Abstract: A method that includes performing a battery module functionality test on battery cell arrays within the battery module to obtain battery test data for each of the battery cell arrays. The battery test data is used to determine if a measured parameter for one of the battery cell arrays deviates from a predetermined threshold for the measured parameter. A focused secondary battery test is performed on each of the battery cell arrays having the measured parameter that deviates from the predetermined threshold. The battery module is then qualified based on at least one of the battery test data and the focused secondary battery test.

Abstract: A rechargeable energy storage system includes a housing including an interior zone, a coolant member arranged in the interior zone of the housing, and a plurality of energy storage cells arranged in the interior zone on the coolant member. Each of the plurality of energy storage cells includes a cell can defining an energy storage medium housing. The cell can includes a first end supported at the coolant member and a second end. An amount of energy storage medium is arranged in the energy storage medium housing. A heat absorption member extends from the first end toward the second end through the amount of energy storage medium.

Abstract: A battery pack having a plurality of battery modules is provided. Each of the plurality of battery modules includes a thermally conductive frame having a plurality of apertures and a plurality of battery cells, wherein each of the plurality of battery cells is disposed in one of the plurality of apertures. Each of the plurality of battery modules also includes a heating element disposed on a top of the thermally conductive frame and a cooling plate disposed on a bottom of the thermally conductive frame. The thermally conductive frame includes a plurality of cooling ribbons disposed between at least two of the plurality of apertures, wherein each of the plurality of cooling ribbons extend from top of the thermally conductive frame to the bottom of the thermally conductive frame.

Abstract: A battery pack having a plurality of battery modules is provided. Each of the plurality of battery modules includes a thermally conductive frame having a plurality of apertures, a plurality of battery cells, wherein each of the plurality of battery cells is disposed in one of the plurality of apertures, and a first potting material disposed in each of the plurality of apertures between each of the plurality of battery cells and the thermally conductive frame.

Abstract: Embodiments include a method for creating a battery pack for a vehicle. Aspects include receiving a plurality of battery cells, measuring an internal resistance level for each of the plurality of battery cells, and creating, based at least in part on the internal resistance level for each of the plurality of battery cells, a plurality of groups from the plurality of battery cells. Aspects also include connecting each of the plurality of battery cells in each of the plurality of groups in parallel and connecting each of the plurality of groups in series.

Abstract: Aspects of the disclosure include a pre-formed battery cell thermal barrier for a battery module. An exemplary battery module can include a plurality of conductively coupled electrochemical cells and a pre-formed thermal barrier. The battery module can further include a cell holder configured to receive the plurality of conductively coupled electrochemical cells and the pre-formed thermal barrier. The pre-formed thermal barrier includes a cured potting material insertable into a cell-to-cell space in the battery module.

Abstract: A modular cell holder assembly includes a first cell holder member including a first cell receptacle and a second cell holder member including a second cell receptacle. The second cell holder member is connected with the first cell holder member forming a modular cell holder with the first cell receptacle and the second cell receptacle combining to form a cell receiving zone. A plurality of current connectors is provided on an outer surface of one of the first cell holder member and the second cell holder member. The plurality of current connectors is configured to establish a selected electrical configuration of energy storage cells in the cell receiving zone.

Abstract: Embodiments include a battery pack having a balanced current collector plate configured to connect a plurality of battery cells to one another and an electric vehicle including the same. The balanced current collector plate includes a terminal and a plurality of cell connection regions, each corresponding to one of the plurality of battery cells. Each of the plurality of cell connection regions includes one or more sidewalls, a cell connection tab that is configured to contact a terminal of a battery cell, and a cell fuse that is configured to electrically connect the cell connection tab to the balanced current collector plate. The geometry of each of the plurality of cell connection regions is configured to minimize a difference among the current draw between each of the plurality of battery cells and the terminal.

Abstract: A system in a vehicle includes two or more smart battery packs to power drive units of the vehicle to move the vehicle. Each of the two or more smart battery packs includes a battery pack, and a battery management system (BMS) to monitor a state of charge of the battery pack. An energy distribution unit facilitates charge transfer among the two or more smart battery packs.

Abstract: A battery module includes: a positive terminal disposed on an exterior of a housing of the battery module; a negative terminal disposed on the exterior of the housing of the battery module; groups of two or more cylindrical battery cells electrically connected in parallel; and electrically conductive bus bars that electrically connect the groups in series, that electrically connect positive terminals of the cylindrical battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the cylindrical battery cells of a second one of the groups with the negative terminal of the battery module.

Abstract: A battery module includes: positive and negative terminals disposed on an exterior of a housing of the battery module; groups of cylindrical battery cells, each of the battery cells of each group having a positive and negative terminals, and a vent; and electrically conductive busbars that electrically connect the groups, that electrically connect positive terminals of the battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the battery cells of a second one of the groups with the negative terminal of the battery module; and a thermal runaway protection blanket including: a first surface; a second surface opposite the first surface; and recessed portions that are recessed relative to the second surface and that extend toward the first surface, where the vents of at least a portion of the battery cells face the recessed portions.

Abstract: A battery module includes: positive and negative terminals disposed on an exterior of a housing of the battery module; groups of two or more cylindrical battery cells, each of the battery cells of each group having positive and negative terminals; and electrically conductive busbars that electrically connect the groups, that electrically connect positive terminals of the battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the battery cells of a second one of the groups with the negative terminal of the battery module; and a cooling plate including: first and second second planar plates; and a coolant channel plate that is sandwiched between the first and second planar plates that includes: an inlet; an outlet; and a coolant channel that extends in at least two different directions.

Abstract: A system in a vehicle includes two or more smart battery packs to power drive units of the vehicle to move the vehicle. Each of the two or more smart battery packs includes a battery pack, and a battery management system (BMS) to monitor a state of charge of the battery pack. An energy distribution unit facilitates charge transfer among the two or more smart battery packs.

Abstract: A switchable powertrain includes a main gear set configured for gear ratio selection. The main gear set includes an input shaft, first gears coupled to a main shaft, and second gears coupled to a second shaft. The second gears are meshed with the first gears. The switchable powertrain further includes a first torque source, a second torque source, a clutch configured for selectively coupling the first torque source to the input shaft of the main gear set, and an adapter. The adapter includes a first selective coupling for forming a first adapter torque transfer pathway from the second torque source directly to the main shaft, and a second selective coupling for forming a second adapter torque transfer pathway from the second torque source, through the main gear set, and to the main shaft.

Abstract: A switchable powertrain comprises at least four points of freedom. The switchable powertrain comprises a main gear set configured for gear ratio selection, the main gear set comprising main gears coupled to a main shaft and second gears coupled to a second shaft. An adapter comprises a first selective coupling configured to selectively couple to the main shaft, and a second selective coupling configured to selectively couple to the second shaft. A first torque source and a clutch are configured for selectively coupling or decoupling first torque to the main shaft. A second torque source is configured for selectively outputting second torque to the first selective coupling or to the second selective coupling.

Abstract: A load management system including a number of sensors structured to sense characteristics of a managed area, a controller including a processor structured to estimate occupancy of the managed area based on outputs of the number of sensors and to implement a load management scheme, a number of circuit breakers, at least one of the number of circuit breakers being electrically connected to a corresponding load circuit and including a metering circuit structured to meter energy provided to the load circuit and a device control unit structured to control one or more load devices electrically connected to the load circuit based on the load management scheme. The processor is structured to implement the load management scheme based on outputs of the sensors and metering information of one or more of the circuit breakers.

Abstract: A switchable powertrain comprises at least four points of freedom. The switchable powertrain comprises a main gear set configured for gear ratio selection, the main gear set comprising main gears coupled to a main shaft and second gears coupled to a second shaft. An adapter comprises a first selective coupling configured to selectively couple to the main shaft, and a second selective coupling configured to selectively couple to the second shaft. A first torque source and a clutch are configured for selectively coupling or decoupling first torque to the main shaft. A second torque source is configured for selectively outputting second torque to the first selective coupling or to the second selective coupling.

Abstract: A load management system including a number of sensors structured to sense characteristics of a managed area, a controller including a processor structured to estimate occupancy of the managed area based on outputs of the number of sensors and to implement a load management scheme, a number of circuit breakers, at least one of the number of circuit breakers being electrically connected to a corresponding load circuit and including a metering circuit structured to meter energy provided to the load circuit and a device control unit structured to control one or more load devices electrically connected to the load circuit based on the load management scheme. The processor is structured to implement the load management scheme based on outputs of the sensors and metering information of one or more of the circuit breakers.

Abstract: A load management system including a number of sensors structured to sense characteristics of a managed area, a controller including a processor structured to estimate occupancy of the managed area based on outputs of the number of sensors and to implement a load management scheme, a number of circuit breakers, at least one of the number of circuit breakers being electrically connected to a corresponding load circuit and including a metering circuit structured to meter energy provided to the load circuit and a device control unit structured to control one or more load devices electrically connected to the load circuit based on the load management scheme. The processor is structured to implement the load management scheme based on outputs of the sensors and metering information of one or more of the circuit breakers.

Abstract: Disclosed is an exemplary method for optimizing vehicle performance. The method includes determining an optimized drive torque for maximizing vehicle fuel economy and detecting a driver requested drive torque. A determination is made on whether the driver requested drive torque is performance related or safety related. The arbitrated drive torque is set to the optimized drive torque when it is determined that the driver requested drive torque is not performance and safety related. The arbitrated drive torque is set to the driver requested drive torque when it is determined that the driver requested drive torque is either performance or safety related.