Abstract: A magnet-free electric machine. The electric machine may include a stator including a first stator winding set and a second stator winding set and a rotor including a first rotor winding set and a second rotor winding set. The electric machine may include a power transfer circuit configured for controlling a polarity and/or a phase sequence of excitation currents used in exciting the first and second stator and rotor windings, and thereby, respectively generated stator and rotor poles.

Abstract: A method for heating a battery pack of an electrified powertrain system having an electric motor includes determining a temperature of the battery pack. Responsive to the battery temperature being less than a predetermined threshold temperature, the method includes executing a self-heating mode of the battery pack. This includes injecting a high-frequency direct-axis alternating current voltage waveform that minimizes output torque and prevents rotation of a rotor of the electric motor. An AC current waveform is applied to the battery pack as a result of the voltage injection. A controller includes a temperature sensor configured for determining a temperature of the battery pack and a processor configured to perform the method. A motor vehicle includes the controller, an electrified powertrain system having the battery pack and an electric motor, and road wheels connected to and powered by electric motor.

Abstract: An electric machine includes a rotor assembly having a rotor shaft disposed along a central axis. The electric machine includes an inductive position sensor having a sensor target that is operatively connected to the rotor shaft. The sensor target is fixed relative to the rotor shaft such that the sensor target rotates with the rotor shaft. The electric machine includes a stationary member and a rotating member operatively connected to the rotor shaft. The rotating member is spaced from the stationary member by an air gap. The stationary member and the rotating member are configured to enable non-contact power transfer from the stationary member to the rotating member through the air gap. The non-contact power transfer may be an inductive power transfer or a capacitive power.

Abstract: An electric drive unit includes a housing and a rotor rotatably supported in the housing. The rotor includes a rotor shaft defining a rotor axis and a plurality of rotor laminations fixedly mounted to the shaft. The plurality of rotor laminations support a plurality of magnetic poles, and a hydraulic unit connected to the plurality of rotor laminations. The hydraulic unit has a magnetic shunt that is selectively shiftable relative to the plurality of magnetic poles. A position sensing system is operable to detect a rotational speed of the rotor and a position of the magnetic shunt relative to the plurality of magnetic poles. The position sensing system includes a rotor shaft position trigger coupled for rotation with the rotor shaft, and a magnetic shunt position trigger supported by the hydraulic unit.

Abstract: In an embodiment, a method is provided for controlling a plurality of converters that are coupled to a plurality of cells of a rechargeable energy storage system (RESS) and configured to supply electric current to other systems that require the electric current, the method including obtaining, via one or more sensors, cell data as to the plurality of cells, the cell data including a state-of-charge for each of the plurality of cells; obtaining other system data as to the other systems, including an amount of electric current required by the other systems; and controlling the plurality of converters, in accordance with instructions provided by a processor, based on both: the cell data, including the state-of-charge for each of the plurality of cells; and the other system data, including the amount of electric current by the other systems.

Abstract: A dual inverter open winding machine for a vehicle. The machine may include an electric motor, a first energy source, a first inverter, a second energy source, and a second inverter. The first inverter may include a plurality of first switches independently operable between an opened position and a closed position to selectively connect and disconnect a first direct current (DC) port and a first alternating current (AC) port with one or more of the first energy source, the first inverter, and the motor. The second inverter may include a plurality of second switches independently operable between an opened position and a closed position to selectively connect and disconnect a second DC port and a second AC port with one or more of the second energy source, the second inverter, and the motor.

Abstract: A power control system for a vehicle includes a charge port and a contactor connected to the charge port and including a first plurality of switches. An energy storage system includes a second plurality of switches and one or more battery packs. A bi-directional DC-DC converter is connected between the energy storage system and a plurality of vehicle loads. A controller is configured to control states of the first and second plurality of switches to configure in a plurality of modes including a range improvement mode, a first charging mode to perform charging at a first voltage level, a second charging mode to perform charging at a second voltage level, a battery preconditioning mode; and an accessory load support mode.

Abstract: A vehicle and a drive system include a method of operating the vehicle. In another exemplary embodiment, a drive system of a vehicle is disclosed. The drive system includes a first sensor, a second sensor and a processor. The first sensor is disposed at a first location of the drive system for measuring a first angle of rotation. The second sensor is disposed at a second location of the drive system for measuring a second angle of rotation. The processor is configured to determine a torque transferred between the first location and the second location based on a difference between the first angle of rotation and the second angle of rotation and control an operation of the drive system based on the torque.

Abstract: A battery system for an electric vehicle includes at least one battery cell configured to store charge for powering an electric vehicle, a high voltage bus electrically coupled with the at least one battery, a DC-DC converter electrically coupled with the battery cell, a low voltage bus electrically connected between the DC-DC converter and at least one vehicle electrical component, and a cell monitor electrically coupled with the at least one battery cell and the DC-DC converter, wherein the cell monitor includes a current sensor configured to detect a current from the at least one battery cell to the DC-DC converter. The cell monitor includes a controller configured to estimate a state of charge of the at least one battery cell according to the current detected by the current sensor, and adjust switching operation of the DC-DC converter according to the current detected by the current sensor.

Abstract: A low voltage (LV) charging system for charging a high voltage (HV) rechargeable energy storage system (RESS), such as a HV RESS operable for electrically powering a traction motor of an electric vehicle. The LV charging system may include an input configured for receiving LV electrical power from a LV source and a distributed converter system configured for charging a plurality of modules of the HV RESS via a plurality of charging circuits. The charging circuits may be configured for separately charging one of the modules with a charging electrical power derived from converting the LV electrical power. The LV charging system may further include a controller configured for individually controlling the charging electrical power provided via each of the charging circuits.

Abstract: Examples described herein provide a method for predicting electrical failures within a vehicle. The method includes selectively enabling and disabling an electrical load for the vehicle. The method further includes collecting operational data about the electrical load during the selectively enabling and disabling of the electrical load. The method further includes training the model based at least in part on the operational data to predict a failure associated with the electrical load or a wiring harness associated with the electrical load.

Abstract: A vehicle includes two or more battery packs configured to power a motor. A controller is configured to dynamically activate an operational mode during operation. The operational mode is one of multiple possible operational modes including a first operational mode defining a series connection between the two or more battery packs and second operational mode defining a parallel connection between the two or more battery packs. The connection between the battery packs is controlled by a first plurality of switches. A plurality of low voltage loads are connected to a subset of the battery packs in the battery packs such that a power output of the subset of the battery packs provides full power to the plurality of low voltage loads. The plurality of low voltage loads are connected to only the subset of the battery packs in both the first operational mode and the second operational mode.

Abstract: A dual inverter open winding machine for a vehicle. The machine may include an electric motor, a first energy source, a first inverter, a second energy source, and a second inverter. The first inverter may include a plurality of first switches independently operable between an opened position and a closed position to selectively connect and disconnect a first direct current (DC) port and a first alternating current (AC) port with one or more of the first energy source, the first inverter, and the motor. The second inverter may include a plurality of second switches independently operable between an opened position and a closed position to selectively connect and disconnect a second DC port and a second AC port with one or more of the second energy source, the second inverter, and the motor.

Abstract: Examples described herein provide a method for managing current in a low voltage bus of a vehicle. The method includes receiving an electrical load request for an electrical load of the vehicle. The method further includes, prior to enabling the electrical load, adjusting a current provided by a direct current (DC)/DC converter for a period of time based at least in part on the electrical load. The method further includes, responsive to expiration of the period of time, enabling or disabling the electrical load based at least in part on the electrical load request.

Abstract: Some embodiments disclosed herein are directed to power transfer in electric motors having segmented windings. In some embodiments, a control system may determine a d-axis command voltage for a secondary winding of an electric motor and a q-axis command voltage for the secondary winding based on a primary winding voltage, primary winding current, secondary winding current, and rotor electrical position. The control system may generate gate control signals based on the determined d-axis command voltage and q-axis command voltage for the secondary winding, and transmit the gate control signals to an inverter coupled to the secondary winding to control an electrical power transfer between the primary winding and the secondary winding. Other embodiments may be disclosed or claimed.

Abstract: A multi-level inverter control system includes a power storage system having a high voltage terminal, a low voltage terminal, and an intermediate voltage terminal. The intermediate voltage terminal is at a voltage between the high voltage terminal and the low voltage terminal. A multi-level inverter includes a plurality of switches, a high voltage input connected to the high voltage terminal, a low voltage input connected to the low voltage terminal, and an intermediate voltage input connected to the intermediate voltage terminal. A controller is controllably coupled to the multi-level inverter. The controller includes at least a processor and a memory. The memory stores instructions configured to cause the controller to operate the multi-level inverter in a three-level inverter mode, a full power two-level inverter mode, a first partial power two-level inverter mode and a second partial power two-level inverter mode.

Abstract: A system for modular dynamically adjustable capacity storage for a vehicle is provided. The system includes a battery pack including a plurality of battery cells, a negative terminal including a chassis ground connection, and a plurality of positive battery pack terminals. The negative terminal and the plurality of positive battery pack terminals are useful for connecting at least one electrical circuit through the battery pack. The system further includes a battery cell switching system, including a plurality of solid-state switches connected to each of the battery cells. The plurality of solid-state switches is operable to selectively connect a portion of the battery cells in parallel, selectively connect the portion of the battery cells in series, and selectively connect one of the plurality of battery cells to one of the plurality of positive battery pack terminals.

Abstract: A system includes an inverter configured to output multiphase alternating current (AC) currents to an electric motor, the multiphase AC currents including a first phase current and a second phase current, the inverter including a set of switches for each phase current. The system also includes a switching controller operably connected to each set of switches, the switching controller configured to control a gate driver connected to a switch of the set of switches, the switching controller configured to determine a time difference between a first switching event of a first phase and a second switching event of a second phase during a switching cycle, and control a switching speed of the switch based on the time difference.

Abstract: A system for controlling a propulsion system of a vehicle includes a switching system including a first switching device connecting a battery system to a first set of windings of an electric motor, and a second switching device connecting the battery system to a second set of windings. The system also includes a controller configured to transition the propulsion system from an initial propulsion mode in which an initial voltage is applied to the electric motor, to a target mode in which a target voltage is applied. The transitioning includes controlling the first switching device to provide current to the first set of windings at the initial voltage to produce torque, and subsequently controlling the second switching device to cause the battery system to apply the target voltage to the second set of windings while the current is provided to the first set of windings at the initial voltage.

Abstract: A system for controlling a propulsion system of a vehicle includes a switching system including a first switching device connecting a battery system to a first set of windings of an electric motor, and a second switching device connecting the battery system to a second set of windings. The system also includes a controller configured to transition the propulsion system from an initial propulsion mode in which an initial voltage is applied to the electric motor, to a target mode in which a target voltage is applied. The transitioning includes controlling the first switching device to provide current to the first set of windings at the initial voltage to produce torque, and subsequently controlling the second switching device to cause the battery system to apply the target voltage to the second set of windings while the current is provided to the first set of windings at the initial voltage.