Abstract: A battery pack having an active thermal management system for use with a hybrid vehicle is provided. The active thermal management system is self-contained within a housing of the battery pack and includes a thermal channel configured to provide fluid communication between an interior of the housing and an exterior of the housing of the battery pack; a set of thermoelectric devices configured to transfer heat from battery cells of the battery pack to the thermal channel; an insulator arranged between the battery cells and the thermal channel; a device configured to control fluid flow via the thermal channel; and a controller configured to control the device to actively control heat transfer from the interior of the housing to the exterior of the housing of the battery pack to maintain the battery pack at a desired temperature.

Abstract: Compact integrated battery packs for hybrid vehicles are fully integrated with an on-board cooling system and include both the battery cells for supplying a primary voltage, such as powering a belt-driven starter generator (BSG) unit for engine start/stop, as well as a direct current (DC) to DC converter for stepping down the primary voltage to a secondary voltage for powering low voltage components and/or recharging a lead-acid battery. The on-board DC to DC converter decreases packaging size and eliminates the need for an alternator, which further decreases packaging size. Primary and secondary voltage output ports can also be implemented for quick and easy connection to other components. Configurations include single-layer and dual-layer arrangements with integrated air or liquid cooling for placement in or beneath a trunk of a vehicle, behind or beneath seats in a cab of a pickup truck, and/or beneath a vehicle.

Abstract: A method for a battery pack controller of an electrified vehicle, the battery pack controller including one or more processors, includes identifying N battery cells of a battery pack that includes M battery cells, the N battery cells being weakest battery cells of the battery pack, wherein N is an integer greater than zero and less than M. The method includes determining one or more first parameters for each of the N battery cells, each of the one or more first parameters indicating a parameter for a specific battery cell. The method includes estimating one or more second parameters for the battery pack based on the one or more first parameters for each of the N battery cells, each of the one or more second parameters indicating a parameter for the battery pack. The method also includes outputting the one or more second parameters for the battery pack.

Abstract: A battery pack having an active thermal management system for use with a hybrid vehicle is provided. The active thermal management system is self-contained within a housing of the battery pack and includes a thermal channel configured to provide fluid communication between an interior of the housing and an exterior of the housing of the battery pack; a set of thermoelectric devices configured to transfer heat from battery cells of the battery pack to the thermal channel; an insulator arranged between the battery cells and the thermal channel; a device configured to control fluid flow via the thermal channel; and a controller configured to control the device to actively control heat transfer from the interior of the housing to the exterior of the housing of the battery pack to maintain the battery pack at a desired temperature.

Abstract: Compact integrated battery packs for hybrid vehicles are fully integrated with an on-board cooling system and include both the battery cells for supplying a primary voltage, such as powering a belt-driven starter generator (BSG) unit for engine start/stop, as well as a direct current (DC) to DC converter for stepping down the primary voltage to a secondary voltage for powering low voltage components and/or recharging a lead-acid battery. The on-board DC to DC converter decreases packaging size and eliminates the need for an alternator, which further decreases packaging size. Primary and secondary voltage output ports can also be implemented for quick and easy connection to other components. Configurations include single-layer and dual-layer arrangements with integrated air or liquid cooling for placement in or beneath a trunk of a vehicle, behind or beneath seats in a cab of a pickup truck, and/or beneath a vehicle.

Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: A method for a battery pack controller of an electrified vehicle, the battery pack controller including one or more processors, includes identifying N battery cells of a battery pack that includes M battery cells, the N battery cells being weakest battery cells of the battery pack, wherein N is an integer greater than zero and less than M. The method includes determining one or more first parameters for each of the N battery cells, each of the one or more first parameters indicating a parameter for a specific battery cell. The method includes estimating one or more second parameters for the battery pack based on the one or more first parameters for each of the N battery cells, each of the one or more second parameters indicating a parameter for the battery pack. The method also includes outputting the one or more second parameters for the battery pack.

Abstract: An improved air foil bearing assembly is disclosed. The air foil bearing assembly includes a bearing housing having an axially extending bore therein and a shaft arranged within the bore for relative coaxial rotation with respect to the bearing housing. The shaft cooperates with the bearing housing to define an annular gap therebetween. A foil assembly is disposed in the annular gap, including at least one foil having at least one laterally extending tab. The tab is adapted to be received in and extend axially from the annular gap and is further adapted to be bent into frictional contact with an outer surface of the bearing housing to militate against axial movement of the foil.

Abstract: A dual axis motorized solar tracking device that can be rotated over 360° and wherein the solar array panel thereof can be tilted from 90° to 10° and wherein the motorized portions of said device is controlled by an internally contained computerized controlling system that is programmed to follow the path of the sun at the installed location thereof and also to adjust the system to allow for any problems in weather. The internally contained computerized controlling device is electrically actuated from a plethora of sources including a separate panel on the solar array dedicated to recharging an energy storage cell system that will power up the internally contained and computerized controlling system. Alternatively, other power sources external to the device may also be employed giving this system a unique ability to keep on running while charging the energy storage cell system under any circumstances. A lithium-ion battery can be used as the rechargeable battery system.

Abstract: A method and system of dynamically displaying a plurality of electric drive range estimations for a vehicle having an electric motor and an energy storage system configured to provide electric power to the electric motor. The display providing information to a driver such that an electric drive range of the vehicle can be optimized.

Abstract: Methods and systems for using compressed gas in a vehicle. The methods include generating mechanical energy by expanding stored compressed gas through a turbine-compressor and distributing the mechanical energy to the engine, motor-generator, or a wheel. The compressed gas vehicle system includes a flask connected to a turbine-compressor, which may be interconnected to the engine and the motor-generator. The system may also include an electric wheel-motor connected electrically to the motor-generator.

Abstract: An improved air foil bearing assembly is disclosed. The air foil bearing assembly includes a bearing housing having an axially extending bore therein and a shaft arranged within the bore for relative coaxial rotation with respect to the bearing housing. The shaft cooperates with the bearing housing to define an annular gap therebetween. A foil assembly is disposed in the annular gap, including at least one foil having at least one laterally extending tab. The tab is adapted to be received in and extend axially from the annular gap and is further adapted to be bent into frictional contact with an outer surface of the bearing housing to militate against axial movement of the foil.

Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: A pinion shaft and bearing assembly is provided having two different surface finish interfaces. A first surface finish functions to locate the bearing to the pinion. A second surface finish functions to improve the cure time of an adhesive used to retain the bearing to the pinion.

Abstract: An improved air foil bearing assembly is disclosed. The air foil bearing assembly includes a bearing housing having an axially extending bore therein and a shaft arranged within the bore for relative coaxial rotation with respect to the bearing housing. The shaft cooperates with the bearing housing to define an annular gap therebetween. A foil assembly is disposed in the annular gap, including at least one foil having at least one laterally extending tab. The tab is adapted to be received in and extend axially from the annular gap and is further adapted to be bent into frictional contact with an outer surface of the bearing housing to militate against axial movement of the foil.

Abstract: A damper assembly for absorbing and attenuating torsionals and vibrations transmitted from an engine to a transmission is provided. The damper assembly includes a damper flange with a plurality of spring-mass damper systems operatively attached thereto and elongated circumferentially about its outer periphery. Each spring-mass damper systems include an inner spring nestably positioned inside an outer spring, a first spring retainer having a base portion defining a first interface surface with a first pilot portion extending therefrom to define a second interface surface with a second pilot portion extending therefrom, and a second spring retainer having a base portion defining an interface surface with a pilot portion extending therefrom to define a fourth interface surface. The first and third pilot portions engage with and thereby restrict axial and radial movement of the outer spring. The second pilot portion is attached to the inner spring thereby restricting relative movement therebetween.

Abstract: An internal gear and cap assembly includes a gear having a base that extends about an axis between a first and second end. The first end defines a groove that extends to a floor and the groove surrounds the axis. Teeth extend from the base. A lip extends from the first end and also surrounds the axis. A cap has a flange that is inserted into the groove. The lip is deformed toward the groove such that material from the lip flows to trap the flange between the lip and the floor of the groove to retain the cap to the gear in the axial direction. Slots may be defined in the flange such that the material from the lip flows into the slots to provide a key-lock between the cap and the gear to prevent rotation of the cap relative to the gear about the axis.

Abstract: A pinion shaft and bearing assembly is provided having two different surface finish interfaces. A first surface finish functions to locate the bearing to the pinion. A second surface finish functions to improve the cure time of an adhesive used to retain the bearing to the pinion.

Abstract: A damper assembly for absorbing and attenuating torsionals and vibrations transmitted from an engine to a transmission is provided. The damper assembly includes a damper flange with a plurality of spring-mass damper systems operatively attached thereto and elongated circumferentially about its outer periphery. Each spring-mass damper systems include an inner spring nestably positioned inside an outer spring, a first spring retainer having a base portion defining a first interface surface with a first pilot portion extending therefrom to define a second interface surface with a second pilot portion extending therefrom, and a second spring retainer having a base portion defining an interface surface with a pilot portion extending therefrom to define a fourth interface surface. The first and third pilot portions engage with and thereby restrict axial and radial movement of the outer spring. The second pilot portion is attached to the inner spring thereby restricting relative movement therebetween.