Abstract: A fluid flow system for a rotatable shaft assembly includes a first fluid flow device installed in a rotatable shaft, and a second fluid flow device installed in the rotatable shaft, spaced axially apart from the first fluid flow device. The first fluid flow device includes a wall portion having a radial dimension that retains oil in the rotatable shaft. The second fluid flow device includes a wall portion having a radial dimension that facilitates discharge of oil from the radial shaft. The first and second fluid flow devices each include a plurality of baffles on the respective wall portions thereof. The plurality of baffles drive the flow of fluid in an axial direction, from the first fluid flow device toward the second fluid flow device, as the first and second fluid flow devices rotate together with the rotatable shaft.

Abstract: A cooler for power electronics comprises: a laminated structure having an inlet and an outlet, the laminated structure comprising a stack of planar members, wherein a first outermost member at an end of the stack forms a first heat exchange surface for mounting a first power electronics baseplate, wherein a second outermost member is positioned at an opposite end of the stack, wherein a first plurality of the planar members adjacent the first outermost member have openings that form a first heat exchange space within the stack, and wherein the inlet and the outlet are coupled to the first heat exchange space.

Abstract: In a general aspect, a method can include detecting, by a motor controller, an operating fault associated with operation of a powertrain of an electric vehicle. The powertrain can include a permanent magnet motor, a multi-phase inverter that is operationally coupled with the permanent magnet motor, and a rotational position sensor that is operationally coupled with the permanent magnet motor. The method can further include determining a classification of the operating fault and determining a present speed of the permanent magnet motor. The method can also include, in response to the detection of the operating fault and, based on at least one of the classification of the operating fault and the present speed of the permanent magnet motor, performing, by the motor controller, a fault reaction operation.

Abstract: A power distribution system is provided that ensures that a car is able to operate safely in an autonomous mode. The system includes multiple power rails, including a pair of safety critical power rails. Associated with each safety critical power rail is a safety switch, vehicle sensors (e.g., vehicle location and obstacle sensors), vehicle actuators (e.g., braking and steering actuators) and an autonomous control unit. If a fault is detected during vehicle initialization or general operation, the safety switch which detected the fault opens and that particular power rail is decoupled from the general purpose power rail as well as the remaining safety critical power rail. The remaining safety critical power rail is then able to provide power to a sufficient number of sensors, actuators and controllers to allow the car to safely and autonomously complete an emergency stop on the side of the road.

Abstract: An electric vehicle comprises: a battery system split into first and second sectors substantially equal to each other; a first bidirectional DC/DC converter, the first bidirectional DC/DC converter being galvanically isolated and coupled to the first sector; and a second bidirectional DC/DC converter, the second bidirectional DC/DC converter being galvanically isolated and coupled to the second sector; wherein the first and second bidirectional DC/DC converters balance respective states of charge of the first and second sectors before the first and second sectors are connected in parallel.

Abstract: A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in one of a series connection, a parallel connection or a series and parallel connection.

Abstract: A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells oriented in the same manner in the battery pack has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in a series connection and a parallel connection.

Abstract: A power distribution system is provided that ensures that a car is able to operate safely in an autonomous mode. The system includes multiple power rails, including a pair of safety critical power rails. Associated with each safety critical power rail is a safety switch, vehicle sensors (e.g., vehicle location and obstacle sensors), vehicle actuators (e.g., braking and steering actuators) and an autonomous control unit. If a fault is detected during vehicle initialization or general operation, the safety switch which detected the fault opens and that particular power rail is decoupled from the general purpose power rail as well as the remaining safety critical power rail. The remaining safety critical power rail is then able to provide power to a sufficient number of sensors, actuators and controllers to allow the car to safely and autonomously complete an emergency stop on the side of the road.

Abstract: A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in one of a series connection, a parallel connection or a series and parallel connection.

Abstract: A half-bridge power supply comprises: a first switch electrically connected to an energy source and to a load; a second switch electrically connected to the energy source and to the load; and circuitry electrically connected to the first and second switches and configured to provide a dynamic dead time for the half-bridge power supply based on one of the first and second switches being turned off having forward current.

Abstract: A half-bridge power supply comprises: a first switch electrically connected to an energy source and to a load; a second switch electrically connected to the energy source and to the load; and circuitry electrically connected to the first and second switches and configured to provide a dynamic dead time for the half-bridge power supply based on one of the first and second switches being turned off having forward current.

Abstract: A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in one of a series connection, a parallel connection or a series and parallel connection.

Abstract: A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery, cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in one of a series connection, a parallel connection or a series and parallel connection.

Abstract: A battery pack monitoring apparatus is provided. The apparatus includes a voltage measurement system configured to couple to opposed ends of each of a plurality of blocks of a battery pack and to measure voltages thereof, the blocks being coupled in series by interconnects each having an interconnect resistance. The voltage measurement system is configured to derive an internal resistance of each of the plurality of blocks based upon the voltages of the opposed ends of each of the plurality of blocks and based upon a measurement of current of the battery pack and derive the interconnect resistance of each of the interconnects based upon the voltages of the opposed ends of each of the plurality of blocks and based upon the measurement of current.

Abstract: A method of manufacturing an electric motor that includes a plurality of structural cooling features is provided, where the electric motor utilizes axial cooling channels integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack. A coolant manifold assembly, incorporated into the stator between left and right stator portions, provides a means of distributing coolant to the axial cooling channels.

Abstract: A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells oriented in the same manner in the battery pack has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in a series connection and a parallel connection.

Abstract: A torque limiting clutch assembly is provided that is mounted between the motor housing and the ring gear of a planetary gear assembly. During normal operation, the clutch assembly prevents rotation of the ring gear relative to the motor housing. In the event of a severe loading condition, the clutch assembly slips, thereby preventing excessive torque from being applied to the drive train and potentially damaging one or more drive train components.

Abstract: A battery pack has bus bars at one end, freeing the other end of the battery pack for cooling or other arrangements. A plurality of battery cells oriented in the same manner in the battery pack has first terminals of the battery cells at first ends of the battery cells. Portions of second terminals of the battery cells are at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of bus bars is assembled proximate to the first ends of the battery cells. The bus bars are coupled to the first terminals and the second terminals of the battery cells at the first ends of the battery cells to place the battery cells in a series connection and a parallel connection.

Abstract: A torque limiting clutch assembly is provided that is mounted between the motor housing and the ring gear of a planetary gear assembly. During normal operation, the clutch assembly prevents rotation of the ring gear relative to the motor housing. In the event of a severe loading condition, the clutch assembly slips, thereby preventing excessive torque from being applied to the drive train and potentially damaging one or more drive train components.

Abstract: A battery assembly utilizing a compact and robust bus bar configuration is provided. The batteries within the assembly are divided into groups with each group formed from at least two rows of batteries. The batteries within each battery group are connected in parallel and the groups are connected in series. The batteries are interconnected using a plurality of non-overlapping bus bars configured in an alternating pattern with the plurality of battery groups, where each of the bus bars includes multiple interconnect mounting platforms. The interconnect mounting platforms simplify coupling multiple rows of batteries to each bus bar while minimizing bus bar current density variations and insuring that individual interconnect resistance remains relatively low and at about the same level per battery.