Abstract: A charging system includes a scalable power source for powering a motor of a vehicle and telematics and battery management modules. The scalable power source includes: N battery packs, where N is an integer greater than or equal to 3; and multiple switches connected to the N battery packs including N?1 switches for serially connecting the N battery packs between supply and return lines and a multiple of N switches for parallel connecting the N battery packs to the supply and return lines. The telematics module requests capability of a charging station and receives a response signal from a device indicating the capability of the charging station. The battery management module: based on the capability of the charging station, selects one of the available arrangements in which to connect the N battery packs, sets states of the multiple switches; and then charges the N battery packs based on the states.

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: System and method of controlling power distribution from a charging source to an electric vehicle having a battery. The system includes a plurality of switches selectively connectable between the charging source, the battery and a thermal circuit. A controller is configured to control operation of the plurality of switches to provide multiple settings for the electric vehicle. The controller is configured to select from the multiple settings based on part on a trigger signal from a mobile application. The multiple settings include an external power mode, a charging mode, a discharging mode and a mixed charging and conditioning mode. The mixed charging and conditioning mode allows charging of the battery concurrently with thermal conditioning of at least one of the battery and a cabin of the vehicle. The mixed charging and conditioning mode enables a power split between a thermal conditioning power (PT) and a charging power (PC).

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 method of using a control system to estimate range of an electrified vehicle operated by a driver includes monitoring a first set of driver behaviors while the vehicle is in operation and comparing the monitored first set of driver behaviors to a plurality of known profiles having respective stored behaviors. The method may include matching the first set of driver behaviors to at least one of the known profiles to create an adapted driver model, modeling an adapted drive cycle profile based on the matched adapted driver model, and calculating a predicted driving range based on the adapted drive cycle profile. The method may classify the monitored first set of driver behaviors as at least one of conservative, neutral, and aggressive, relative to the plurality of known profiles, and model the adapted drive cycle profile is further based on the conservative, neutral, or aggressive classification.

Abstract: A method of detecting misfire in a combustion engine of a motor vehicle engine includes measuring a speed of a crankshaft, calculating a modal coefficient for each cylinder of the combustion engine, and indicating a misfire for at least one of the cylinders based on the calculation of the modal coefficients.

Abstract: Systems, methods and motor-generators with preform windings and a molded core are described. The preform windings include a first end, a second end, and a plurality of in-slot portions extending from the first end to the second end. The molded core includes a plurality of slots. Each of the plurality of slots including a respective in-slot portion disposed therein. Each of the plurality of slots includes a wall conforming to an outer profile of the respective in-slot portion.

Abstract: System and method of controlling power distribution from a charging source to an electric vehicle having a battery. The system includes a plurality of switches selectively connectable between the charging source, the battery and a thermal circuit. A controller is configured to control operation of the plurality of switches to provide multiple settings for the electric vehicle. The controller is configured to select from the multiple settings based on part on a trigger signal from a mobile application. The multiple settings include an external power mode, a charging mode, a discharging mode and a mixed charging and conditioning mode. The mixed charging and conditioning mode allows charging of the battery concurrently with thermal conditioning of at least one of the battery and a cabin of the vehicle. The mixed charging and conditioning mode enables a power split between a thermal conditioning power (PT) and a charging power (PC).

Abstract: Systems, methods and motor-generators with preform windings and a molded core are described. The preform windings include a first end, a second end, and a plurality of in-slot portions extending from the first end to the second end. The molded core includes a plurality of slots. Each of the plurality of slots including a respective in-slot portion disposed therein. Each of the plurality of slots includes a wall conforming to an outer profile of the respective in-slot portion.

Abstract: Presented are slotted permanent magnets (PM) for electric machines, motor generator units using slotted PMs, methods for making/using slotted PMs, and motor vehicles equipped with an electric traction motor using slotted PMs. An electric machine includes an annular stator with a hollow core and one or more internal stator slots. One or more electrically conductive windings is/are disposed in the stator slot(s). A cylindrical rotor is rotatably disposed inside the hollow core of the stator. One or more permanent magnets is/are mounted to the rotor. Each permanent magnet includes a rigid, single-piece PM body with opposing first and second faces. A first set of elongated grooves is recessed into the first face. An optional second set of elongated grooves is recessed into the second face. Each of the grooves has a depth that is substantially parallel to a direction of a magnetic field generated by the permanent magnet.

Abstract: Presented are slotted permanent magnets (PM) for electric machines, motor generator units using slotted PMs, methods for making/using slotted PMs, and motor vehicles equipped with an electric traction motor using slotted PMs. An electric machine includes an annular stator with a hollow core and one or more internal stator slots. One or more electrically conductive windings is/are disposed in the stator slot(s). A cylindrical rotor is rotatably disposed inside the hollow core of the stator. One or more permanent magnets is/are mounted to the rotor. Each permanent magnet includes a rigid, single-piece PM body with opposing first and second faces. A first set of elongated grooves is recessed into the first face. An optional second set of elongated grooves is recessed into the second face. Each of the grooves has a depth that is substantially parallel to a direction of a magnetic field generated by the permanent magnet.

Abstract: A method of detecting misfire in a combustion engine of a motor vehicle engine includes measuring a speed of a crankshaft, calculating a modal coefficient for each cylinder of the combustion engine, and indicating a misfire for at least one of the cylinders based on the calculation of the modal coefficients.

Abstract: A fuel injector for an internal combustion engine. The fuel injector has a needle and a nozzle that inter-relate with each other in assembly. Relative movement between the needle and nozzle bring the fuel injector between a closed state of operation and an open state of operation amid use of the fuel injector. The nozzle has one or more passages therein through which fuel is discharged. Fuel flow is precluded at a sac volume of the fuel injector.

Abstract: An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.

Abstract: An engine block assembly includes a head structure assembly, and a cylinder structure assembly. A plurality of fasteners interconnect the head structure assembly and the cylinder structure assembly. An outer shell encapsulates and supports both the head structure assembly and the cylinder structure assembly. The outer shell is a unitary polymer structure that is simultaneously over-molded onto the head structure assembly and the cylinder structure assembly. The head structure assembly and the cylinder structure assembly are constructed of components that are designed to carry the operational loads of the engine with minimal weight. The outer shell provides additional structural integrity, and provides fluid passages for lubrication and cooling, as well as support for other engine components.