Abstract: A system for use with a direct current fast-charging (DCFC) station includes a controller and battery system. The battery system includes first and second battery packs, and first, second, and third switches. The switches have ON/OFF conductive states commanded by the controller to connect the battery packs in a parallel-connected (P-connected) or series-connected (S-connected) configuration. An electric powertrain with one or more electric machines is powered via the battery system. First and second charge ports of the system are connectable to the station via a corresponding charging cable. The first charge port receives a low or high charging voltage from the station. The second charge port receives a low charging voltage. When the station can supply the high charging voltage to the first charge port, the controller establishes the S-connected configuration via the switches, and thereafter charges the battery system solely via the first charge port.

Abstract: A protection system for a battery system includes a battery control module configured to selectively open at least one contactor to isolate the battery system from a load in response to a sensed current being greater than a first threshold and within a first current range, at least one fuse connected between first and second terminals of the battery system and configured to open to isolate the battery system from the load in response to the sensed current being greater than a second threshold and within a second current range that is greater than and offset from the first current range, and an auxiliary protection module configured to selectively form a short circuit between first and second terminals in response to the sensed current being greater than the first threshold, less than the second threshold, and within a coverage gap region between the first and second current ranges.

Abstract: The present invention involves a laser-welded driveshaft and method of making same. The laser-welded driveshaft comprises a tube and a yoke laser welded to the tube. The tube has a driveshaft wall extending to an open end, wherein the wall has inner and outer surfaces. The yoke includes a tube-engaging pilot which is disposed through the open end and the yoke is laser-welded to the open end of the tube.