Abstract: A modular battery and power control system provides a range of electrical power to high-voltage and low-voltage power demand systems in a hybrid vehicle. The modular battery and power control system provides a single high-voltage modular battery pack that is selectively connected to high-voltage and low-voltage demand systems by a switch system. The switch system is controlled by a voltage controller module which monitors power demand and charge states of the electrical system and determines the switch positions to effect the indicated electrical demands of the hybrid vehicle.

Abstract: A vehicle power system may include a signal driver system electrically connected with a signal receiver system, and a traction battery electrically connected with contactors responsive to the signal receiver system. The electrical connections may be routed through a common interface. A voltage associated with a control signal commanding the signal receiver system to cause the contactors to close and driven into the electrical connection between the signal driver and signal receiver systems by the signal driver system may indicate whether the electrical connection between the traction battery and contactors at the common interface is faulty.

Abstract: An illustrative embodiment of a cable joint integrity detection systems for an electric vehicle includes an electric vehicle power converter module; a fastener joint on the power converter module; vehicle wiring connections electrically interfacing with the power converter module at the fastener joint; a current sensor electrically interfacing with the fastener joint; and a controller interfacing with the current sensor, the current sensor transmits a sensor signal to the controller to ensure connectional integrity between the fastener joint and the vehicle wiring connections. Cable joint integrity detection methods are also disclosed.

Abstract: An operation includes disabling a vehicle from moving while connection status of the vehicle with external charging infrastructure is unknown. A message is generated to advise a user to check the connection status. The vehicle is enabled to move upon a user indication that the vehicle is disconnected from the charging infrastructure.

Abstract: A vehicle includes a traction battery, an auxiliary battery, a charger, and two DC-DC converters. A first DC-DC converter is connected between the traction battery and the auxiliary battery through a main contactor. A second DC-DC converter is connected between the charger and the auxiliary battery. The charger is configured to charge the auxiliary battery via the second DC-DC converter when the charger is receiving power. The second DC-DC converter is configured to charge the auxiliary battery when the first DC-DC converter is disconnected from the traction battery. The second DC-DC converter can charge the auxiliary battery independent of the charger charging the traction battery. The second DC-DC converter may be configured to generally maximize power conversion efficiency in a range of power outputs associated with charging the auxiliary battery.

Abstract: A vehicle connected to electric vehicle supply equipment is configured to wake-up an onboard charger based on a pilot signal. A controller is configured to interrupt the pilot signal to prevent the pilot signal from subsequently waking the charger to reduce power consumed by the charger while the vehicle is connected. The interruption may be triggered by a completion of a charge cycle, an extensive charge wait interval, or a charging system condition that prevents charging. The controller may discontinue interruption of the pilot signal in response to a wake-up source other than the pilot signal.

Abstract: Electric and plug-in hybrid vehicles connect to Electric Vehicle Supply Equipment (EVSE) to recharge a traction battery. Existing standards define the signal interface between the vehicle and EVSE including control pilot and proximity detect signals. The vehicle may use the status of these signals to detect when a connection is established with EVSE. The vehicle may indicate a connection when the signals provide conflicting statuses. The vehicle may prevent driving off and permit charging in the event of a proximity detect signal indicating a state of engagement other than connected as long as a valid control pilot signal is present. The status of the control pilot signal may be utilized to prevent drive-off and permit charging.

Abstract: An operation includes disabling a vehicle from moving while connection status of the vehicle with external charging infrastructure is unknown. A message is generated to advise a user to check the connection status. The vehicle is enabled to move upon a user indication that the vehicle is disconnected from the charging infrastructure.

Abstract: A system and method for managing electrical loads in a vehicle includes a high voltage power source capable of providing electrical power to at least one high voltage load. An electrical converter is operable to receive an input of high voltage power from the high voltage power source and to provide an output of low voltage power to one or more low voltage loads. A control system is in communication with the converter, and it is configured to receive signals from the converter related to the converter output, and cut power to at least one of the low voltage loads when the signals received from the converter indicate that the high voltage power source cannot provide full power to the low voltage loads.

Abstract: A power management system for a vehicle having wheels and an electric machine operable to provide torque to drive at least one of the wheels includes a first energy storage system capable of supplying power to operate the electric machine. The system also includes a second energy storage system capable of supplying power directly to at least one vehicle load at a lower voltage than the first energy storage system. A voltage conversion device is operable to reduce a voltage of the power supplied by the first energy storage system to the lower voltage to charge the second energy storage system when the vehicle is in a key-off state.

Abstract: An electric or hybrid electric vehicle includes a battery coupled to a traction motor and a DC-DC power converter for managing transient current demands of vehicle accessories such as an electrical power assisted steering (EPAS) motor or antilock braking system (ABS) with a controller coupled to the power converter that generates a first duty cycle signal to supply current at a first level for a first time period to accommodate transient current for an EPAS, ABS, or other short duration event, and a second duty cycle signal that limits the current to a second level lower than the first level for a second time period upon expiry of the first time period to manage temperature of the converter. The controller may also generate a duty cycle signal based on measured or estimated transistor temperature of the DC-DC converter to lower the current limit when transistor temperature exceeds a threshold.

Abstract: A vehicle power system may include a signal driver system electrically connected with a signal receiver system, and a traction battery electrically connected with contactors responsive to the signal receiver system. The electrical connections may be routed through a common interface. A voltage associated with a control signal commanding the signal receiver system to cause the contactors to close and driven into the electrical connection between the signal driver and signal receiver systems by the signal driver system may indicate whether the electrical connection between the traction battery and contactors at the common interface is faulty.

Abstract: A system and method for managing electrical loads in a vehicle includes a high voltage power source capable of providing electrical power to at least one high voltage load. An electrical converter is operable to receive an input of high voltage power from the high voltage power source and to provide an output of low voltage power to one or more low voltage loads. A control system is in communication with the converter, and it is configured to receive signals from the converter related to the converter output, and cut power to at least one of the low voltage loads when the signals received from the converter indicate that the high voltage power source cannot provide full power to the low voltage loads.

Abstract: A system and method is provided for preventing disengagement between an electrical plug and a charge port on an electric vehicle. One or more projections are disposed on the electric vehicle. The projection has an extended locked position and a retracted unlocked position. An actuator selectively extends and retracts the projection between the locked and unlocked positions. When the projection is in the locked position, the projection engages the plug and prevents disengagement of the plug and the port.

Abstract: A system and method is provided for preventing disengagement between an electrical plug and a charge port on an electric vehicle. One or more projections are disposed on the electric vehicle. The projection has an extended locked position and a retracted unlocked position. An actuator selectively extends and retracts the projection between the locked and unlocked positions. When the projection is in the locked position, the projection engages the plug and prevents disengagement of the plug and the port.