Abstract: An AC electronic solid-state switch includes an electrically insulating and thermally conductive layer, a first electrically conductive trace, a second electrically conductive trace, and a plurality of semiconductor dies each electrically connected to the first electrically conductive trace and the second electrically conductive trace. Each of the plurality of semiconductor dies forms a MOSFET, IGBT or other types of electronically controllable switch. The AC electronic solid-state switch further includes a common drain conductor that is electrically connected to each drain terminal of the plurality of semiconductor dies. The AC electronic solid-state switch is configured to block between 650 volts and 1700 volts in the off-state in a first direction and a second direction, the second direction being opposite the first direction, and the AC electronic solid-state switch is configured to carry at least 500 A continuously in the on-state with a voltage drop of less than 2V.

Abstract: A disconnect device includes a mounting plate having a thermally conductive substrate applied onto the mounting plate. A first layer of an electrically conductive material is applied onto the substrate. A semiconductor switch supported on the first layer connects or disconnects an input power source to or from a load. A second layer of an electrically conductive material applied onto the substrate is electrically isolated from the first layer. An electronic sensing, control and protection circuit is supported on the second layer and is connected to the semiconductor switch to control operation of the semiconductor switch. A control unit in communication with the electronic sensing, control and protection circuit via an electrically isolated control path provides control and communication between the electronic sensing, control and protection circuit and the semiconductor switch.

Abstract: A system includes a position sensor configured to detect positions of a rotor of a starter motor relative to the position sensor and to output signals indicating the detected positions and a controller configured to rotate the rotor to a plurality of predetermined positions relative to a stator of the starter motor, determine sensed positions of the rotor based on the signals output by the position sensor, and calculate an initial detected position of the rotor based on relationships between the determined sensed positions of the rotor and an expected angular distance between adjacent ones of the predetermined positions.

Abstract: A solid-state switch assembly includes a base plate and an electrically insulating layer affixed to the base plate. First, second, third, and fourth power traces are affixed to the electrically insulating layer. First semiconductor devices are arranged on the first power trace to control power flow between the first power trace and the second power trace, second semiconductor devices are arranged on the second power trace to control power flow between the second power trace and the third power trace, and third semiconductor devices are arranged on the third power trace to control power flow between the third and fourth power traces. A first signal conductor communicates with the first semiconductor devices. A second signal conductor communicates with the second semiconductor devices. A third signal conductor communicates with the third semiconductor devices.

Abstract: An electric powertrain includes a sensor-controller interface, an inverter-controller electrically connected to the battery pack, and an electric machine connected to the inverter-controller and having a rotor with an angular position. The rotor powers a driven load at a torque and/or speed level controlled by the inverter-controller in response to position signals indicative of the angular position. A rotary position sensor is operatively connected to the rotor to generate and output the position signals. The sensor derives the position signals from unmodulated sine and cosine signals, and communicates the position signals and a binary sensor state of health (SOH) to the inverter-controller over the interface. The inverter-controller also decodes the position signals and the binary sensor SOH to generate decoded control data, and controls the torque and/or speed level using the decoded control data.

Abstract: A system for use with a direct current fast-charging (DCFC) station includes a controller and battery system. The battery system includes first and second battery packs, and first, second, and third switches. The switches have ON/OFF conductive states commanded by the controller to connect the battery packs in a parallel-connected (P-connected) or series-connected (S-connected) configuration. An electric powertrain with one or more electric machines is powered via the battery system. First and second charge ports of the system are connectable to the station via a corresponding charging cable. The first charge port receives a low or high charging voltage from the station. The second charge port receives a low charging voltage. When the station can supply the high charging voltage to the first charge port, the controller establishes the S-connected configuration via the switches, and thereafter charges the battery system solely via the first charge port.

Abstract: A method for operating an advanced park assist system of a vehicle includes a vehicle controller receiving, from front and side cameras mounted proximate front and side sections of the vehicle, real-time images of the vehicle's forward-facing and side-facing views. These images are analyzed to detect target elements present in the vehicle's forward-facing and/or side-facing views. Responsive to detecting a target element, heading control signals are transmitted to the vehicle's steering system to reposition the vehicle and thereby locate the target element at the center of the forward-facing view and at the top of the side-facing view. Speed control signals are transmitted to the vehicle's propulsion system to propel the vehicle such that the target element disappears from the side-facing view and moves to a calibrated distance from the vehicle body's front end. The control signals are modulated to align the vehicle with a target marker of the target element.

Abstract: A modular drive system includes a first motor and a second motor. The first motor generates a first torque over a first torque bandwidth, and has a first stator, a first rotor, and a first winding. The first winding has a first number of turns, a first conductor area and a first insulation suitable for a first peak voltage of the first motor. The second motor generates the first torque over a second torque bandwidth, and has a second stator matching the first stator, a second rotor matching the first rotor and a second winding. The second winding has the first number of turns, the first conductor area and a second insulation suitable for a second peak voltage of the second motor. The second peak voltage is greater than the first peak voltage. The second torque bandwidth is wider than the first torque bandwidth.

Abstract: A method for operating an advanced driver assistance (ADAS) system of a motor vehicle includes a vehicle controller receiving, from side and end cameras mounted to the vehicle, camera signals indicative of real-time images of outboard-facing side and end views of the vehicle. The controller determines a region of interest (ROI) inset within each end/side view within which is expected foreign objects and/or hazards. These ROIs are analyzed to detect if a foreign object/hazard is present in the vehicle's end and/or side views. Responsive to detecting the foreign object/hazard, movement of the foreign object/hazard is tracked to determine if the foreign object/hazard moves towards or away from the vehicle's underbody region. If the foreign object/hazard moves to the underbody region, control signals are transmitted to the vehicle's propulsion and/or steering system to automate preventative action that prevents collision of the vehicle with and/or removes the foreign object/hazard from the underbody.

Abstract: An electric machine includes a machine rotor circumscribed by a machine stator, and having a rotor shaft, rotor stack, and end cap which rotate about an axis. The end cap includes lobes equal in number to a number of pole pairs of the machine rotor. A position sensor assembly has a predetermined alignment with the machine rotor and stator. The sensor assembly includes a sensor rotor formed by the lobes and a sensor stator having a printed circuit board with conductive sine and cosine traces. Machine rotor rotation causes the sensor assembly to output an unmodulated sine and cosine signals to a controller, which then calculates a calibrated reference angle. A magnetic axis of an electrical phase of the machine is aligned with and bisects a peak of the sine trace. A direct axis of the machine rotor aligns with an edge of a lobe.

Abstract: An integrated smart relay assembly includes a case and an electronic solid-state switch disposed inside the case and a gate driver circuit electrically connected to the electronic solid-state switch. The gate driver circuit is configured to drive the electronic solid-state switch with a predetermined gate voltage and a predetermined gate current. The relay assembly further includes a protection circuit electrically connected to the gate driver circuit. The protection circuit is configured to protect the electronic solid-state switch against over-voltage, short circuit, and overheating. The relay assembly further includes a communication interface integrated with the electronic solid-state switch. Each of the protection circuit, electronic solid-state switch, and the communication interface is disposed inside the case.

Abstract: A starter assembly includes a multi-phase brushless electric motor including a stator, a rotor disposed on a rotatable shaft, and a motor endcap disposed at a first end of the stator. An electronic commutator assembly includes a sensing circuit, a control electronics subassembly, a power electronics subassembly and a heat sink. The sensing circuit is disposed adjacent to the second end of the rotatable shaft. The control electronics subassembly, the power electronics subassembly and the heat sink are disposed on disk-shaped devices arranged in a stacked configuration orthogonal to the axis defined by the rotatable shaft. The control electronics subassembly is disposed adjacent to the sensing circuit, and the power electronics subassembly is disposed adjacent to the control electronics subassembly. The control electronics subassembly is interposed between the power electronics subassembly and the sensing circuit. The heat sink is disposed adjacent to the power electronics subassembly.

Abstract: A circuitry includes an electronic solid-state switch including a first power terminal and a second power terminal and a driver and switch protection system electrically connected to the electronic solid-state switch. The driver and switch protection system includes an isolated bias power circuit configured to output a direct current voltage of at least fifteen volts, a current buffer circuit electrically connected between the isolated bias power circuit and the electronic solid-state switch, and a snubber circuit electrically connected to the first power terminal and the second power terminal.

Abstract: An electric propulsion system includes a battery pack and a DC-DC converter. The converter has a bypass switch and semiconductor switches. A traction power inverter module (“TPIM”) rectifies a DC bus voltage on the voltage bus to produce an AC bus voltage. An electric machine is connected to the TPIM and energized via the AC bus voltage. A controller calculates required output power from the converter based on a requested operating mode, and speed and torque of the electric machine. When the output power exceeds a threshold, the bypass switch closes to bypass the converter. When the output power is less than the threshold, the controller uses a minimum loss voltage from a loss map as a target control voltage of the converter to optimize efficiency of the electric propulsion system.

Abstract: An AC electronic solid-state switch includes an electrically insulating and thermally conductive layer, a first electrically conductive trace, a second electrically conductive trace, and a plurality of semiconductor dies each electrically connected to the first electrically conductive trace and the second electrically conductive trace. Each of the plurality of semiconductor dies forms a MOSFET, IGBT or other types of electronically controllable switch. The AC electronic solid-state switch further includes a common drain conductor that is electrically connected to each drain terminal of the plurality of semiconductor dies. The AC electronic solid-state switch is configured to block between 650 volts and 1700 volts in the off-state in a first direction and a second direction, the second direction being opposite the first direction, and the AC electronic solid-state switch is configured to carry at least 500 A continuously in the on-state with a voltage drop of less than 2V.

Abstract: A system for utilizing a deployable flex range battery to augment a primary battery is provided. The system includes a flex electronics bay. The flex electronics bay is electrically connected to an electrical sub-system including the primary battery and includes a DC-DC converter operable to change a voltage of electric power and at least one battery connection terminal. The system further includes the deployable flex range battery removably connected to the at least one battery connection terminal and a flex electronics bay controller programmed to selectively supply electric power from the flex electronics bay to the electrical sub-system.

Abstract: An electric drive system includes a battery pack, a power inverter module (“PIM”), an electric machine, a switching circuit, and a controller. The electric machine has three or more phase legs. The PIM has a DC-side connected to the battery pack, and an alternating current (“AC”)-side connected to the electric machine. The switching circuit includes AC switches, and for each phase leg also includes three or more winding sections each electrically connectable to or disconnectable from the battery pack and PIM via the AC switches. The controller commands a binary switching state of each respective AC switch based on the rotary speed to implement one of three different speed-based operating modes of the electric machine, and to thereby vary a conductive path from the PIM to the electric machine through one or more of the connected winding sections.

Abstract: An integrated smart relay assembly includes a case and an electronic solid-state switch disposed inside the case and a gate driver circuit electrically connected to the electronic solid-state switch. The gate driver circuit is configured to drive the electronic solid-state switch with a predetermined gate voltage and a predetermined gate current. The relay assembly further includes a protection circuit electrically connected to the gate driver circuit. The protection circuit is configured to protect the electronic solid-state switch against over-voltage, short circuit, and overheating. The relay assembly further includes a communication interface integrated with the electronic solid-state switch. Each of the protection circuit, electronic solid-state switch, and the communication interface is disposed inside the case.

Abstract: A system includes a position sensor configured to detect positions of a rotor of a starter motor relative to the position sensor and to output signals indicating the detected positions and a controller configured to rotate the rotor to a plurality of predetermined positions relative to a stator of the starter motor, determine sensed positions of the rotor based on the signals output by the position sensor, and calculate an initial detected position of the rotor based on relationships between the determined sensed positions of the rotor and an expected angular distance between adjacent ones of the predetermined positions.

Abstract: A dual-voltage charging station system for an alternating current (“AC”) power supply and a mobile platform having a charging port includes a charge coupler, an AC-to-DC conversion stage, a cable, and a controller. The charge coupler has AC pins and direct current (“DC”) pins configured to engage with respective AC and DC receptacles of the charging port. The conversion stage is connected to the charge coupler and the AC power supply, converts the supply voltage to a DC charging voltage, and relays an appropriate AC or DC accessory voltage. The cable connects to the charge coupler such that the AC pins receive the accessory voltage and the DC pins receive the DC charging voltage. The controller simultaneously delivers the accessory voltage and the DC voltage to the mobile platform via the AC pins and the DC pins, respectively.