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.

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 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 traction control system is provided that is applicable to both two wheel drive and four wheel drive electric vehicles, and which is capable of handling both low frequency and high frequency control duties. The system uses proportional gains in order to minimize controller delays and insure a natural feeling traction control system.

Abstract: A traction control system is provided that is applicable to both two wheel drive and four wheel drive electric vehicles, and which is capable of handling both low frequency and high frequency control duties. The system uses proportional gains in order to minimize controller delays and insure a natural feeling traction control system.

Abstract: A method of thermally pre-conditioning a vehicle's battery pack prior to vehicle departure is provided. The system, after determining that the vehicle is off and/or the driver has left the car, monitors a variety of conditions corresponding to both the vehicle and the driver in order to determine the probability of the driver requiring near-term use of the car. Typical monitored conditions may include driver and vehicle location, driver proximity, time of day, day of week, driver's upcoming appointments, and a historical data base that tracks driver behavior. Once the probability that the car will be needed within a preset time period exceeds a preset level, the system determines whether the battery pack should be heated or cooled based on the current battery pack temperature, and then activates an appropriate thermal management system.

Abstract: A method of thermally pre-conditioning a vehicle's battery pack prior to vehicle departure is provided. The system, after determining that the vehicle is off and/or the driver has left the car, monitors a variety of conditions corresponding to both the vehicle and the driver in order to determine the probability of the driver requiring near-term use of the car. Typical monitored conditions may include driver and vehicle location, driver proximity, time of day, day of week, driver's upcoming appointments, and a historical data base that tracks driver behavior. Once the probability that the car will be needed within a preset time period exceeds a preset level, the system determines whether the battery pack should be heated or cooled based on the current battery pack temperature, and then activates an appropriate thermal management system.

Abstract: A system for thermally pre-conditioning a vehicle's battery pack prior to vehicle departure is provided. The system, after determining that the vehicle is off and/or the driver has left the car, monitors a variety of conditions corresponding to both the vehicle and the driver in order to determine the probability of the driver requiring near-term use of the car. Typical monitored conditions may include driver and vehicle location, driver proximity, time of day, day of week, driver's upcoming appointments, and a historical data base that tracks driver behavior. Once the probability that the car will be needed within a preset time period exceeds a preset level, the system determines whether the battery pack should be heated or cooled based on the current battery pack temperature, and then activates an appropriate thermal management system.

Abstract: A method of thermally pre-conditioning a vehicle's passenger cabin prior to vehicle departure is provided. The system, after determining that the vehicle is off and/or the driver has left the car, monitors a variety of conditions corresponding to both the vehicle and the driver in order to determine the probability of the driver requiring near-term use of the car. Typical monitored conditions may include driver and vehicle location, driver proximity, time of day, day of week, driver's upcoming appointments, and a historical data base that tracks driver behavior. Once the probability that the car will be needed within a preset time period exceeds a preset level, the system determines whether the passenger cabin should be heated or cooled based on the current passenger cabin temperature, and then activates an appropriate thermal management system.

Abstract: A system for thermally pre-conditioning a vehicle's passenger cabin prior to vehicle departure is provided. The system, after determining that the vehicle is off and/or the driver has left the car, monitors a variety of conditions corresponding to both the vehicle and the driver in order to determine the probability of the driver requiring near-term use of the car. Typical monitored conditions may include driver and vehicle location, driver proximity, time of day, day of week, driver's upcoming appointments, and a historical data base that tracks driver behavior. Once the probability that the car will be needed within a preset time period exceeds a preset level, the system determines whether the passenger cabin should be heated or cooled based on the current passenger cabin temperature, and then activates an appropriate thermal management system.

Abstract: A method of maintaining a calibrated DC fan motor is provided in which normal operation of the motor is periodically and temporarily suspended in order to calibrate the motor. During normal operation, the motor controller selects an appropriate PWM control signal to achieve the desired motor speed. This PWM control signal is later modified during the calibration process on the basis of the difference between the desired motor speed and the actual motor speed, where the actual motor speed is determined by temporarily interrupting power to the motor, measuring the back EMF of the motor, and calculating the actual motor speed based on the back EMF. When normal operation is resumed, the motor controller uses the modified PWM control signal.

Abstract: A dual stage accelerator pedal spring assembly is provided that allows the transition point between stroke stages to be set, thereby controlling pedal travel within the first stroke stage, and notifies the driver of a critical operating condition, such as a low battery pack level, via a pedal feedback system. The spring assembly, which uses two springs exhibiting different spring force, allows adjustment of the relative positions of the two springs in order to control the transition point between the first and second pedal stroke stages. The change in pedal resistance used to notify the driver of a change in a monitored vehicle characteristic is achieved by preloading one of the springs in the spring assembly.

Abstract: A method is provided for testing the performance of a vehicle-mounted heat exchanger and determining whether debris is preventing air from efficiently passing through the heat exchanger. To test performance, after the vehicle is traveling faster than a preset minimum speed, the power to the DC fan motor that is adjacent to the heat exchanger is interrupted and the back EMF of the motor is used to determine fan motor speed. As rotation of the unpowered fan motor is due to the air flowing through the heat exchanger, the rate of fan rotation is used to indicate the relative health of the heat exchanger. If the rotation of the fan motor indicates insufficient air flow, then a notification message (e.g., visual or auditory warning indicator) is transmitted. If the test indicates sufficient air flow, normal operation of the fan motor is re-initiated and power is re-connected to the motor.

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 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 method of diagnosing DC fan motor performance is provided in which normal operation of the motor is periodically and temporarily suspended in order to verify that the motor is operating within an acceptable performance range. When normal fan motor operation is suspended, the back EMF of the motor is used to determine (i) whether the motor is seized and/or (ii) whether the rate of deceleration after interrupting power to the motor is indicative of a failing motor.

Abstract: A dual stage accelerator pedal spring assembly is provided that allows the transition point between stroke stages to be set, thereby controlling pedal travel within the first stroke stage, and notifies the driver of a critical operating condition, such as a low battery pack level, via a pedal feedback system. The spring assembly, which uses two springs exhibiting different spring force, allows adjustment of the relative positions of the two springs in order to control the transition point between the first and second pedal stroke stages. The change in pedal resistance used to notify the driver of a change in a monitored vehicle characteristic is achieved by preloading one of the springs in the spring assembly.