Abstract: Provided are battery packs and interface modules for electrically interconnecting electrochemical cells in the packs and for providing heat distribution with the packs. An interface module interfaces one side of all electrochemical cells in a battery pack. The interface module may have a substantially planar shape such that the space occupied by the module in the battery pack is minimal. Most, if not all, conductive components of the interface module may be formed from the same sheet of metal. In some embodiments, the interface module includes multiple bus bars such that each bus bar interconnects two or more terminals of different electrochemical cells in the battery pack. Each bus bar may have a separate voltage sense lead extending from the bus bar to a connecting portion. The bus bars may be flexibly supported within the module. The interface module may also include multiple thermistors disposed on different bus bars.

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 fractional-slot-winding motors and electric vehicles using such fractional-slot-winding motors. In some examples, a fractional-slot-winding motor comprises a stator, a bus-bar assembly, and a plurality of coil units. The stator comprises a plurality of stator slots (e.g., 63 slots) extending through the core and radially offset relative to each other. Each dual-leg coil unit extends through two different stator slots and is electrically coupled to two other coil units on the coil-interconnection side of the rotor. Each single-leg coil unit extends through one coil slot and is electrically coupled to one other coil unit on the coil-interconnection side. At least some single-leg coil units can be coupled to a bus-bar assembly. Furthermore, the ends of the coil unit can have radial offsets relative to protruding portions, e.g., closer to the motor primary axis at the coil-interconnection side and further away on the opposite side.

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 drive unit of an electric commercial vehicle. The drive unit may include an electric motor, a transmission, and a differential. The electric motor, transmission, and differential may share lubrication and cooling fluids. Various features for collecting and distribution the lubrication and cooling fluids are also described herein.

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 fractional-slot-winding motors and electric vehicles using such fractional-slot-winding motors. In some examples, a fractional-slot-winding motor comprises a stator, a bus-bar assembly, and a plurality of coil units. The stator comprises a plurality of stator slots (e.g., 63 slots) extending through the core and radially offset relative to each other. Each dual-leg coil unit extends through two different stator slots and is electrically coupled to two other coil units on the coil-interconnection side of the rotor. Each single-leg coil unit extends through one coil slot and is electrically coupled to one other coil unit on the coil-interconnection side. At least some single-leg coil units can be coupled to a bus-bar assembly. Furthermore, the ends of the coil unit can have radial offsets relative to protruding portions, e.g., closer to the motor primary axis at the coil-interconnection side and further away on the opposite side.

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 rear axle of a commercial electric vehicle. In various embodiments, the rear axle includes a curved de Dion axle that includes stub axles, CV cups, each configured to receive a portion of a CV axle, and a central portion disposed downward and rearward of the stub axles. The rear axle includes a curved form factor to allow for a portion of an electric drive unit to be disposed in a manner where a hub centerline connecting the stub axles intersects the electric drive unit.

Abstract: A park lock for an output drive gear includes a pawl, a rotational cam, and a rotational spring. The pawl has an engagement protrusion that extends outward from a body disposed on a pawl rotational shaft, such that rotation moves the engagement protrusion toward the output drive gear. The rotational cam rotates such that a circumferential side engages with a portion of the pawl opposite the engagement protrusion, causing rotation of the pawl about the rotational pawl shaft to move the engagement protrusion towards the output drive gear. The rotational spring maintains tension on the pawl and cam such that the engagement protrusion maintains an engagement with the output drive gear based on rotation of the cam and a speed of the output drive gear.

Abstract: Vehicle platforms, and systems, subsystems, and components thereof are described. A self-contained vehicle platform or chassis incorporating substantially all of the functional systems, subsystems and components (e.g., mechanical, electrical, structural, etc.) necessary for an operative vehicle. Functional components may include at least energy storage/conversion, propulsion, suspension and wheels, steering, crash protection, and braking systems. Functional components are standardized such that vehicle platforms may be interconnected with a variety of vehicle body designs (also referred to in the art as “top hats”) with minimal or no modification to the functional linkages (e.g., mechanical, structural, electrical, etc.) therebetween. Configurations of functional components are incorporated within the vehicle platform such that there is minimal or no physical overlap between the functional components and the area defined by the vehicle body.

Abstract: Provided are battery packs and interface modules for electrically interconnecting electrochemical cells in the packs and for providing heat distribution with the packs. An interface module interfaces one side of all electrochemical cells in a battery pack. The interface module may have a substantially planar shape such that the space occupied by the module in the battery pack is minimal. Most, if not all, conductive components of the interface module may be formed from the same sheet of metal. In some embodiments, the interface module includes multiple bus bars such that each bus bar interconnects two or more terminals of different electrochemical cells in the battery pack. Each bus bar may have a separate voltage sense lead extending from the bus bar to a connecting portion. The bus bars may be flexibly supported within the module. The interface module may also include multiple thermistors disposed on different bus bars.

Abstract: Provided are systems for vehicle energy storage having parallel cooling comprising a plurality of modules. Each module may comprise two half modules coupled together. Each half module can include a plurality of battery cells. A current carrier of each half module may be electrically coupled to the cells. The cells may be disposed between the current carrier and a plate. Each half module can have the cells, current carrier, and blast plate disposed in an enclosure. The enclosure can have a coolant sub-system for circulating coolant in parallel to the plurality of cells such that each of the battery cells is at approximately the same predetermined temperature. The modules may be disposed in a tray. A coolant system may be provided for circulating coolant across the plurality of modules in parallel such that each of the modules can be maintained at approximately the same predetermined temperature.

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: 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: Vehicle platforms, and systems, subsystems, and components thereof are described. A self-contained vehicle platform or chassis incorporating substantially all of the functional systems, subsystems and components (e.g., mechanical, electrical, structural, etc.) necessary for an operative vehicle. Functional components may include at least energy storage/conversion, propulsion, suspension and wheels, steering, crash protection, and braking systems. Functional components are standardized such that vehicle platforms may be interconnected with a variety of vehicle body designs (also referred to in the art as “top hats”) with minimal or no modification to the functional linkages (e.g., mechanical, structural, electrical, etc.) therebetween. Configurations of functional components are incorporated within the vehicle platform such that there is minimal or no physical overlap between the functional components and the area defined by the vehicle body.

Abstract: A battery enclosure for use in an electric vehicle where the structural support members of the battery enclosure are multi-functional and act to provide support for internally positioned batteries as well as provide additional strength to the framework of the electric vehicle. Furthermore, the structural elements can provide impact resistance to prevent unwanted intrusion into the battery enclosure.