Abstract: A charging system for use in providing power for charging a battery. The system includes a first, alternating-current-to-direct-current, stage and a second, direct-current-to-direct-current, stage. The first stage includes a single-phase diode rectifier for rectifying an input alternating-current input voltage, and a power-factor-correcting sub-circuit including a switch. The second stage includes multiple switches. The system further includes a high-frequency capacitor connected between the first stage and the second stage. The system also includes a controller connected to the switches of the first and second stages and configured to control, by way of the switches, timing of boost inductor current passing through the charging system.

Abstract: An electrical system includes a direct current (DC) voltage bus, a power supply providing a supply voltage to the DC voltage bus, an electric machine connected to the power supply, a reverse current protection (RCP) circuit positioned between the power supply and the electric machine, the RCP circuit including an energy dissipating element, and a controller. As part of an associated method, the controller detects a reverse current condition in which a current flows from the electric machine toward the power supply when an induced voltage of the electric machine exceeds a voltage level of the voltage bus. The controller transmits a control signal to the RCP circuit to direct the electrical current through the energy dissipating element for a duration of the reverse current condition or for a predetermined duration equal to or greater than that of the reverse current condition.

Abstract: A vehicle propulsion system includes a combustion engine configured to output a propulsion torque to satisfy a propulsion demand, and a traction electric machine to generate a supplemental torque to selectively supplement the propulsion torque. The propulsion system also includes a controller programmed to forecast an acceleration demand based on at least one estimation model. The controller is also programmed to issue a command indicative of a required axle torque corresponding to the acceleration demand. The controller is further programmed to engage at least one fuel conservation action in response to the required axle torque being within a first predetermined torque threshold range.

Abstract: An electromagnetic actuation system includes an electrical coil, a magnetic core, an armature, a controllable bi-directional drive circuit for selectively driving current through the coil in either of two directions, and a control module providing an actuator command to the drive circuit. Current is driven though the electrical coil in a first direction when an actuation is desired. When the actuation is not desired current is driven through the electrical coil including in a second direction sufficient to reduce residual flux within the actuator below a level passively attained within the actuator at zero coil current.

Abstract: An electric machine is provided for a dual voltage power system having a first energy storage system (HV-ESS) with a first nominal voltage and second energy storage system (LV-ESS with a second nominal voltage). The electric machine includes a rotor assembly having a rotor core configured to support permanent magnets spaced around the rotor core to define a number of rotor poles. The rotor core has multiple rotor slots arranged as at least one barrier layer at each of the rotor poles. Permanent magnets are disposed in the at least one barrier layer. A stator assembly surrounds the rotor assembly. The electric machine is configured to be operatively connected with the HV-ESS. The electric machines has at least one of a predetermined efficiency at rated power, a predetermined power density, a predetermined torque density, a predetermined peak power range, or a predetermined maximum speed of the electric machine.

Abstract: A magnetodynamic apparatus for separating conductive non-ferrous blanks includes at least one magnet positioned adjacent to a stack of the blanks and configured to generate a magnetic field in a first direction with respect to a major surface of an uppermost blank within the stack. The apparatus includes an actuator device for positioning the magnet with respect to the stack during production of an electric current in a second direction along the major surface. The second direction is normal to the first direction such that a magnetic separation force is generated in a third direction normal to the first and second directions. The separation force is sufficient for magnetically separating the uppermost blank from remaining blanks in the stack. The magnets may be rotated on a rotor or held stationary. The electric current may be induced or directly injected into the uppermost blank.

Abstract: Disclosed are electromagnetic apparatuses for separating non-ferrous blanks, methods for making and for using such apparatuses, and automated systems with electromagnetic destacking unit for handling stacks of non-ferrous blanks. Presented is a destacking unit with a magnet placed adjacent a stack of non-ferrous blanks, and two electrical terminals placed in contact with the top blank of the stack. The magnet generates a magnetic field across the surface of the top blank. The terminals pass electrical current through the blank transversely across the top surface. The direction of the electrical current is generally normal to the direction of the magnetic field such that a magnetic separation force sufficient to displace the blank from the stack is generated in a generally vertical direction.

Abstract: A method for operating a diagnostic system of a vehicle including a fail operational power system (FOPS) module and a fail operational system (FOS) module includes the FOS module requesting a microcontroller of the FOPS module to generate a diagnostic control signal. The FOS module receives the diagnostic information from a component module of the FOPS module based on the diagnostic control signal generated by the microcontroller. The FOS module executes isolator diagnostics based on the received diagnostic information.

Abstract: A vehicle propulsion system includes an engine and a first electric machine each configured to selectively provide torque to propel the vehicle. A second electric machine is coupled to the engine to provide torque to start the engine from an inactive state. A high-voltage power source is configured to power both of the first electric machine and the second electric machine over a high-voltage bus. A propulsion controller is programmed to start the engine using cranking torque output from the second electric machine powered by the high-voltage power source. The controller is also programmed to operate both of the first electric machine and the combustion engine to propel the vehicle in response to an acceleration demand greater than a threshold. The controller is further programmed to decouple the engine and propel the vehicle using the first electric machine in response to vehicle speed less than a speed threshold.

Abstract: A hybrid vehicle propulsion includes an engine and a first electric machine, where each is configured to selectively provide torque to propel the vehicle. The propulsion system also includes a second electric machine coupled to the engine to provide torque to start the engine from an inactive state. A high-voltage power source is configured to power both of the first electric machine and the second electric machine over a high-voltage bus. The propulsion system further includes a controller programmed to deactivate the engine and propel the vehicle using the first electric machine in response to the vehicle being driven at a steady-state speed for a predetermined duration of time. The controller is also programmed to restart the engine using the second electric machine powered by the high-voltage power source.

Abstract: A device for supplying electric power includes a rectifier, an adaptive voltage clamping circuit, and a DC-DC voltage regulator. The rectifier receives electrical power, and is electrically connected to an input line of the adaptive voltage clamping circuit. The adaptive voltage clamping circuit includes a power transistor, a voltage feedback circuit, and a controller. The DC-DC voltage regulator is electrically connected to the adaptive voltage clamping circuit and, in one embodiment an actuator. The controller monitors the voltage feedback circuit and controls the power transistor to a fully open state to transfer electric power to the DC-DC voltage regulator when the voltage level supplied to the DC-DC voltage regulator is less than a threshold. The controller controls the power transistor in a linear state to regulate the voltage transferred to the DC-DC voltage regulator when the voltage level supplied to the DC-DC voltage regulator is greater than the threshold.

Abstract: An electric drive system for a three-phase PM electric machine. The drive system includes a split stator winding for each phase of the machine including a first winding section and a second winding section, and an inverter circuit including a pair of inverter switches for each phase, where the pair of inverter switches for each phase is electrically coupled to the first and second winding sections for that phase in the stator. The drive system also includes a switching system including a switch circuit, where the switch circuit includes a plurality of switch assemblies for switching between a full winding control mode and a half winding control mode, where each switch assembly includes a first AC switching device and a second AC switching device, and where each switch assembly is electrically coupled to the pair of inverter switches and the first and second winding sections for a particular phase.

Abstract: An electric power management system for a vehicle includes a first power bus arranged in parallel with a second power bus between first and second nodes. A third power bus couples a first battery and an auxiliary load at the second node. The second power bus couples a starter, a second battery and a generator at the first node, and selectively couples the first node to the second node when a first switch is activated. The second battery couples to the first node when a second switch is activated and the engine starter couples to the first node when a starter switch is activated. The second power bus couples the first node to the second node when a third switch is activated. A controller monitors states of charge of the first battery and the second battery and controls activations of the first switch, the second switch and the third switch.

Abstract: A transmission assembly has an integrated torque machine including a torque machine stator and a torque machine rotor. The torque machine rotor includes at least one set of rotor magnets. An integrated rotational position sensor is configured to monitor rotational position of the torque machine rotor in relation to the torque machine stator. The integrated rotational position sensor includes a sensor rotor element and a sensor stator element. The sensor rotor element includes at least one set of sensor rotor magnets. The sensor rotor element is positioned such that the at least one set of sensor rotor magnets are aligned with respect to a rotor pole of the at least one set of rotor magnets of the torque machine rotor. The sensor stator element is positioned such that the sensor stator element is aligned with a magnetic axis of the torque machine stator.

Abstract: An electromagnetic actuation system includes an actuator having an electrical coil, a magnetic core, and an armature. The system further includes a controllable drive circuit for selectively driving current through the electrical coil. A control module provides an actuator command to the drive circuit effective to drive current through the electrical coil to actuate the armature. The control module includes a magnetic force control module configured to adapt the actuator command to converge magnetic force within the actuator to a preferred force level.

Abstract: A vehicle propulsion system includes an engine and a first electric machine each configured to selectively provide torque to propel the vehicle. The propulsion system also includes a second electric machine coupled to the engine and configured to start the engine from an inactive state. A high-voltage battery powers both of the first electric machine and the second electric machine over a high-voltage bus. The vehicle further includes a controller programmed to issue a command to start the engine using the second electric machine in response to a threshold acceleration demand following a period of reduced acceleration demand.

Abstract: An interior permanent magnet electric machine includes a stator having a plurality of teeth disposed around a circumference oriented radially towards a center defining slots interposed between each of the teeth, and a conductive winding wrapped around at least one of the teeth of the stator to receive an electrical current. The electric machine also includes a rotor which is rotatable relative to the stator. The rotor defines a plurality of openings configured to hold permanent magnets near an outer portion of the rotor and a number of spokes interposed between mass reduction cutouts located closer to a center of the rotor relative to the permanent magnets. Each of the permanent magnets defines a magnetic pole and each of the spokes is circumferentially aligned with one of the magnetic poles.

Abstract: An interior permanent magnet electric machine includes a stator having a plurality of teeth disposed around a circumference oriented radially towards a center defining slots interposed between each of the teeth, and a conductive winding wrapped around each of the teeth of the stator to receive an electrical current. The electric machine also includes a rotor which is rotatable relative to the stator. The rotor defines a plurality of openings to receive permanent magnets near an outer portion of the rotor and a number of spokes interposed between mass reduction cutouts located closer to the center relative to the permanent magnets. Each of the permanent magnets defines a magnetic pole and each of the spokes is circumferentially aligned with one of the magnetic poles.

Abstract: A vehicle propulsion system includes an engine and a first electric machine each configured to selectively provide torque to propel the vehicle. The propulsion system also includes a second electric machine coupled to the engine and configured to start the engine from an inactive state. A controller is programmed to execute a first control algorithm while output speed of the second electric machine is less than a first speed threshold. The controller is also programmed to execute a second control algorithm while output speed of the second electric machine is greater than the first speed threshold and less than a second speed threshold.

Abstract: A powertrain system is described, and includes an internal combustion engine including a crankshaft and an electric machine including a rotatable shaft, wherein the rotatable shaft is coupled to a motor pulley. A torque converter includes an impeller and a pump, wherein the pump is coupled to an outer sheave. An off-axis mechanical drive system includes the outer sheave of the torque converter rotatably coupled to the motor pulley of the electric machine. The electric machine is coupled to the pump of the torque converter via the off-axis mechanical drive system, and the crankshaft is coupled to the pump of the torque converter via a clutch.