Abstract: An axial flux motor includes: a ring-shaped stator, a ring-shaped rotor and a planetary gear set. The ring-shaped stator includes a stator core and segments arranged on the stator core, where each of the segments includes a laminated stack and windings wrapped around the laminated stack. The ring-shaped rotor defines an inner open area and including a body and permanent magnets arranged on the body adjacent to and spaced from the segments. The planetary gear set is disposed within the inner open area and configured to receive an input torque from the rotor and provide an output torque, which is greater than the input torque.

Abstract: A rotor for mounting on a rotational axis in an axial flux electric motor includes a ferromagnetic rotor core. The rotor also includes a plurality of alternating south and north pole permanent magnets (PMs) arranged on the ferromagnetic rotor core symmetrically around the rotational axis and facing the stator. The ferromagnetic rotor core includes a plurality of core saliencies extending to the rotor exterior surface. Each of the core saliencies is arranged between one south pole PM and one north pole PM. The plurality of core saliencies is phase-angle shifted relative to the plurality of alternating south and north pole PMs to thereby alter magnetic reluctance of the electric motor. An axial flux electric motor employing the above-described rotor is also contemplated.

Abstract: An electric machine includes a housing having an inner surface; and a stator including a stator core mounted in the housing. The stator core includes a plurality of stator windings, a thermal bridge extends between the stator core and the inner surface of the housing. The thermal bridge is formed from a non-magnetic material and includes a plurality of individual thermal bridge elements.

Abstract: The present disclosure describes a multi-function, integrated Super Beam assembly structure with integrated structural, cooling, and transverse elastic compliance functions; and Thermal Management Propagation (TMP) protection. The Super Beam assembly includes a pair of parallel face plates, coolant channel cover plates, and coolant channels that are defined by the face plate and the one or more coolant channel cover plates. The structural design of the cooling channels, and the corresponding air gaps formed in-between them, allows a transverse elastic compliance of the Super Beam assembly to be tuned to different amounts of elasticity. Top, bottom and/or end structural channels may be included. A pair of TMP suppression channels may be attached to the Super Beam assembly structure with an adhesive “thermal fuse” that preferentially melts and causes the pair of TMP suppression channels to detach from the Super Beam assembly during overheating in a TMP event.

Abstract: A battery pack includes a first header having a first conduit and a second header having a second conduit. The battery pack also includes an energy storage system having energy storage cells arranged between the first header and the second header. A coolant plate assembly is arranged between the first header and the second header and abuts the plurality of energy storage cells. The coolant plate assembly includes a coolant channel having a first end fluidically connected to the first conduit, a second end fluidically connected to the second conduit, and an intermediate portion defining a flow path. The coolant plate assembly also includes a first planar section having a first surface facing the energy storage cells and a second surface having protrusions extending into the coolant channel.

Abstract: A stator for an electrical machine defines a central axis and has a first stator face facing parallel to the central axis and a second stator face facing parallel to the central axis, with the first stator face and the second stator face facing in opposite directions. The stator includes a plurality of ferromagnetic segments disposed about the central axis, each segment having a pair of parallel faces that face parallel to the central axis of the stator. On each stator face, faces of adjacent segments of the plurality of segments form gaps therebetween, the gaps extending radially relative to the central axis, the gaps on the first stator face being angularly offset relative to the central axis from the gaps on the second stator face.

Abstract: An electrical machine includes a rotationally-fixed stator defining a rotational axis of the electrical machine and having a plurality of stator magnetic poles, the stator magnetic poles disposed about the rotational axis. The electrical machine also has a rotor rotatably mounted coaxially with the rotational axis and axially spaced from the stator, the rotor having a plurality of permanent magnets facing the stator magnetic poles. Each stator magnetic pole includes a plurality of ferromagnetic laminations in a lamination stack that extends from a radially-inward extent to a radially-outward extent relative to the rotational axis, and a ferromagnetic composite pole portion affixed to the radially-outward extent or the radially-inward extent of the lamination stack of the stator magnetic pole.

Abstract: A cooled axial flux electric motor includes a rotationally-fixed stator defining a rotational axis and having a plurality of conductive stator magnetic poles arranged radially about the axis. The motor also includes a rotor spaced axially from one side from the stator and rotatably mounted coaxially with the rotational axis and defined by inside and outside diameters. The rotor has a first exterior surface facing the stator and a second exterior surface arranged opposite the first exterior surface. A ferromagnetic rotor core defines the rotor second exterior surface. The rotor also includes alternating south and north pole permanent magnets (PMs) arranged on the rotor core symmetrically around the axis and facing the stator. The rotor additionally includes channels extending radially outwardly across the rotor and configured to direct a coolant, via centrifugal force, from the inside diameter toward the outside diameter as the rotor rotates about the axis.

Abstract: A power control system for a vehicle includes a charge port and a contactor connected to the charge port and including a first plurality of switches. An energy storage system includes a second plurality of switches and one or more battery packs. A bi-directional DC-DC converter is connected between the energy storage system and a plurality of vehicle loads. A controller is configured to control states of the first and second plurality of switches to configure in a plurality of modes including a range improvement mode, a first charging mode to perform charging at a first voltage level, a second charging mode to perform charging at a second voltage level, a battery preconditioning mode; and an accessory load support mode.

Abstract: An electrical system includes a high-voltage battery pack assembly having a first cell set with a first group of energy storage cells and a second cell set having a second group of energy storage cells connectable to the first cell set. The first cell set includes at least one first battery chemistry cell and the second cell set includes at least one second battery chemistry cell. At least one switch is in electrical communication with the first or second cell set. Battery connection terminals are in electrical communication with at least one of the first or second cell sets. A controller is configured to determine an operating strategy of the high-voltage battery pack assembly and place at least one of the first cell set or the second cell set in electrical communication with the battery connection terminals in response to the operating strategy of the high-voltage battery pack.

Abstract: A mixed chemistry battery having a first battery cell having a first chemistry and a second battery cell having a second chemistry that is different than the first chemistry is provided. The first battery cell is connected to the second battery cell in series. The mixed chemistry battery includes a battery monitoring system configured to obtain a first SOC of the first battery cell and a second SOC of the second battery cell and based on a determination that an absolute value of a difference between the first SOC and the second SOC is greater than a threshold value, obtain a first capacity retention rate for the first battery cell and a second capacity retention rate for the second battery cell; and update the second SOC based on the first SOC, the first capacity retention rate, and the second capacity retention rate.

Abstract: Embodiments include balancing modules during charging of a mixed chemistry battery pack having a first battery module connected in series to a second battery module. Aspects include monitoring a first state-of-charge (SOC) of the first battery module having a first battery chemistry and monitoring a second SOC of the second battery module having a second battery chemistry. Aspects also include selectively activating one of a first bypass switch and a first activation switch of the first battery module based on the first SOC and the second SOC and selectively activating one of a second bypass switch and a second activation switch of the second battery module based on the first SOC and the second SOC. The activation of the first bypass switch prevents the first battery module from charging and activation of the second bypass switch prevents the second battery module from charging.

Abstract: Presented are torque converters (TC) with hydraulic systems for converter feed and clutch control, methods for making/operating such TC assemblies, and vehicles equipped with such TC assemblies. A TC assembly includes a housing that drivingly connects to an electric motor, and an output member that drivingly connects to a multi-gear transmission. Rotatable within the TC housing are a turbine attached to the TC output member and an impeller juxtaposed with the turbine. A lockup clutch disposed inside the TC housing, between the turbine and housing, is operable to lock the housing to the output member. A disconnect clutch disposed inside the housing, between the impeller and housing, is operable to lock the housing to the impeller. A pump is attached to the TC housing and drivingly connected to the motor for feeding fluid into the housing to increase pressure within the TC chamber and activate the lockup and disconnect clutches.

Abstract: A system for estimating a parameter of a battery assembly includes a sensing device connected to a cell of the battery assembly, the battery assembly having a first battery chemistry, the sensing device including a measurement cell having a second battery chemistry that is different than the first battery chemistry. The system includes an estimator configured to acquire a set of first estimates of a first state of charge (SOC) of the battery assembly, acquire a set of second estimates of a second SOC of the sensing device, and blend the sets of estimates to generate a blended SOC relation describing the second SOC of the sensing device as a function of the first SOC of the battery assembly. The estimator is also configured to filter the set of first estimates using the blended SOC relation to generate a final estimate of the SOC of the battery assembly.

Abstract: A system for thermal management of a battery assembly includes a protective cover in thermal communication with the battery assembly and disposed at a location that is proximate to an external surface of the battery assembly, the protective cover including at least one moveable component. The system also includes an actuator device configured to move the at least one moveable component of the protective cover to establish an insulating air gap between a portion of the protective cover and the battery system, the insulating air gap causing an increase in a thermal resistance of the protective cover.

Abstract: Aspects of the disclosure include a layout for a battery pack having mixed chemistry cells. An exemplary battery pack can include a plurality of first battery cells of a first cell chemistry. Each one of the plurality of first battery cells can include a same first height, a same first width, and a same first length. The battery pack can further include a plurality of second battery cells of a second cell chemistry different than the first cell chemistry. The second cell chemistry can provide a lower capacity than the first cell chemistry. Each one of the plurality of second battery cells can include the same first height, the same first width, and a same second length. The second length can be greater than the first length.

Abstract: A mixed chemistry battery including a sensing cell having a first chemistry, a battery cell having a second chemistry that is different than the first chemistry. The mixed chemistry battery also includes a sensor configured to measure a temperature of the mixed chemistry battery and a heating system configured to heat the second battery cell. The mixed chemistry battery further includes a battery monitoring system configured to selectively connect the heating system to at least one of the first battery cell and the second battery cell based upon the temperature of the mixed chemistry battery.

Abstract: A battery pack includes a first header including a first conduit, a second header including a second conduit, and an energy storage system including a plurality of energy storage cells arranged between the first header and the second header. A coolant plate is arranged between the first header and the second header and abuts the plurality of energy storage cells. The coolant plate including a coolant channel having a first end fluidically connected to the first conduit, a second end fluidically connected to the second conduit, and an intermediate portion defining a flow path.

Abstract: An electrical system can include a rechargeable energy storage system (RESS) and a direct current to direct current (DC-DC) converter. The DC-DC converter is connected to the RESS and configured to connect to a DC charging station. The DC-DC converter is configured to selectively connect the RESS to the DC charging station such that a charging current is selectively provided to the RESS during a recharging operation.

Abstract: A process for making a hollow electrical coil for an electric motor includes forming a sacrificial insert material into a coil shaped insert. The coil shaped insert is placed into a copper plating bath and a copper plated coil shaped member is removed from the copper plating bath. The sacrificial material is removed from within the copper plated coil shaped member to create a hollow passage through a hollow copper coil shaped member. An exterior of the hollow copper coil shaped member is coated with an insulating adhesive material and the copper coil shaped member is compressed until the insulating adhesive material is set.