Abstract: Described herein are methods and systems of a chassis of a commercial electric vehicle. In various embodiments, the chassis may include a ladder frame with a plurality of frame rails. Batteries and drive units may be packaged within the frame rails of the ladder frame. The chassis may further include an independent front suspension and batteries may be disposed between the suspension members of the independent front suspension.

Abstract: Described herein are battery packs and electric vehicles using these packs. In some examples, a battery pack comprises two portions/covers and a set of battery modules positioned within the enclosed cavity formed by these portions. A battery pack may comprise a set of pressure-relief valves positioned in and protruding through a wall of at least one portion. Each valve can be coaxial with a corresponding gap provided between two adjacent modules. The valve is configured to provide a fluid path (to the exterior of the battery pack) when the pressure inside the pack exceeds a set threshold. In some examples, the battery pack comprises an inlet tube fluidically coupled to the inlet port of each module and an outlet tube fluidically coupled to the outlet port of each module. A set of specially configured orifices or controllable valves is positioned on the fluid path through each module.

Abstract: Described herein are battery modules and methods of fabricating thereof. In some examples, a battery module comprises an enclosure, separated into two enclosure portions and a thermal portion, positioned between the two enclosure portions. Two enclosure portions are in part defined by side walls, which can be tapered. The thermal portion comprises two thermal walls, which are operable as the bottoms of the two enclosure portions and form a thermal cavity between these thermal walls. In some examples, the enclosure is a monolithically cast component. Alternatively, the enclosure can be partially cast with one thermal wall welded thereafter to a cast subassembly. The battery module also comprises two sets of batteries, each positioned into a corresponding enclosure portion. Each battery set is interconnected with an interconnecting assembly, positioned between the battery set and the corresponding cover, for this enclosure portion.

Abstract: Described herein are methods and systems of a chassis of a commercial electric vehicle. In various embodiments, the chassis may include a ladder frame with a plurality of frame rails. Batteries and drive units may be packaged within the frame rails of the ladder frame. The chassis may further include an independent front suspension and batteries may be disposed between the suspension members of the independent front suspension.

Abstract: Described herein are battery modules and methods of fabricating thereof. In some examples, a battery module comprises an enclosure, separated into two enclosure portions and a thermal portion, positioned between the two enclosure portions. Two enclosure portions are in part defined by side walls, which can be tapered. The thermal portion comprises two thermal walls, which are operable as the bottoms of the two enclosure portions and form a thermal cavity between these thermal walls. In some examples, the enclosure is a monolithically cast component. Alternatively, the enclosure can be partially cast with one thermal wall welded thereafter to a cast subassembly. The battery module also comprises two sets of batteries, each positioned into a corresponding enclosure portion. Each battery set is interconnected with an interconnecting assembly, positioned between the battery set and the corresponding cover, for this enclosure portion.

Abstract: Described herein are battery packs and electric vehicles using these packs. In some examples, a battery pack comprises two portions/covers and a set of battery modules positioned within the enclosed cavity formed by these portions. A battery pack may comprise a set of pressure-relief valves positioned in and protruding through a wall of at least one portion. Each valve can be coaxial with a corresponding gap provided between two adjacent modules. The valve is configured to provide a fluid path (to the exterior of the battery pack) when the pressure inside the pack exceeds a set threshold. In some examples, the battery pack comprises an inlet tube fluidically coupled to the inlet port of each module and an outlet tube fluidically coupled to the outlet port of each module. A set of specially configured orifices or controllable valves is positioned on the fluid path through each module.

Abstract: Described herein are methods and systems of a chassis of a commercial electric vehicle. In various embodiments, the chassis may include a ladder frame with a plurality of frame rails. Batteries and drive units may be packaged within the frame rails of the ladder frame. The chassis may further include an independent front suspension and batteries may be disposed between the suspension members of the independent front suspension.

Abstract: Described herein are battery modules and methods of fabricating thereof. In some examples, a battery module comprises an enclosure, separated into two enclosure portions and a thermal portion, positioned between the two enclosure portions. Two enclosure portions are in part defined by side walls, which can be tapered. The thermal portion comprises two thermal walls, which are operable as the bottoms of the two enclosure portions and form a thermal cavity between these thermal walls. In some examples, the enclosure is a monolithically cast component. Alternatively, the enclosure can be partially cast with one thermal wall welded thereafter to a cast subassembly. The battery module also comprises two sets of batteries, each positioned into a corresponding enclosure portion. Each battery set is interconnected with an interconnecting assembly, positioned between the battery set and the corresponding cover, for this enclosure portion.

Abstract: Described herein are battery packs and electric vehicles using these packs. In some examples, a battery pack comprises two portions/covers and a set of battery modules positioned within the enclosed cavity formed by these portions. A battery pack may comprise a set of pressure-relief valves positioned in and protruding through a wall of at least one portion. Each valve can be coaxial with a corresponding gap provided between two adjacent modules. The valve is configured to provide a fluid path (to the exterior of the battery pack) when the pressure inside the pack exceeds a set threshold. In some examples, the battery pack comprises an inlet tube fluidically coupled to the inlet port of each module and an outlet tube fluidically coupled to the outlet port of each module. A set of specially configured orifices or controllable valves is positioned on the fluid path through each module.

Abstract: Aspects of a modular clip for an electric battery module, a battery module comprising multiple such modular clips, and a battery pack comprising multiple battery modules are provided. The modular clip includes a housing configured to receive a plurality of battery cells. The modular clip may further comprise at least one interconnect plate. The modular clip may further comprise a retainer plate including a plurality of top cell recesses, each of the plurality of top cell recesses may comprise an opening to enable wire bonds between electrical terminals of a battery cell and the at least one interconnect plate. The battery module may comprise a plurality of wire bonds between at least one voltage sensing PCB and the at least one interconnect plate.

Abstract: A pan tilt unit comprises a support, a slip ring, a rotating platform, and a tilting mechanism. An outer rotating portion of the slip ring is able to rotate about the support. The slip ring comprises connections between an inner static portion of the slip ring and the outer rotating portion of the slip ring. The rotating platform is coupled to the outer rotating portion of the slip ring. The tilting mechanism is coupled to the rotating platform.

Abstract: Described herein are methods and systems for the weight estimation of commercial vehicles and using these estimates to control different vehicle systems such as powertrain, brakes, and suspension. A vehicle comprises a weight estimator, which receives input from different vehicle systems and/or sensors (e.g., suspension, powertrain, speedometer, tire pressure monitoring system) and uses these inputs to determine weight values associated with the vehicle (e.g., total weight, weight distribution per axle, weight distribution per wheel, load distribution). These weight values are then used by the power train, brakes, and/or suspension as additional input for operating these systems besides drivers' input, e.g., provided as pedal positions. For example, different weight values can cause different powertrain outputs for the same accelerator pedal position, e.g., greater output for a heavier vehicle. As such, a driver experiences more uniform vehicle responses for different vehicle loads.

Abstract: Described herein are systems and methods for using different truck types for deliveries. A package is initially loaded into a specially configured cargo container that can be transported either on a primary truck or a secondary truck. A secondary truck is smaller than a primary truck and is configured to transport fewer cargo containers than the primary truck. An initial leg of the overall delivery (e.g., from a warehouse to a transfer point) is performed using a primary truck. The cargo container is then transferred to a secondary truck, which completes the delivery. Empty cargo containers can be transferred back to a primary truck, e.g., in a stacked or folded manner, for transporting back to the warehouse. The configurations of primary and secondary trucks are such that these transfers can occur at any location (e.g., a parking lot) with minimal human involvement.

Abstract: Systems and methods relating to controlling a driving system operatively coupled to a vehicle are disclosed. A location is identified using one or more sensors included with the vehicle. An input of the driving system is identified using the location. A desired output of the driving system is determined using the input.

Abstract: Described herein are methods and systems for estimating the current weight of commercial vehicles. A system comprising a weight estimator, which receives input from one or more vehicle systems and/or sensors, such as suspension, power train, speedometer, tire pressure monitoring system, and the like. The weight estimator uses these inputs to determine one or more weight values associated with the vehicle, such as the total vehicle weight, weight distribution per axle, weight distribution per wheel, load distribution, and the like. In some examples, the weight estimator submits these weight values to one or more other systems. For example, the weight values may be used as an indicator that the vehicle is overloaded and/or that the weight is distributed unevenly. In some examples, the weight values are used by a maintenance scheduler to determine the next required maintenance.

Abstract: Described herein are systems and methods for using different truck types for deliveries. A package is initially loaded into a specially configured cargo container that can be transported either on a primary truck or a secondary truck. A secondary truck is smaller than a primary truck and is configured to transport fewer cargo containers than the primary truck. An initial leg of the overall delivery (e.g., from a warehouse to a transfer point) is performed using a primary truck. The cargo container is then transferred to a secondary truck, which completes the delivery. Empty cargo containers can be transferred back to a primary truck, e.g., in a stacked or folded manner, for transporting back to the warehouse. The configurations of primary and secondary trucks are such that these transfers can occur at any location (e.g., a parking lot) with minimal human involvement.

Abstract: A battery system includes a power bus and a set of battery packs. A battery pack is one or more batteries, a sensor board, and a power board. The power bus is used to electrically connect the set of battery packs. The sensor board receives a voltage difference between a battery pack not connected to the power bus and the power bus; determines whether the voltage difference indicates that a battery pack voltage is too high compared to a power bus voltage; in response to determining the voltage difference indicates that the battery pack voltage is too high compared to the power bus voltage, provides a drain indication to drain off the battery pack using a power draw mechanism until the voltage of the battery pack is within a threshold voltage difference of the power bus; and provides a connect indication to connect the disconnected battery pack to the power bus.

Abstract: Disclosed herein are electric vehicles with various characteristics. For example, electric vehicles with at least two energy storage systems are described. As another example, electric vehicles with liquid temperature regulated battery packs are described. As yet another example, electric vehicles with high voltage battery limit optimization are disclosed. And, as another example, electric vehicles with dual-battery system charge management are described.

Abstract: Aspects of a modular clip for an electric battery module, a battery module comprising multiple such modular clips, and a battery pack comprising multiple battery modules are provided. The modular clip includes a housing configured to receive a plurality of battery cells. The modular clip may further comprise at least one interconnect plate. The modular clip may further comprise a retainer plate including a plurality of top cell recesses, each of the plurality of top cell recesses may comprise an opening to enable wire bonds between electrical terminals of a battery cell and the at least one interconnect plate. The battery module may comprise a plurality of wire bonds between at least one voltage sensing PCB and the at least one interconnect plate.

Abstract: A pan tilt unit comprises a support, a slip ring, a rotating platform, and a tilting mechanism. An outer rotating portion of the slip ring is able to rotate about the support. The slip ring comprises connections between an inner static portion of the slip ring and the outer rotating portion of the slip ring. The rotating platform is coupled to the outer rotating portion of the slip ring. The tilting mechanism is coupled to the rotating platform.