Abstract: A vehicle system includes a contactor including a coil and relay, a traction battery, a load, and a controller configured to transfer current from the traction battery through the coil to pre-charge the load without causing the relay to close such that a voltage drop across the relay falls below a threshold value, and subsequently cause the relay to close.

Abstract: A vehicle system includes a relay and coil of a contactor. The relay is configured to transfer current between a traction battery and an electrical load when closed. The system also includes a controller configured to operate a switch such that current flow from the traction battery through the coil and switch, and bypassing the relay, causes the relay to close to permit pre-charging of the load.

Abstract: An exemplary busbar assembly includes a first layer, and a second layer having a portion that contacts the first layer and a portion that is spaced from the first layer to provide an opening between the first layer and the second layer. An exemplary method of managing thermal energy includes contacting a first layer and a second layer in a first area of a busbar, and separating, in a second area of the busbar, the first layer from the second layer to provide an opening between the first layer and the second layer.

Abstract: An example method includes intentionally precharging a powertrain of an electric vehicle for an first time period that is different than a second precharge time period. An example electric vehicle assembly includes a precharge contactor transitionable back and forth between an open state and a closed state, a first main contactor, a second main contactor, and a controller configured to selectively close the second main contactor after the precharge contactor has been closed for a first time period that is different than a second precharge time period.

Abstract: An exemplary vehicle connector assembly includes, among other things, a first housing, and a second housing configured to selectively engage the first housing in a first position to accommodate a first take-out location. The first housing is further configured to engage the second housing in a second position to accommodate a second take-out location different than the first take-out location. An exemplary electrical connection method includes, among other things, securing a first housing of a connector to a second housing in a first position to accommodate a first take-out location. The first housing is securable to the second housing in a second position to accommodate a second take-out location instead of the first take-out location. The first position circumferentially offset from the second position.

Abstract: A fuse assembly according to an exemplary aspect of the present disclosure includes, among other things, a housing, a fuse received within a receptacle of the housing and a retention device configured to retain the fuse within the receptacle and cover a conductive surface of the fuse.

Abstract: A charging system for a high voltage battery includes a pair of contactors each electrically connected to one of positive and negative terminals of the battery and configured to enable charging of the battery when closed; and a controller programmed to generate a notification indicating that one of the contactors is welded closed based on port voltage values achieved while issuing a predetermined sequence of open and close commands to the contactors after charge completion.

Abstract: A traction battery assembly is provided which may include first and second arrays spaced apart and each having a plurality of battery cells. The battery cells may each have a positive and a negative terminal on a cell face facing the other array. The cells may be oriented in tilted stacks such that the terminals of at least one of the cells of the first array are aligned with oppositely charged terminals of two different cells of the second array. The assembly may also include a frame supporting and orienting the cells such that the cells of the arrays are tilted at opposing and inversely equal angles which are based on a width and length of each battery cell to facilitate the alignment of the terminals of at least one of the cells of the first array with the oppositely charged terminals of two different cells of the second array.

Abstract: A traction battery assembly is provided which may include first and second arrays spaced apart and each having a plurality of battery cells. The battery cells may each have a positive and a negative terminal on a cell face facing the other array. The cells may be oriented in tilted stacks such that the terminals of at least one of the cells of the first array are aligned with oppositely charged terminals of two different cells of the second array. The assembly may also include a frame supporting and orienting the cells such that the cells of the arrays are tilted at opposing and inversely equal angles which are based on a width and length of each battery cell to facilitate the alignment of the terminals of at least one of the cells of the first array with the oppositely charged terminals of two different cells of the second array.

Abstract: An example method includes intentionally precharging a powertrain of an electric vehicle for an first time period that is different than a second precharge time period. An example electric vehicle assembly includes a precharge contactor transitionable back and forth between an open state and a closed state, a first main contactor, a second main contactor, and a controller configured to selectively close the second main contactor after the precharge contactor has been closed for a first time period that is different than a second precharge time period.