Abstract: A vehicle including a cooling fan that is rotatably coupled to an electric motor that is electrically powered by a DC power source via an inverter is described. A method for controlling the cooling fan includes monitoring, via a first controller, a vehicle speed, and selecting a preferred operating state for the electric motor based upon the vehicle speed. The preferred operating state includes one of a first command associated with controlling the cooling fan to force air through the cooling system, a second command associated with a fan brake request, and a third command associated with an energy recovery mode. A discrete message from the first controller is communicated to an inverter controller, wherein the discrete message is based upon the preferred operating state for the electric motor. The inverter controller controls the inverter to control the electric motor in response to the discrete message.

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 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: An electrodynamic apparatus for separating electrically conductive, non-ferrous, blanks includes a linear induction machine (LIM) stator, a polyphase power source, and a controller. Stator slots are wound with polyphase AC windings. The power source outputs a polyphase voltage or current. The controller supplies the windings with the voltage or current via the power source to induce an electric current in an uppermost blank and produce a traveling wave magnetic field. The electric current and magnetic field generate a force on the uppermost blank sufficient for separating the uppermost blank from an adjacent blank in the stack. A method for separating the blanks includes positioning the stack with respect to the apparatus and supplying the windings with AC voltage or current via the power source to generate the traveling wave magnetic field and induce the electric current, and ultimately generate the force on the uppermost blank.

Abstract: An apparatus for controlling operation of an electromagnetically-activated actuator includes an activation controller that is one of integrated within a connector assembly of the actuator and integrated into a power transmission cable in close proximity to the actuator. The activation controller comprises a control module configured to generate an actuator command signal, and an actuator driver comprising a bi-directional current driver. The actuator driver is configured to receive the actuator command signal from the control module and generate an activation command signal for controlling the direction and amplitude of the current provided to the actuator.

Abstract: A method for parameter estimation in an electromagnetic actuator having a main coil and a search coil includes driving a current through the main coil, determining a main coil voltage, determining a search coil voltage, determining a main coil current, and estimating at least one parameter of the actuator based on the main coil voltage, the search coil voltage and the main coil current.

Abstract: A powertrain and an electromechanical apparatus are disclosed. A ring gear is attached to a first distal end of a crankshaft such that the ring gear and the crankshaft are rotatable in unison about a longitudinal axis. A motor-generator includes a motor/generator shaft being rotatable about a first axis spaced from the longitudinal axis. A starter mechanism includes a first starter gear coupleable to the motor/generator shaft and rotatable about a second axis spaced from the longitudinal axis. The first starter gear is movable along the second axis between a first position engaging the ring gear such that torque is transferred from the motor/generator shaft through the first starter gear and the ring gear to the crankshaft to start the engine, and a second position disengaged from the ring gear to rotatably disconnect the starter mechanism from the ring gear.

Abstract: An electromagnetic actuator includes an electrical coil and a high permeability magnetic flux path. The magnetic flux path includes a magnetic core, an armature and a flux return structure. The electromagnetic actuator further includes a flux sensor which is integrated within the actuator and is configured to detect a magnetic flux within the high permeability magnetic flux path.

Abstract: An apparatus for closed loop operation of a solenoid-activated actuator includes an external control module and a power source which are electrically and operatively coupled to an activation controller of the actuator. The external control module and the power source are located externally to the actuator. The apparatus further includes an activation controller which is integrated within the body of the actuator. The activation controller includes a control module and an actuator driver and is configured to communicate with the external control module and to receive electrical power from the power source. The apparatus additionally includes at least one sensor device which is integrated within the body of the actuator and is electrically and operatively coupled to the activation controller. The at least one sensor device is configured to measure one or more parameters during operation of the actuator and the measured parameters are provided as feedback to the activation controller.

Abstract: A method for controlling switching between a full winding control mode and a half winding control mode for a multi-phase electric machine. The machine includes a stator and a rotor, split stator windings for each phase of the machine, where each stator winding includes a first winding section and a second winding section, an inverter circuit including a pair of inverter switches for each phase of the machine, where the pair of inverter switches for each phase is electrically coupled to the first and second winding sections for that phase, and a plurality of switch assemblies for switching between the full winding mode and the half winding mode, where each switch assembly is electrically coupled to the pair of inverter switches and the first and second winding sections for a particular phase, and where each switch assembly includes a first AC switching device and a second AC switching device.

Abstract: A powertrain includes a first switching device transitionable between an open state disconnecting a first energy storage device from one of a motor-generator and an auxiliary electric system, and a closed state connecting the first energy storage device to one of the motor-generator and the auxiliary electric system. A second switching device is transitionable between an open state disconnecting a second energy storage device from one of the motor-generator and the auxiliary electric system, and a closed state connecting the second energy storage device to one of the motor-generator and the auxiliary electric system. A third switching device is transitionable between an open state disconnecting the auxiliary electric system from one of the motor-generator, and the first and second energy storage devices, and a closed state connecting the auxiliary electric system to one of the motor-generator, and the first and second energy storage devices.

Abstract: A method of controlling a powertrain of a hybrid vehicle includes comparing an operating efficiency of a motor-generator-inverter to an upper MGI efficiency threshold when a boost operating mode is selected. When the operating efficiency of the motor-generator-inverter is equal to or greater than the upper MGI efficiency threshold, the motor-generator-inverter is controlled to operate in the boost operating mode. The operating efficiency of the motor-generator-inverter is compared to a lower MGI efficiency threshold when a regenerative operating mode is selected. When the operating efficiency of the motor-generator-inverter is equal to or greater than the lower MGI efficiency threshold, the motor-generator-inverter is controlled to operate in the regenerative operating mode.

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: 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 electrical system includes an engine, a motor-generator and a starter mechanism, and engine systems also include the engine. The electrical system includes a first energy storage device having a first voltage level and a second energy storage device having a second voltage level less than the first voltage level. The electrical system further includes a controller configured to control the motor-generator, the starter mechanism and first and second switching devices. Current from at least one of the first and second energy storage devices is delivered to the motor-generator when at least one of the first switching device is in a first closed state and the second switching device is in a second closed state such that the motor-generator transfers torque to the starter mechanism and the starter mechanism uses the torque to start the engine.

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: An electric machine is provided that has 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 multiple barrier layers at each of the rotor poles. The multiple barrier layers are positioned adjacent one another between an inner periphery of the rotor core and an outer periphery of the rotor core and include a first barrier layer nearest the inner periphery. Permanent magnets are disposed in at least the first barrier layer. A stator assembly surrounds the rotor assembly. The electric machine is configured to function as a motor in a motoring mode and as a generator in a generating mode. The electric machine is configured with predetermined operating parameters selected for optimizing operation in the motoring mode and/or the generating mode.

Abstract: A powertrain for a vehicle includes an engine and a method of assembling the powertrain includes providing the engine. A starter mechanism is selectively operable to start the engine. A motor-generator includes an adapter to dispose the motor-generator and the starter mechanism in alternative assembly configurations being a first assembly configuration and a second assembly configuration. The first assembly configuration is when the starter mechanism is coupleable to the adapter to selectively transfer torque from the motor-generator through the adapter and the starter mechanism to start the engine. The second assembly configuration is when the starter mechanism is spaced from the adapter to operate independently of the motor-generator such that the starter mechanism selectively transfers torque to start the engine.

Abstract: A generator system includes an AC machine including a plurality of armature coils and a rectifier circuit electrically coupled to the armature coils. The rectifier circuit includes a plurality of switches. The generator system additionally includes a sensor device electrically coupled to a control circuit. The sensor device is configured to determine a rotor position of the AC machine. The control circuit determines a desired phase angle between a phase current and an induced voltage of the AC machine and provides a control signal to the rectifier circuit to switch the switches on and off to convert an AC signal to a DC signal and to control the rotor position of the AC machine to achieve the desired phase angle.

Abstract: An electrical system includes an engine, a motor-generator and a starter mechanism, and engine systems also include the engine. The electrical system includes a first energy storage device having a first voltage level and a second energy storage device having a second voltage level less than the first voltage level. The electrical system further includes a controller configured to control the motor-generator, the starter mechanism and first and second switching devices. Current from at least one of the first and second energy storage devices is delivered to the motor-generator when at least one of the first switching device is in a first closed state and the second switching device is in a second closed state such that the motor-generator transfers torque to the starter mechanism and the starter mechanism uses the torque to start the engine.