Abstract: A rotor of a permanent magnet synchronous machine includes a rotor core structure. A first set of apertures are formed in a first radial layer of the rotor core structure having a first set of permanent magnets disposed therein forming respective poles. A second set of apertures formed in a second radial layer of the rotor core structure of each pole. A third set of apertures is formed in a third radial layer of the rotor core structure. A second set of permanent magnets is inserted within the third set of apertures. A plurality of bridges each extends across a respective side of each of the third set of apertures in the third radial layer. The plurality of bridges provides structural support of the rotor core structure when operating. The plurality of bridges are integrally formed as single-piece laminations.

Abstract: A vehicle includes an engine, a transmission connected to the engine, an auxiliary electrical load, and an electrical system. The electrical system includes a high-voltage energy storage system (HV-ESS), an auxiliary/low-voltage energy storage system (LV-ESS) connected to the load, a full-bridge active rectifier/inverter, a semi-active auxiliary rectifier, and a motor generator unit (MGU) connected to the HV-ESS via the active rectifier/inverter, and to the LV-ESS via the semi-active auxiliary rectifier. A controller establishes a first operating mode in which the MGU is operated as a motor for restarting or assisting the engine via the active rectifier/inverter, and second operating mode in which the MGU operates as a generator and the semi-active rectifier provides an auxiliary DC output voltage to the LV-ESS and the load. Another vehicle has first and second switches in lieu of the semi-active rectifier, with the active rectifier connected to the HV-ESS and LV-ESS via different switches.

Abstract: A method and device for regulating charging and discharging current through a battery pack. Two or more battery packs are connected in parallel to an inverter, such that the inverter can use grid power to charge the battery packs or the battery packs can provide AC power through the inverter. A current balancing circuit device is placed in series with each battery pack and is used to regulate the current through the battery pack so that none of the battery packs is excessively charged or discharged. The current balancing circuit includes two field effect transistors (FETs) arranged in series and in opposite directions, where one FET controls charging current and the other controls discharging current. The balancing circuit also includes a current sensor, and uses proportional-integral control to provide a signal to the FETs such that the actual current flowing through the circuit is regulated to a target current value.

Abstract: An exhaust system for an engine comprises an exhaust heat recovery apparatus configured to receive exhaust gas from the engine and comprises a first flow passage in fluid communication with the exhaust gas and a second flow passage in fluid communication with the exhaust gas. A heat exchanger/energy recovery unit is disposed in the second flow passage and has a working fluid circulating therethrough for exchange of heat from the exhaust gas to the working fluid. A control valve is disposed downstream of the first and the second flow passages in a low temperature region of the exhaust heat recovery apparatus to direct exhaust gas through the first flow passage or the second flow passage.

Abstract: A vehicle includes an engine, a transmission connected to the engine, an auxiliary electrical load, and an electrical system. The electrical system includes a high-voltage energy storage system (HV-ESS), an auxiliary/low-voltage energy storage system (LV-ESS) connected to the load, a full-bridge active rectifier/inverter, a semi-active auxiliary rectifier, and a motor generator unit (MGU) connected to the HV-ESS via the active rectifier/inverter, and to the LV-ESS via the semi-active auxiliary rectifier. A controller establishes a first operating mode in which the MGU is operated as a motor for restarting or assisting the engine via the active rectifier/inverter, and second operating mode in which the MGU operates as a generator and the semi-active rectifier provides an auxiliary DC output voltage to the LV-ESS and the load. Another vehicle has first and second switches in lieu of the semi-active rectifier, with the active rectifier connected to the HV-ESS and LV-ESS via different switches.

Abstract: A powertrain is disclosed. A ring gear is attached to a first distal end of a crankshaft such that the ring gear and the crankshaft are rotatable in unison about a longitudinal axis. A motor-generator includes a motor/generator shaft rotatable about a first axis spaced from the longitudinal axis. A starter mechanism includes a first starter gear coupleable to the motor/generator shaft and rotatable about a second axis spaced from the longitudinal axis. The first and second axes are spaced and substantially parallel to each other. The first starter gear is movable along the second axis between a first position engaging the ring gear such that torque is transferred from the motor/generator shaft through the first starter gear and the ring gear to the crankshaft to start the engine, and a second position disengaged from the ring gear to rotatably disconnect the starter mechanism from the ring gear.

Abstract: A powertrain for a vehicle is disclosed. The powertrain includes an engine, a motor-generator and a starter mechanism. The powertrain also includes a first energy storage device disposed in a parallel electrical relationship with a motor-generator and an auxiliary electric system. Additionally, the powertrain includes a first switching device selectively transitionable between a first open state to electrically disconnect the first energy storage device from at least one of the motor-generator and the auxiliary electric system, and a first closed state to electrically connect the first energy storage device to at least one of the motor-generator and the auxiliary electric system. Electrical communication between the motor-generator and the auxiliary electric system is independent of the first switching device being in the first open and closed states.

Abstract: A vehicle includes a chassis, engine, transmission, electric machine operable to selectively power the engine, and an electrical system. The electrical system includes a DC propulsion energy storage system (P-ESS) and a DC auxiliary ESS (A-ESS). Positive terminals of the two ESSs are electrically connected. The A-ESS negative terminal connects to the chassis as an electrical ground. The P-ESS negative terminal is not connected to ground, such that voltage levels of the P-ESS negative terminal float with respect to ground. A power invertor module (PIM) is connected to the MGU via an AC propulsion bus, and to the positive and negative terminals of the P-ESS. Positive input terminal and output terminals of a DC-DC converter system are tied together and connected to positive terminals of the P-ESS and A-ESS. A negative input terminal of the DC-DC converter system is electrically connected to the negative terminal of the P-ESS.

Abstract: A powertrain and an electromechanical apparatus are disclosed. A ring gear is attached to a first distal end of a crankshaft such that the ring gear and the crankshaft are rotatable in unison about a longitudinal axis. A motor-generator includes a motor/generator shaft being rotatable about a first axis spaced from the longitudinal axis. A starter mechanism includes a first starter gear coupleable to the motor/generator shaft and rotatable about a second axis spaced from the longitudinal axis. The first starter gear is movable along the second axis between a first position engaging the ring gear such that torque is transferred from the motor/generator shaft through the first starter gear and the ring gear to the crankshaft to start the engine, and a second position disengaged from the ring gear to rotatably disconnect the starter mechanism from the ring gear.

Abstract: An electrical system includes a battery for providing electrical power to a starter mechanism and an auxiliary load of a hybrid-electric vehicle. An electric double-layer capacitor (“EDLC”) is electrically connectable to the battery and the auxiliary load. A separation switch is electrically connected between the battery and the EDLC for electrically separating the battery from the EDLC and the auxiliary load. The separation switch is opened in response to the voltage across the battery being less than the voltage across the EDLC.

Abstract: An exhaust gas treatment system for an internal combustion engine is provided. The internal combustion engine has an engine off condition. The exhaust gas treatment system includes particulate filter (“PF”) device in fluid communication with an exhaust gas conduit, an electric heater, a primary energy storage device, a single secondary energy storage device, and a control module. The PF device has a filter structure for removal of particulates in the exhaust gas, and is selectively regenerated based on an amount of particulates trapped within the filter structure of the PF device. The electric heater is disposed upstream of the filter structure and is selectively energized to provide heat for regeneration of the PF device. The single secondary energy storage device is selectively connected to the primary energy storage device. The single secondary energy storage device selectively energizes the electric heater.

Abstract: Apparatus for voltage stabilization in a vehicle includes a battery distribution module having a load module managing electrical power to one or more auxiliary loads, a first switch coupling a starter motor and an ESD to the load module only when closed, a second switch coupling an auxiliary ESD to the load module only when closed, and a controller integrated with a PC board attached to the first and second switch devices. The controller is configured to control opening and closing of the first and second switches based on at least one of a plurality of signals received by the controller. The primary ESD is electrically coupled a primary fuse terminal of the battery distribution module which electrically couples the primary ESD to a second terminal of the first switch and the starter motor. The auxiliary ESD is electrically coupled to an auxiliary fuse terminal of the battery distribution module which electrically couples a first terminal of the second switch to the auxiliary ESD.

Abstract: Method for voltage stabilization during an engine starting event of a vehicle includes receiving, at a switch device module, an active Start_ON signal from a starter solenoid module indicating initiation of the engine starting event. At the switch device module, an auxiliary electrical energy storage device (ESD) is electrically coupled to one or more auxiliary loads within a predetermined delay since the active Start_ON signal was received. A primary ESD and a starter motor are electrically decoupled from the one or more auxiliary loads only after the auxiliary ESD has been electrically coupled to the one or more auxiliary loads. In response to a predetermined condition occurring while the primary ESD and the starter motor are electrically decoupled from the one or more auxiliary loads, the primary ESD and the starter motor are electrically coupled to the one or more auxiliary loads.

Abstract: An exhaust gas treatment system for an internal combustion engine is provided. The internal combustion engine has an engine off condition. The exhaust gas treatment system includes particulate filter (“PF”) device in fluid communication with an exhaust gas conduit, an electric heater, a primary energy storage device, a plurality of secondary energy storage devices, and a control module. The PF device has a filter structure for removal of particulates in the exhaust gas, and is selectively regenerated based on an amount of particulates trapped within the filter structure of the PF device. The electric heater is disposed upstream of the filter structure and is selectively energized to provide heat for regeneration of the PF device. The plurality of secondary energy storage devices are selectively connected to the primary energy storage device. The secondary energy storage devices selectively energize the electric heater.

Abstract: An electrical system includes a battery for providing electrical power to a starter mechanism and an auxiliary load of a hybrid-electric vehicle. An electric double-layer capacitor (“EDLC”) is electrically connectable to the battery and the auxiliary load. A separation switch is electrically connected between the battery and the EDLC for electrically separating the battery from the EDLC and the auxiliary load. The separation switch is opened in response to the voltage across the battery being less than the voltage across the EDLC.

Abstract: A method and device for regulating charging and discharging current through a battery pack. Two or more battery packs are connected in parallel to an inverter, such that the inverter can use grid power to charge the battery packs or the battery packs can provide AC power through the inverter. A current balancing circuit device is placed in series with each battery pack and is used to regulate the current through the battery pack so that none of the battery packs is excessively charged or discharged. The current balancing circuit includes two field effect transistors (FETs) arranged in series and in opposite directions, where one FET controls charging current and the other controls discharging current. The balancing circuit also includes a current sensor, and uses proportional-integral control to provide a signal to the FETs such that the actual current flowing through the circuit is regulated to a target current value.

Abstract: An exhaust gas treatment system for an internal combustion engine is provided. The internal combustion engine has an engine off condition. The exhaust gas treatment system includes particulate filter (“PF”) device in fluid communication with an exhaust gas conduit, an electric heater, a primary energy storage device, a plurality of secondary energy storage devices, and a control module. The PF device has a filter structure for removal of particulates in the exhaust gas, and is selectively regenerated based on an amount of particulates trapped within the filter structure of the PF device. The electric heater is disposed upstream of the filter structure and is selectively energized to provide heat for regeneration of the PF device. The plurality of secondary energy storage devices are selectively connected to the primary energy storage device. The secondary energy storage devices selectively energize the electric heater.

Abstract: An exhaust gas treatment system for an internal combustion engine is provided. The internal combustion engine has an engine off condition. The exhaust gas treatment system includes particulate filter (“PF”) device in fluid communication with an exhaust gas conduit, an electric heater, a primary energy storage device, a single secondary energy storage device, and a control module. The PF device has a filter structure for removal of particulates in the exhaust gas, and is selectively regenerated based on an amount of particulates trapped within the filter structure of the PF device. The electric heater is disposed upstream of the filter structure and is selectively energized to provide heat for regeneration of the PF device. The single secondary energy storage device is selectively connected to the primary energy storage device. The single secondary energy storage device selectively energizes the electric heater.

Abstract: A method for operating a thermoelectric generator supplying a variable-load component includes commanding the variable-load component to operate at a first output and determining a first load current and a first load voltage to the variable-load component while operating at the commanded first output. The method also includes commanding the variable-load component to operate at a second output and determining a second load current and a second load voltage to the variable-load component while operating at the commanded second output. The method includes calculating a maximum power output of the thermoelectric generator from the determined first load current and voltage and the determined second load current and voltage, and commanding the variable-load component to operate at a third output. The commanded third output is configured to draw the calculated maximum power output from the thermoelectric generator.

Abstract: A method of operating an engine stop/start system includes connecting an armature of a starter motor to the engine through an overrunning clutch when the engine changes a rotational direction.