Abstract: A power distribution system is provided that ensures that a car is able to operate safely in an autonomous mode. The system includes multiple power rails, including a pair of safety critical power rails. Associated with each safety critical power rail is a safety switch, vehicle sensors (e.g., vehicle location and obstacle sensors), vehicle actuators (e.g., braking and steering actuators) and an autonomous control unit. If a fault is detected during vehicle initialization or general operation, the safety switch which detected the fault opens and that particular power rail is decoupled from the general purpose power rail as well as the remaining safety critical power rail. The remaining safety critical power rail is then able to provide power to a sufficient number of sensors, actuators and controllers to allow the car to safely and autonomously complete an emergency stop on the side of the road.

Abstract: In a general aspect, an electrical device assembly (e.g., a battery module) can include a first electrical contact surface, a second electrical contact surface, and a ribbon wire extending along a longitudinal axis. The ribbon wire can include a first portion, a second portion and a third portion. The first portion of the ribbon wire can be coupled with the first electrical contact surface via a first wedge bond. The second portion of the ribbon wire can be coupled with the second electrical contact surface via a second wedge bond. The third portion of the ribbon wire can extend between the first portion and the second portion. The first portion can have a first width transverse to the longitudinal axis of the ribbon wire, and the third portion can have a second width transverse to the longitudinal axis, the first width being greater than the second width.

Abstract: A power distribution system is provided that ensures that a car is able to operate safely in an autonomous mode. The system includes multiple power rails, including a pair of safety critical power rails. Associated with each safety critical power rail is a safety switch, vehicle sensors (e.g., vehicle location and obstacle sensors), vehicle actuators (e.g., braking and steering actuators) and an autonomous control unit. If a fault is detected during vehicle initialization or general operation, the safety switch which detected the fault opens and that particular power rail is decoupled from the general purpose power rail as well as the remaining safety critical power rail. The remaining safety critical power rail is then able to provide power to a sufficient number of sensors, actuators and controllers to allow the car to safely and autonomously complete an emergency stop on the side of the road.

Abstract: A powertrain backlash control system is provided for use with an electric vehicle (EV), where the EV uses at least one powertrain to provide forward vehicle motion and at least one additional powertrain to provide rearward vehicle motion. The control system eliminates backlash by maintaining a positive motor torque within each powertrain when the vehicle is in-gear, thus applying a minimum forward torque demand to the powertrain dedicated to forward motion and applying a minimum reverse torque demand to the powertrain dedicated to rearward motion.

Abstract: A power distribution system is provided that ensures that a car is able to operate safely in an autonomous mode. The system includes multiple power rails, including a pair of safety critical power rails. Associated with each safety critical power rail is a safety switch, vehicle sensors (e.g., vehicle location and obstacle sensors), vehicle actuators (e.g., braking and steering actuators) and an autonomous control unit. If a fault is detected during vehicle initialization or general operation, the safety switch which detected the fault opens and that particular power rail is decoupled from the general purpose power rail as well as the remaining safety critical power rail. The remaining safety critical power rail is then able to provide power to a sufficient number of sensors, actuators and controllers to allow the car to safely and autonomously complete an emergency stop on the side of the road.

Abstract: A power management system for an electric vehicle is provided which maintains power to the various vehicle ‘always-on’ components and subsystems during periods of vehicle non-use without requiring the low voltage battery to undergo frequent charge/discharge cycling. The system uses a secondary DC/DC converter that has a lower output voltage, and operates at a higher efficiency, then the primary DC/DC converter. As a result of this system, the life of the low voltage battery is prolonged and power consumption efficiency is improved, thereby minimizing range loss while the car is parked.

Abstract: A powertrain backlash control system is provided for use with an electric vehicle (EV), where the EV uses at least one powertrain to provide forward vehicle motion and at least one additional powertrain to provide rearward vehicle motion. The control system eliminates backlash by maintaining a positive motor torque within each powertrain when the vehicle is in-gear, thus applying a minimum forward torque demand to the powertrain dedicated to forward motion and applying a minimum reverse torque demand to the powertrain dedicated to rearward motion.

Abstract: A feedback system is provided for use with an electric vehicle's accelerator pedal, where the pedal is adjustable between a fully depressed position and a fully released position, and where a neutral pedal position is located between the fully depressed and fully released positions. When the pedal is located at the neutral position, the vehicle power train does not apply any torque; when the pedal is located between the neutral position and the fully depressed position, the vehicle power train applies a driving torque; and when the pedal is located between the neutral position and the fully released position, the vehicle power train applies a braking torque. The feedback system automatically sets the fully released position for the accelerator pedal based on the available regenerative braking torque.

Abstract: A method of operating the thermal management system in a vehicle is provided, where the thermal management system includes a heat exchanger (e.g., a radiator) and a heat source (e.g., battery pack, drive train, power electronics, etc.). After characterizing the thermal management system, whenever the system controller issues a cooling demand an appropriate set of operating settings is determined that minimizes the amount of power consumed by the system's actuators (e.g., blower fan, coolant pump) while still meeting the cooling demand. As a result, the heat source is cooled to the degree required with a minimum expenditure of power, thereby minimizing the impact on driving range and vehicle performance.

Abstract: A high current fuse with a short time constant is provided for use in an electric vehicle. The fuse is designed to exhibit thermal characteristics that are similar if not substantially identical to those of the wire bond interconnects used in the vehicle's battery pack. As a result, the system does not go into an overheat protection condition when the system is subjected to repetitive high current cycles, such as those common during aggressive and/or spirited driving. The fuse includes an arc suppressor.

Abstract: A method for automatically cleaning a vehicle's heat exchanger or air filter is provided. In use, once the system determines that the heat exchanger/air filter should be cleaned, for example based on total operational time or the number of use cycles or air flow, the system temporarily reverses the direction of the corresponding fan assembly, thereby reversing the flow of air through the heat exchanger/air filter and forcing out dust, dirt and other debris.

Abstract: A high current fuse with a short time constant is provided for use in an electric vehicle. The fuse is designed to exhibit thermal characteristics that are similar if not substantially identical to those of the wire bond interconnects used in the vehicle's battery pack. As a result, the system does not go into an overheat protection condition when the system is subjected to repetitive high current cycles, such as those common during aggressive and/or spirited driving.

Abstract: A motor assembly with an integrated cooling system is provided in which a coolant (e.g., oil) is injected into a hollow region of the rotor shaft. The coolant is expelled out of the rotor shaft and into the motor enclosure via multiple thru-holes, thereby allowing efficient cooling of both the stator and the rotor assemblies.

Abstract: A high current fuse with a short time constant is provided for use in an electric vehicle. The fuse is designed to exhibit thermal characteristics that are similar if not substantially identical to those of the wire bond interconnects used in the vehicle's battery pack. As a result, the system does not go into an overheat protection condition when the system is subjected to repetitive high current cycles, such as those common during aggressive and/or spirited driving.

Abstract: A high current fuse with a short time constant is provided for use in an electric vehicle. The fuse is designed to exhibit thermal characteristics that are similar if not substantially identical to those of the wire bond interconnects used in the vehicle's battery pack. As a result, the system does not go into an overheat protection condition when the system is subjected to repetitive high current cycles, such as those common during aggressive and/or spirited driving. The fuse includes an arc suppressor.

Abstract: A self-cleaning fan assembly is provided that can be used to automatically clean the assembly's heat exchanger or air filter. In use, once the system determines that the heat exchanger/air filter should be cleaned, for example based on the total operational time or the number of use cycles for the system, or based on the air flow passing through the heat exchanger/air filter, the controller temporarily reverses the direction of the fan, thereby reversing the flow of air through the heat exchanger/air filter and forcing out dust, dirt and other debris.

Abstract: A method of operating the thermal management system in a vehicle is provided, where the thermal management system includes a heat exchanger (e.g., a radiator) and a heat source (e.g., battery pack, drive train, power electronics, etc.). After characterizing the thermal management system, whenever the system controller issues a cooling demand an appropriate set of operating settings is determined that minimizes the amount of power consumed by the system's actuators (e.g., blower fan, coolant pump) while still meeting the cooling demand. As a result, the heat source is cooled to the degree required with a minimum expenditure of power, thereby minimizing the impact on driving range and vehicle performance.

Abstract: A battery pack monitoring system is provided that continually monitors the current at the fuse and, when the system determines that the fuse is close to its operating limit, limits battery pack current by limiting traction motor torque.

Abstract: A method of limiting belt slip in a continuously variable transmission (CVT) of a vehicle. The CVT is operatively connected to an engine. The method includes determining a slip speed of a belt of the CVT, determining the accumulated energy based on the slip speed of the belt and an engine torque produced by the engine, and controlling the engine torque in an intervention mode when the accumulated energy is greater than a threshold energy. Controlling the engine torque in the intervention mode comprises controlling at least one of cycling the engine torque, and limiting the engine torque. Systems and vehicles for performing the method are also disclosed.

Abstract: A battery pack monitoring system is provided that continually monitors the current at the fuse and, when the system determines that the fuse is close to its operating limit, limits battery pack current by limiting traction motor torque.