Abstract: A battery pack venting system includes a traction battery pack having at least one array of battery cells and a structural member having an interior. The array is configured to vent into the interior. a traction battery pack venting method includes opening a vent to an interior of a structural member. At a position between a first axial end of the structural member and an opposite, second axial end of the structural member, the method includes venting a gas from at least one array of a traction battery pack into the interior, and then venting gas from the interior.

Abstract: A traction battery pack for an electrified vehicle may include a protection bracket for shielding a vent feature of the traction battery pack. An exemplary protection bracket may be made of a polymeric material and is designed to shield the vent feature from debris impingement. The protection bracket may include features such as a mesh venting pattern and a melting point that is lower than the temperature of battery vent byproducts that may be released during battery thermal events of the traction battery pack.

Abstract: This disclosure relates to an access cover detection circuit for an electrified vehicle component and a corresponding method. An exemplary component of an electrified vehicle includes an access cover configured to selectively open and close relative to the component, and a circuit configured to indicate whether the access cover is open. The circuit includes a light sensitive electronic component.

Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery pack having a coolant inlet and a coolant outlet, a coolant source to cool the battery pack, and a proportional valve in communication with the coolant inlet and the coolant outlet, and in communication with the coolant source. A battery control module controls the proportional valve such that a direction of flow is switchable at the coolant inlet and the coolant outlet based on temperatures at the coolant inlet and the coolant outlet to provide bi-directional cooling flow through the battery pack. The battery control module directly connects the coolant outlet to the coolant inlet via the proportional valve to bypass the coolant source in response to a predetermined condition.

Abstract: A busbar assembly includes a mesh busbar configured to electrically couple a first component to a second component. An electrical coupling method including securing a mesh busbar to a first component and a second component to electrical couple the first component to the second component.

Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery pack having a coolant inlet and a coolant outlet, a coolant source to cool the battery pack, and a proportional valve in communication with the coolant inlet and the coolant outlet, and in communication with the coolant source. A battery control module controls the proportional valve such that a direction of flow is switchable at the coolant inlet and the coolant outlet based on temperatures at the coolant inlet and the coolant outlet to provide bi-directional cooling flow through the battery pack. The battery control module directly connects the coolant outlet to the coolant inlet via the proportional valve to bypass the coolant source in response to a predetermined condition.

Abstract: This disclosure relates to an access cover detection circuit for an electrified vehicle component and a corresponding method. An exemplary component of an electrified vehicle includes an access cover configured to selectively open and close relative to the component, and a circuit configured to indicate whether the access cover is open. The circuit includes a light sensitive electronic component.

Abstract: An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.

Abstract: A busbar assembly includes a mesh busbar configured to electrically couple a first component to a second component. An electrical coupling method including securing a mesh busbar to a first component and a second component to electrical couple the first component to the second component.

Abstract: A vehicle includes an electric machine, a battery, an inverter, and a flexible circuit. The electric machine is configured to propel the vehicle. The inverter is configured to convert direct current from the battery into alternating current. The flexible circuit has a sensor embedded therein that is configured to measure a first phase of the alternating current. The sensor is secured to an output terminal of the inverter that is connected to a first winding phase of the electric machine.

Abstract: A vehicle includes main contactors powered via a low voltage bus and disposed electrically between a traction battery and a high voltage bus, and a controller. The controller, responsive to the contactors remaining open following activation of the low voltage bus and reported voltage values associated with the high voltage bus being less than a threshold, operates a horn of the vehicle.

Abstract: An integrated endplate for a battery pack includes an inner wall and an outer wall. The outer wall has a first side adjacent to the inner wall and a second side opposite the first side. The outer wall includes a connector interface protruding from the second side and defining at least one aperture therethrough. The integrated endplate further includes at least one electrical connector extending between the inner wall and the outer wall to the at least one aperture of the connector interface.

Abstract: Method and apparatus are disclosed for controlling a high voltage power supply. An example vehicle includes first and second power supply buses, a high voltage power supply coupled to the first and second power supply buses, and a high voltage controller. The high voltage controller is configured to control the high voltage power supply, detect a short circuit on the first power supply bus, and responsively change a power source of the high voltage controller by activating an opto-isolator and one or more smart FETs.

Abstract: A vehicle charging includes a housing, a sensor system configured to detect if a vehicle is parked near the housing, and a notification system configured to communicate an alert if the vehicle is parked near the housing and charging has not been initiated within a threshold amount of time. The alert indicates improper usage of the vehicle charging station to an operator of the vehicle.

Abstract: A power control system for a vehicle includes a precharge circuit that is configured to selectively couple a resistor across either a main or return contactor that are configured to selectively couple terminals of a battery to a load bus. The power control system includes a controller programmed to, in response to a precharge request in a presence of the main contactor being closed when commanded to open and the return contactor being open, couple the resistor across the return contactor to precharge the load bus.

Abstract: A vehicle includes main contactors powered via a low voltage bus and disposed electrically between a traction battery and a high voltage bus, and a controller. The controller, responsive to the contactors remaining open following activation of the low voltage bus and reported voltage values associated with the high voltage bus being less than a threshold, operates a horn of the vehicle.

Abstract: A hybrid electric vehicle having one or more controllers, at least two axles independently driven by respective electric machines (EMs) that are each coupled to a separate battery, and a combustion engine (CE) coupled to one of the axles. At least one of the controller(s) are configured to deliver power to one of the axles in a single axle drive mode, and in response to a torque demand signal (TDS) exceeding a single axle power limit, to deliver power to another axle, and/or all axles. The controller(s) are further configured to respond to the TDS exceeding a multiple axle power limit, and to deliver additional CE power to the coupled axle. In response to a braking signal, the controller(s) may also adjust at least one of the EMs to capture mechanical braking energy from a respective axle, and generate negative torque to charge one or more of the separate batteries.

Abstract: An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.

Abstract: Method and apparatus are disclosed for controlling a high voltage power supply. An example vehicle includes first and second power supply buses, a high voltage power supply coupled to the first and second power supply buses, and a high voltage controller. The high voltage controller is configured to control the high voltage power supply, detect a short circuit on the first power supply bus, and responsively change a power source of the high voltage controller by activating an opto-isolator and one or more smart FETs.

Abstract: A hybrid electric vehicle having one or more controllers, at least two axles independently driven by respective electric machines (EMs) that are each coupled to a separate battery, and a combustion engine (CE) coupled to one of the axles. At least one of the controller(s) are configured to deliver power to one of the axles in a single axle drive mode, and in response to a torque demand signal (TDS) exceeding a single axle power limit, to deliver power to another axle, and/or all axles. The controller(s) are further configured to respond to the TDS exceeding a multiple axle power limit, and to deliver additional CE power to the coupled axle. In response to a braking signal, the controller(s) may also adjust at least one of the EMs to capture mechanical braking energy from a respective axle, and generate negative torque to charge one or more of the separate batteries.