Abstract: Aspects of the disclosure include air flow systems configured to regulate air flow when laser welding to improve laser weld quality. An exemplary air flow system can include a primary inlet coupled to an air source and one or more secondary inlets coupled to the primary inlet. At least one of the one or more secondary inlets can include an internal valve. Each internal valve is actuatable between a fully open state, a fully closed state, and an intermediate state. The air flow system can further include an outlet coupled to each of the one or more secondary inlets downstream of the internal valve and a controller configured to adjust a position of each internal valve. The controller is configured to adjust the position of each internal valve based on an air flow mapping to increase an average air flow velocity along a laser beam of a welding laser.

Abstract: A system includes a battery pack module and a control module. The battery pack module is configured to be implemented in a battery pack. The battery pack module includes cells and one or more force sensors configured to generate at least one force signal indicative of force on the cells within the battery pack module. The control module is configured to: receive the at least one force signal; based on the at least one force signal, detect a state of the cells; and based on the detected state of the cells, at least one of i) modify the state of the cells, ii) generate an alert message, and iii) perform a mitigation operation to address a detected abnormality of the cells.

Abstract: Methods and systems for detecting weld defects, and methods for manufacturing vehicles using such methods or systems, are provided. An exemplary method includes receiving an input indicating a weld material and material thickness by a portable computing device and determining, with the portable computing device, a detection protocol for the weld material and material thickness. Further, the method includes communicating the detection protocol from the portable computing device to a portable heating source and to a portable thermographic sensor, heating a weld with the portable heating source according to the detection protocol, and recording thermographic data from the weld with the portable thermographic sensor according to the detection protocol.

Abstract: A system for inspecting a battery component includes a heating device configured to heat a surface of the battery component to a selected temperature, an optical-visible imaging device configured to take an optical image of the surface, a thermal imaging device configured to take a thermal image of the surface, and a processor configured to acquire the optical image and the thermal image. The processor is configured to correlate the thermal image with the optical image, identify a feature of interest in at least one of the optical image and the thermal image, determine a geometric characteristic and a temperature characteristic associated with the feature of interest, and determine whether the feature of interest is a defect based on the geometric characteristic and the temperature characteristic.

Abstract: A method for detecting thermal runaway of a cell includes: positioning a battery pack having multiple cells in an automobile vehicle; measuring a cell voltage of the multiple cells at a predetermined sample rate; and identifying if the cell voltage decreases and modulates coincident with a cell surface temperature increase indicating initiation of a cell short.

Abstract: Systems and methods for responding to in a battery. A battery cell for a battery system includes a core of a known battery type, and a cell film having an initial thickness, the cell film configured as a pouch enclosing the core. The battery cell has at least one engraved groove in the cell film, the at least one engraved groove characterized by a groove thickness that is less than the initial thickness. The groove thickness configured to break open responsive to a predetermined gas pressure or target temperature in the pouch.

Abstract: Methods and systems for detecting weld defects, and methods for manufacturing vehicles using such methods or systems, are provided. An exemplary method includes receiving an input indicating a weld material and material thickness by a portable computing device and determining, with the portable computing device, a detection protocol for the weld material and material thickness. Further, the method includes communicating the detection protocol from the portable computing device to a portable heating source and to a portable thermographic sensor, heating a weld with the portable heating source according to the detection protocol, and recording thermographic data from the weld with the portable thermographic sensor according to the detection protocol.

Abstract: A control system to prevent thermal runaway includes an enclosure housing a plurality of battery cells of a battery module. Each of the battery cells is a pouch-type battery cell includes a core and a pouch enclosing the core and including one or more portions along one or more side surfaces thereof that are attached together by adhesive to form a seal. The adhesive is configured to release the seal when pressure within the pouch exceeds a predetermine pressure value. A gas sensor is configured to sense a predetermined gas in the enclosure. A valve is configured to selectively deliver thermal control fluid from a source. A controller is configured to open the valve in response to the gas sensor sensing the predetermined gas in the enclosure.

Abstract: In an exemplary embodiment, a LiDAR is provided that is configured for installation in a mobile platform. The LiDAR includes a scanner and a light-intensity receiver. The scanner includes a light source configured to direct illumination in an illuminating direction. The light-intensity receiver includes one or more light-intensity sensors; and one or more lens assemblies configured with respect to the one or more light-intensity sensors, such that that at least one sensor plane from the one or more light-intensity sensors is tilted to form a non-zero angle with at least one equivalent lens plane from the one or more lens assemblies, transferring the sensor focal plane to be align with the main light illumination direction and be consistent with the direction of movement of a mobile platform.

Abstract: A method for detecting thermal runaway of a cell includes: positioning a battery pack having multiple cells in an automobile vehicle; measuring a cell voltage of the multiple cells at a predetermined sample rate; and identifying if the cell voltage decreases and modulates coincident with a cell surface temperature increase indicating initiation of a cell short.

Abstract: A method for predicting a rotor temperature of an electric motor for an electric vehicle. The method includes measuring at least one of an operating parameter of the electric motor; inputting the at least one of the operating parameter of the electric motor into a predetermined regression model to predict a rotor temperature of the electric motor; and communicating the rotor temperature of the electric motor to a vehicle control module for managing the electric motor. The operating parameters includes a measured stator temperature, a torque level output, a rotor speed, and a coolant flowrate of the fixture electric motor. The electric motor may be that of an induction motor.

Abstract: An apparatus for automobile vehicle rotor temperature measurement includes a motor having a rotor. A stator has the rotor positioned within the stator. An aperture extends through the stator. A sensor is positioned in alignment with the aperture sensing a temperature of at least a surface of the rotor.

Abstract: An apparatus for automobile vehicle rotor temperature measurement includes a motor having a rotor. A stator has the rotor positioned within the stator. An aperture extends through the stator. A sensor is positioned in alignment with the aperture sensing a temperature of at least a surface of the rotor.

Abstract: An electric motor comprises a housing, a stator mounted stationary within the housing and having end turn windings, a rotatable central shaft, a rotor mounted onto the central shaft for rotation within the stator, the stator, central shaft and rotor all positioned co-axially within the housing, a rotor end ring mounted onto the central shaft adjacent an axial end of the rotor, the rotor end ring including a body, a plurality of outlets adapted to allow coolant to flow from a back side to a face of the body, and a recess formed within the face of the body, wherein coolant flowing through the outlets flows across the recess toward an outer circumference of the body, and the outer circumference of the body is configured to prevent coolant from flowing into a circumferential air gap between the stator and the rotor.

Abstract: An electric motor comprises a housing, a stator mounted stationary within the housing and having end turn windings, a rotatable central shaft, a rotor mounted onto the central shaft for rotation within the stator, the stator, central shaft and rotor all positioned co-axially within the housing, a rotor end ring mounted onto the central shaft adjacent an axial end of the rotor, the rotor end ring including a body, a plurality of outlets adapted to allow coolant to flow from a back side to a face of the body, and a recess formed within the face of the body, wherein coolant flowing through the outlets flows across the recess toward an outer circumference of the body, and the outer circumference of the body is configured to prevent coolant from flowing into a circumferential air gap between the stator and the rotor.

Abstract: In an exemplary embodiment, a LiDAR is provided that is configured for installation in a mobile platform. The LiDAR includes a scanner and a light-intensity receiver. The scanner includes a light source configured to direct illumination in an illuminating direction. The light-intensity receiver includes one or more light-intensity sensors; and one or more lens assemblies configured with respect to the one or more light-intensity sensors, such that that at least one sensor plane from the one or more light-intensity sensors is tilted to form a non-zero angle with at least one equivalent lens plane from the one or more lens assemblies, transferring the sensor focal plane to be align with the main light illumination direction and be consistent with the direction of movement of a mobile platform.

Abstract: In various embodiments, cameras and mobile platforms are provided. In one exemplary embodiment, a mobile platform is provided that includes a body and a camera disposed on the body. The camera includes one or more image sensors, and one or more lens assemblies. The one or more lens assemblies are configured with respect to the one or more image sensors, that at least one image plane from the one or more image sensors is tilted to form a non-zero angle with at least one equivalent lens plane from the one or more lens assemblies, transferring the image focal plane to be parallel to the movement direction of the mobile platform in which the camera is installed. The use of multiple image sensors or lens assemblies in certain embodiments increases camera angle of view.

Abstract: In various embodiments, cameras and mobile platforms are provided. In one exemplary embodiment, a mobile platform is provided that includes a body and a camera disposed on the body. The camera includes one or more image sensors, and one or more lens assemblies. The one or more lens assemblies are configured with respect to the one or more image sensors, that at least one image plane from the one or more image sensors is tilted to form a non-zero angle with at least one equivalent lens plane from the one or more lens assemblies, transferring the image focal plane to be parallel to the movement direction of the mobile platform in which the camera is installed. The use of multiple image sensors or lens assemblies in certain embodiments increases camera angle of view.

Abstract: A fuel injector for an internal combustion engine. The fuel injector has a needle and a nozzle that inter-relate with each other in assembly. Relative movement between the needle and nozzle bring the fuel injector between a closed state of operation and an open state of operation amid use of the fuel injector. The nozzle has one or more passages therein through which fuel is discharged.

Abstract: A fuel injector for an internal combustion engine. The fuel injector has a needle and a nozzle that inter-relate with each other in assembly. Relative movement between the needle and nozzle bring the fuel injector between a closed state of operation and an open state of operation amid use of the fuel injector. The nozzle has one or more passages therein through which fuel is discharged. Fuel flow is precluded at a sac volume of the fuel injector.