disconnect architecture for use with a system having a battery pack and positive and negative bus rails includes a mid-pack low-power (LP) relay, a fuse, semiconductor switches, and a sequencer circuit. The mid-pack LP relay is positioned between the rails at a mid-stack point of the battery pack, and divides a voltage across the battery pack when commanded open. The fuse is positioned between the mid-pack LP relay and the positive bus rail, and opens in response to a dead short condition of the system. The semiconductor switches are positioned in electrical parallel with the mid-pack LP relay. The sequencer circuit selectively turns on the semiconductor switches and thereby coordinates a flow of electrical current through the semiconductor switches and the mid-pack LP relay in response to a detected partial short condition of the system. A system includes the battery pack, bus rails, and disconnect architecture.

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 battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: A high-voltage battery assembly includes a high-voltage battery electrically connected to a high-voltage bus including a positive rail and a negative rail, wherein the negative rail includes a controllable contactor switch. A boost charging module includes a DC-DC boost converter, a low-voltage power input line, a boost switch and a boost controller. The DC-DC boost converter is electrically connected to the low-voltage power input line via activation of the boost switch. The DC-DC boost converter connects to the positive rail. A low-voltage electrical connector is electrically connected to the low-voltage power input line of the DC-DC boost converter. The boost controller detects low-voltage power from the low-voltage electrical connector, detects that the controllable contactor switch, closes the boost switch, and controls the DC-DC boost converter to convert the low-voltage power on the low-voltage power input line to high-voltage power to charge the high-voltage battery.

Abstract: Systems and methods for switching high-voltage contactors in a battery system with reduced degradation over time are presented. In certain embodiments, a system may include solid-state switches disposed is parallel with the high-voltage contactors. The solid-state switches may be configured to selectively close when the high-voltage contactors are in transition from a closed state to an open state. By closing the solid-state switches during this transition, electrical arcing and associated degradation and/or damage to the contactors may be reduced.

Abstract: Systems and methods for monitoring a state of a battery system based on information related to a measured pressure within the battery system are presented. In certain embodiments, the disclosed systems and methods may utilize a pressure-sensitive smart foam material in connection with measuring a pressure within the battery system. Based on the measured pressure information, a variety of information relating to the battery system may be determined. For example, information relating to a state of a battery system, certain events occurring within the battery system, and/or battery lifecycle information may be determined based on the measured pressure information.

Abstract: Systems and methods are disclosed for determining a weld state of a contactor (e.g., normal, partially welded, and/or welded states) based on a variety of actuator coil characteristics during actuation. In some embodiments, the disclosed systems and methods may be utilized in connection with determining contactor weld states in a variety of contactor designs. In further embodiments, the disclosed systems and methods may utilize a probability weighted score accounting for contactor design characteristics and information obtained from a reference contactor to identify a weld state associated with a contactor device.

Abstract: Systems and methods are disclosed for determining a weld state of a contactor (e.g., normal, partially welded, and/or welded states) based on a variety of actuator coil characteristics during actuation. In some embodiments, the disclosed systems and methods may be utilized in connection with determining contactor weld states in a variety of contactor designs. In further embodiments, the disclosed systems and methods may utilize a probability weighted score accounting for contactor design characteristics and information obtained from a reference contactor to identify a weld state associated with a contactor device.

Abstract: A system and method for discharging a high voltage vehicle battery. The system includes a discharge circuit having a reference voltage source providing a reference voltage and a load for discharging the battery. A negative terminal of the voltage source is electrically coupled to a negative terminal of the battery so that upon initiation of the discharging sequence, the battery is discharged through the load to the reference voltage. The discharge circuit can be electrically configured so that the battery, the voltage source and the load are electrically coupled in series or the battery, the voltage source and the load are electrically coupled in parallel.

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 system and method for discharging a high voltage vehicle battery. The system includes a discharge circuit having a reference voltage source providing a reference voltage and a load for discharging the battery. A negative terminal of the voltage source is electrically coupled to a negative terminal of the battery so that upon initiation of the discharging sequence, the battery is discharged through the load to the reference voltage. The discharge circuit can be electrically configured so that the battery, the voltage source and the load are electrically coupled in series or the battery, the voltage source and the load are electrically coupled in parallel.

Abstract: A high-voltage relay system for a vehicle. The system includes a high-voltage bus, a parallel relay set and a controller. The parallel relay set includes two or more relays wired in parallel and that are electrically coupled to the high-voltage bus. The controller is programmed to adjust the power flowing through the parallel relay set when a malfunction is detected in one of the relays in the set. The system can include a high-voltage power source electrically coupled to the high voltage bus through the parallel relay set, where the controller reduces the power flowing through the parallel relay by reducing output of the high-voltage power source. The system can include a high-voltage motor electrically coupled to the high voltage bus through the parallel relay set, where the controller reduces the power flowing through the parallel relay set by reducing the motor's power demands.

Abstract: A method of guiding an operator of a vehicle to a target location of a wireless charging station is disclosed herein. An exemplary embodiment of the method determines proximity of the vehicle to the wireless charging station, and activates a haptic feedback subsystem onboard the vehicle to indicate an approach alignment of the vehicle relative to the target location. The haptic feedback subsystem can be operated to generate haptic output that indicates fore-aft and lateral alignment (or misalignment) of the vehicle relative to the target location.