Abstract: A multi-pack battery system having at least first and second battery packs each with positive and negative terminals, and each with upper and lower switches respectively connected to the positive and negative terminals. The battery packs have a first voltage level, and are connectable in either series or parallel. A controller controls an ON/OFF state of the switches in response to input signals to select between two series charging modes, three parallel charging modes, and one or more propulsion modes. Some embodiments have a series propulsion mode. An electric powertrain system includes first and second power inverter modules (“PIMs”), an electrical load, front and rear electric machines connected to a respective one of the first and second PIMs, and the battery system. The powertrain system may selectively provide all-wheel, front-wheel, or rear-wheel drive capabilities in each of the various propulsion modes.

Abstract: An electric propulsion system for a mobile platform includes a battery system connected to positive and negative bus rails, an accessory load having a rotary electric machine, a traction power inverter module (“TPIM”), and an accessory load, switches configured to transition the battery modules to a series-connected (“S-connected”) configuration during a direct current fast-charging (“DCFC”) operation of the battery system, and a controller. When battery modules of the battery system are connected in series during a direct current fast-charging (“DCFC”) operation, the controller executes a diagnostic method to determine bus rail voltages on the positive and negative bus rails and a mid-bus voltage, identifies a diagnosed electrical condition of the electric propulsion system by comparing the voltages to expected values or ranges, and executes a control action in response to the diagnosed electrical condition.

Abstract: A differential drive system includes an electric motor for generating an electric motor torque and an input planetary gear-set operatively connected to the electric motor to receive the electric motor torque. The input planetary gear-set has first, second, and third members. The first member receives the electric motor torque, the second member provides a first input torque in a first rotational direction in response to the electric motor torque, and the third member provides a second input torque in a second rotational direction, opposite the first direction, in response to the electric motor torque. The system also includes a first output gear-set operatively connected to the input planetary gear-set, and providing a first output torque in response to the first input torque. The system additionally includes a second output gear-set operatively connected to the input planetary gear-set and providing a second output torque in response to the second input torque.

Abstract: An electric propulsion system for a mobile platform includes a battery system connected to positive and negative bus rails, an accessory load having a rotary electric machine, a traction power inverter module (“TPIM”), and an accessory load, switches configured to transition the battery modules to a series-connected (“S-connected”) configuration during a direct current fast-charging (“DCFC”) operation of the battery system, and a controller. When battery modules of the battery system are connected in series during a direct current fast-charging (“DCFC”) operation, the controller executes a diagnostic method to determine bus rail voltages on the positive and negative bus rails and a mid-bus voltage, identifies a diagnosed electrical condition of the electric propulsion system by comparing the voltages to expected values or ranges, and executes a control action in response to the diagnosed electrical condition.

Abstract: A multi-pack battery system having at least first and second battery packs each with positive and negative terminals, and each with upper and lower switches respectively connected to the positive and negative terminals. The battery packs have a first voltage level, and are connectable in either series or parallel. A controller controls an ON/OFF state of the switches in response to input signals to select between two series charging modes, three parallel charging modes, and one or more propulsion modes. Some embodiments have a series propulsion mode. An electric powertrain system includes first and second power inverter modules (“PIMs”), an electrical load, front and rear electric machines connected to a respective one of the first and second PIMs, and the battery system. The powertrain system may selectively provide all-wheel, front-wheel, or rear-wheel drive capabilities in each of the various propulsion modes.

Abstract: An electric drive-unit encased in a housing includes an electric motor, a first output member, and a second output member. The drive-unit also includes first, second, and third planetary gear-sets, each having first, second, and third nodes. The first gear-set has one node connected to the electric motor. The second gear-set has one node connected to the first planetary gear-set, another node connected to the first output member, and the remaining node fixed to the housing. The third gear-set has one node connected to the first gear-set and another node connected to the second output member. The drive-unit additionally includes a first torque-transmitting device configured to selectively connect one third gear-set node to the housing to thereby affect a first speed-ratio. Furthermore, the drive-unit includes a second torque-transmitting device configured to selectively connect one first gear-set node to one of the third gear-set nodes to thereby affect a second speed-ratio.

Abstract: An electric drive-unit encased in a housing includes an electric motor, a first output member, and a second output member. The drive-unit also includes first, second, and third planetary gear-sets, each having first, second, and third nodes. The first gear-set has one node connected to the electric motor. The second gear-set has one node connected to the first planetary gear-set, another node connected to the first output member, and the remaining node fixed to the housing. The third gear-set has one node connected to the first gear-set and another node connected to the second output member. The drive-unit additionally includes a first torque-transmitting device configured to selectively connect one third gear-set node to the housing to thereby affect a first speed-ratio. Furthermore, the drive-unit includes a second torque-transmitting device configured to selectively connect one first gear-set node to one of the third gear-set nodes to thereby affect a second speed-ratio.

Abstract: A differential drive system includes an electric motor for generating an electric motor torque and an input planetary gear-set operatively connected to the electric motor to receive the electric motor torque. The input planetary gear-set has first, second, and third members. The first member receives the electric motor torque, the second member provides a first input torque in a first rotational direction in response to the electric motor torque, and the third member provides a second input torque in a second rotational direction, opposite the first direction, in response to the electric motor torque. The system also includes a first output gear-set operatively connected to the input planetary gear-set, and providing a first output torque in response to the first input torque. The system additionally includes a second output gear-set operatively connected to the input planetary gear-set and providing a second output torque in response to the second input torque.

Abstract: An electrical system includes cables, a DC charge connector, first and second battery modules, a splice device, and a controller. Each battery module has first, second, third, and fourth electrical connectors receiving a respective one of the cables. The battery modules are connected to each other via the cables, and further have first, second, third, and fourth switches that connect battery cell strings to one or more connectors. The charge connector is connected to one of the cables between the first electrical connectors. The splice device connects the charge connector to the first connector of the first battery module and to a pair of the cables. A charging current may be split between the battery modules. The controller selectively establishes parallel charging, parallel drive, and separate drive and charging modes for each battery module. The system may have an independent drive mode.

Abstract: An electrical system includes cables, a DC charge connector, first and second battery modules, a splice device, and a controller. Each battery module has first, second, third, and fourth electrical connectors receiving a respective one of the cables. The battery modules are connected to each other via the cables, and further have first, second, third, and fourth switches that connect battery cell strings to one or more connectors. The charge connector is connected to one of the cables between the first electrical connectors. The splice device connects the charge connector to the first connector of the first battery module and to a pair of the cables. A charging current may be split between the battery modules. The controller selectively establishes parallel charging, parallel drive, and separate drive and charging modes for each battery module. The system may have an independent drive mode.

Abstract: A modular battery pack system includes a battery pack and controller. The battery pack has first and second battery modules interconnected via electrical cables, with each module having a battery cell string. The pack has first, second, and third electrical connectors and four switches that selectively connect the strings to one or more of the electrical connectors. A DC charging connector is electrically connected to one of the cables between the first electrical connectors of the battery modules, and electrically connects the pack to an off-board DC fast-charging station. In response to input signals corresponding to a requested mode, the controller commands an open/closed state of each of the switches, via switching control signals, to establish a series charge mode, a parallel charge mode, and one or more of a series and/or parallel drive mode of the battery pack. A motor vehicle includes the system.

Abstract: A modular battery pack system includes a battery pack and controller. The battery pack has first and second battery modules interconnected via electrical cables, with each module having a battery cell string. The pack has first, second, and third electrical connectors and four switches that selectively connect the strings to one or more of the electrical connectors. A DC charging connector is electrically connected to one of the cables between the first electrical connectors of the battery modules, and electrically connects the pack to an off-board DC fast-charging station. In response to input signals corresponding to a requested mode, the controller commands an open/closed state of each of the switches, via switching control signals, to establish a series charge mode, a parallel charge mode, and one or more of a series and/or parallel drive mode of the battery pack. A motor vehicle includes the system.

Abstract: A DC charging circuit has a pair of switches and a battery pack with a maximum voltage capacity, and a power inverter module (PIM). The pair of switches connects/disconnects the battery pack to/from the PIM. An electric machine has phase windings sharing a motor neutral terminal. The phase windings are electrically connected to respective switching pair of the PIM. A switching module has one or two additional switches selectively connecting the PIM to the station, and a center switch selectively connecting the station to the motor neutral terminal. A controller executes a method that establishes a boost mode of the PIM when the maximum voltage capacity exceeds the maximum charging voltage. The boost mode is established by closing the pair of switches of the RESS, closing the center switch of the switching module and one of the additional switches, and opening the other additional switch if present.

Abstract: A DC charging circuit has a pair of switches and a battery pack with a maximum voltage capacity, and a power inverter module (PIM). The pair of switches connects/disconnects the battery pack to/from the PIM. An electric machine has phase windings sharing a motor neutral terminal. The phase windings are electrically connected to respective switching pair of the PIM. A switching module has one or two additional switches selectively connecting the PIM to the station, and a center switch selectively connecting the station to the motor neutral terminal. A controller executes a method that establishes a boost mode of the PIM when the maximum voltage capacity exceeds the maximum charging voltage. The boost mode is established by closing the pair of switches of the RESS, closing the center switch of the switching module and one of the additional switches, and opening the other additional switch if present.

Abstract: An electric vehicle drive system includes an electric motor, first and second planetary gear sets, including sun gear, carrier and ring gear members, first and second output shafts, and a housing. The members of the first planetary gear set are connected with the electric motor, the first output shaft, and a member of the second planetary gear set. The members of the second planetary gear set are connected with the first planetary gear set, the housing, and the second output shaft. The first planetary gear set provides differential reduction and the second planetary gear set provides reversal and reduction. Optional clutches can provide the function of a limited slip differential and distribute torque preferentially to one output shaft or the other.

Abstract: A power system is configured to deliver direct current (DC) electric power to an energy storage system (ESS) at a first voltage and to deliver DC electric power from the ESS at a second voltage. A converter is coupled to an electric power source at the second voltage. The converter includes a boost converter and a buck converter. The boost converter and the buck converter are configurable in a first interleaved arrangement and in a second interleaved arrangement, different than the first interleaved arrangement. In the first interleaved arrangement the converter provides DC electric power from the power source to the ESS at the first voltage, and in the second interleaved arrangement the converter provides DC electric power from the ESS to the power source at the second voltage.

Abstract: A transmission includes an input member, an output member, a first electric device, and a second electric device. A first planetary gear set is coupled to the first electric device. A second planetary gear set is coupled to the second electric device. The output is coupled to both the first planetary gear set and the second planetary gear set. The input is connected to the first planetary gear set. A fixed ratio gear reduction system couples the input and the second planetary gear set. The fixed ratio gear reduction system is operable to transmit rotation from the input to the second planetary gear set at a reduced rotational speed and at an increased torque.

Abstract: An electric vehicle drive system includes an electric motor, first and second planetary gear sets, including sun gear, carrier and ring gear members, first and second output shafts, and a housing. The members of the first planetary gear set are connected with the electric motor, the first output shaft, and a member of the second planetary gear set. The members of the second planetary gear set are connected with the first planetary gear set, the housing, and the second output shaft. The first planetary gear set provides differential reduction and the second planetary gear set provides reversal and reduction. Optional clutches can provide the function of a limited slip differential and distribute torque preferentially to one output shaft or the other.

Abstract: A high voltage bus system for electrified vehicles may include a direct current (DC) bus. A rectifier may be electrically coupled to the DC bus. The rectifier may be configured to receive an alternating current (AC) input and to provide a first DC electric power output to the DC bus. An energy storage system (ESS) may be electrically coupled to the DC bus. A converter may be electrically coupled to the ESS. The converter may be configured to provide a second DC electric power output to the DC bus. A load may be electrically coupled to the DC bus to receive the second DC electric power output.

Abstract: A system includes a rechargeable energy storage system (RESS) having an enclosure, battery cells, contactors, a first pair of high-voltage interlock (HVIL) ports, and female blind-mate electrical sockets selectively connected to the battery cells via the contactors. The battery cells and contactors are within the RESS enclosure. The system includes a high-power distribution module (HPDM) having another enclosure, male blind-mate electrical pins, a second pair of HVIL ports engagable with the first pair, ring-terminal connections connected to the blind-mate electrical pins and connectable to high-current components, and HV280 electrical connectors electrically connected to one or more of the male blind-mate electrical pins. The male blind-mate electrical pins insert directly into and engage with the female blind-mate electrical sockets of the RESS enclosure. A vehicle includes the system, a transmission, and an electric machine.