Abstract: An electric propulsion system for a mobile platform includes a battery system connected to positive and negative bus rails, an accessory load having a rotary electric machine, a traction power inverter module (“TPIM”), and an accessory load, switches configured to transition the battery modules to a series-connected (“S-connected”) configuration during a direct current fast-charging (“DCFC”) operation of the battery system, and a controller. When battery modules of the battery system are connected in series during a direct current fast-charging (“DCFC”) operation, the controller executes a diagnostic method to determine bus rail voltages on the positive and negative bus rails and a mid-bus voltage, identifies a diagnosed electrical condition of the electric propulsion system by comparing the voltages to expected values or ranges, and executes a control action in response to the diagnosed electrical condition.

Abstract: A multi-pack battery system having at least first and second battery packs each with positive and negative terminals, and each with upper and lower switches respectively connected to the positive and negative terminals. The battery packs have a first voltage level, and are connectable in either series or parallel. A controller controls an ON/OFF state of the switches in response to input signals to select between two series charging modes, three parallel charging modes, and one or more propulsion modes. Some embodiments have a series propulsion mode. An electric powertrain system includes first and second power inverter modules (“PIMs”), an electrical load, front and rear electric machines connected to a respective one of the first and second PIMs, and the battery system. The powertrain system may selectively provide all-wheel, front-wheel, or rear-wheel drive capabilities in each of the various propulsion modes.

Abstract: An electrical system includes a high-voltage bus connected to a rechargeable energy storage system (RESS) and a high-voltage component connected to the RESS via the voltage bus. The component defines a service opening spanned by a removable cover. The electrical system may include a fastener connecting the cover to the component, as well as a battery disconnect unit (BDU) having a high-voltage switch device connecting the RESS to the high-voltage bus. The switch device closes responsive to a low-voltage drive current to connect the RESS to the high-voltage bus. A drive circuit conducts the current to the switch device. An electrical connector has multiple connector pieces collectively forming a switch in the drive circuit. Disconnection of the pieces from each other opens the switch to interrupt the drive current and cause the high-voltage switch device to open, which disconnects the RESS from the high-voltage bus.

Abstract: An active isolation detection method may be used with an electrical system having a battery pack connected to a high-voltage bus. The bus has positive and negative bus rails, each having a respective rail-to-ground voltage. The method may include connecting variable resistance element to the high-voltage bus, and determining input information indicative electrical characteristics of the battery pack, the high-voltage bus, and/or a charging station. The method includes varying a bias resistance of the high-voltage bus, via control of the variable resistance element, e.g., via duty cycle control of a binary switch in series with a bias resistor, to produce a varied bias resistance based on the input information. A target voltage shift is achieved on the high-voltage bus as a target level of change in one of the rail-to-ground voltages. An isolation resistance of the electrical system is determined via the controller using the varied bias resistance.

Abstract: An electrical system includes a voltage bus, voltage sensor(s) measuring a first voltage between a positive bus rail and electrical ground, and a second voltage between a negative bus rail and electrical ground, a bias resistor, and a controller. When the switch is closed, the controller measures four or more discrete voltage samples of the first and second voltages. The samples are grouped into first and second sample groups each having three discrete voltage samples, with the second and third voltage samples of the first group being the first and second samples of the second group. The controller estimates a steady-state voltage of the first and second voltages using the sample groups, prior to the first and second voltages converging on actual steady-state voltage values. The controller executes a corresponding control action when the steady-state voltage estimate is stable or unstable relative to a defined stability threshold.

Abstract: A destination selection system for determining travel destinations includes a human-machine interface (HMI); a positioning system in communication with the HMI; a controller in communication with the HMI and the positioning system, the controller having a processor, and a memory, the processor executing programmatic logic stored in the memory. The programmatic logic includes a first logic to display an icon on the HMI based on position data received from the positioning system; and a second logic for sizing the icon based on at least one of the position data and one or more additional factors, and in response to at least one of the position data and one or more additional factors actively and continuously resizing the icon.

Abstract: An electrical system includes a voltage bus, voltage sensor(s) measuring a first voltage between a positive bus rail and electrical ground, and a second voltage between a negative bus rail and electrical ground, a bias resistor, and a controller. When the switch is closed, the controller measures four or more discrete voltage samples of the first and second voltages. The samples are grouped into first and second sample groups each having three discrete voltage samples, with the second and third voltage samples of the first group being the first and second samples of the second group. The controller estimates a steady-state voltage of the first and second voltages using the sample groups, prior to the first and second voltages converging on actual steady-state voltage values. The controller executes a corresponding control action when the steady-state voltage estimate is stable or unstable relative to a defined stability threshold.

Abstract: An electrical system includes a high-voltage bus connected to a rechargeable energy storage system (RESS) and a high-voltage component connected to the RESS via the voltage bus. The component defines a service opening spanned by a removable cover. The electrical system may include a fastener connecting the cover to the component, as well as a battery disconnect unit (BDU) having a high-voltage switch device connecting the RESS to the high-voltage bus. The switch device closes responsive to a low-voltage drive current to connect the RESS to the high-voltage bus. A drive circuit conducts the current to the switch device. An electrical connector has multiple connector pieces collectively forming a switch in the drive circuit. Disconnection of the pieces from each other opens the switch to interrupt the drive current and cause the high-voltage switch device to open, which disconnects the RESS from the high-voltage bus.

Abstract: A destination selection system for determining travel destinations includes a human-machine interface (HMI); a positioning system in communication with the HMI; a controller in communication with the HMI and the positioning system, the controller having a processor, and a memory, the processor executing programmatic logic stored in the memory. The programmatic logic includes a first logic to display an icon on the HMI based on position data received from the positioning system; and a second logic for sizing the icon based on at least one of the position data and one or more additional factors, and in response to at least one of the position data and one or more additional factors actively and continuously resizing the icon.

Abstract: A wire harness of a vehicle includes a trunk including a plurality of wires that are bundled together. A first branch branches from the trunk at a location and includes a first subset of the plurality of wires. A first electrical connector is electrically connected to the wires of the first subset of the plurality of wires, respectively. A second branch branches from the trunk at the location and that includes a second subset of the plurality of wires. The wires of the second subset of the plurality of wires are different than the wires of the first subset of the plurality of wires. A second electrical connector is electrically connected to the wires of the second subset of the plurality of wires, respectively. A visual indicator is located directly on a predetermined one of the first and second branches.

Abstract: A method and apparatus that display a view alert are provided. The method includes determining that information of a sensor is being provided, in response to determining that the information of the sensor is being provided, determining whether an angle or field of view of the sensor is correctly oriented, and in response to determining that the angle or field of view of the camera is incorrectly oriented, providing an alert indicating that the angle or field of view of the camera is incorrectly oriented.

Abstract: A battery module includes a pack section and a cover assembly. The pack section has an interconnect board, conductive channels, and battery cells extending through the interconnect board. Each battery cell includes electrode cell tabs joined to a corresponding conductive channel. The cover assembly is connectable to the pack section, and has conductive interconnect members, electrical fuses, and sense lines built into or integral with a cover plate. The interconnect members extend from the cover plate and form part of an electrical circuit between the conductive channels of the pack section and the fuses and sense lines of the cover plate when the cover assembly is connected to the pack section. An electrical system includes the battery module, a DC voltage bus, and at least one high-voltage component connected to the battery module via the DC voltage bus. The electrical system may be part of a motor vehicle.

Abstract: A sensing circuit, a vehicular battery pack using a sensing circuit, a method of protecting a circuit with a fuse and a method of providing battery power to a vehicle. The sensing circuit includes the fuse, which is made up of a main element and a sensing element such that the sensing element defines a pre-open detection capability through at least one of a dissimilar geometric profile or a different material choice from that of the main element. The sensing circuit also includes an electrical connector between one or more battery cells and an electronic control module so that the circuit provides indicia of the fusing event.

Abstract: A battery module includes a pack section and a cover assembly. The pack section has an interconnect board, conductive channels, and battery cells extending through the interconnect board. Each battery cell includes electrode cell tabs joined to a corresponding conductive channel. The cover assembly is connectable to the pack section, and has conductive interconnect members, electrical fuses, and sense lines built into or integral with a cover plate. The interconnect members extend from the cover plate and form part of an electrical circuit between the conductive channels of the pack section and the fuses and sense lines of the cover plate when the cover assembly is connected to the pack section. An electrical system includes the battery module, a DC voltage bus, and at least one high-voltage component connected to the battery module via the DC voltage bus. The electrical system may be part of a motor vehicle.

Abstract: A method of fabricating a fuse includes providing a fuse element within a casing. The fuse element has a plurality of ligaments configured to direct a current therethrough. A mechanical tension is then applied to the fuse element and a filler material is added to the casing so as to support the fuse element. The filler material is then solidified. Next, the mechanical tension is removed with the fuse element retaining a residual tensile stress after removal of the mechanical tension.

Abstract: A fuse system includes a fuse element configured to receive a current. A controller is operatively connected to the fuse element and has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method for determining a remaining fuse life (LR) of the fuse element. Execution of the instructions by the processor causes the controller to determine a temperature (T) of the fuse element. The fuse system may be part of a vehicle. The controller may be configured to determine if the remaining fuse life is below first and second thresholds. If the remaining fuse life is above the second threshold, a first message may be displayed to a vehicle display. If the remaining fuse life is below the second threshold, the vehicle may be shifted to a predefined alternative operating mode.

Abstract: A method of controlling an automatic transmission connected to an engine in a motor vehicle includes receiving an input signal generated via an application of force by a switch inside the vehicle. The switch has a predetermined travel and is configured to request a transmission speed-ratio change via an output signal indicative of the received input signal. The output signal is received via a controller programmed with a permitted engine speed range. The transmission is commanded to execute a change from a currently selected speed-ratio to another speed-ratio if the requested speed-ratio change would generate an engine speed within the permitted engine speed range. The switch is commanded to execute full travel under the application of force if the speed-ratio change in the transmission was commanded. Alternatively, the switch is commanded to execute partial travel under the application of force if the speed-ratio change in the transmission was not commanded.

Abstract: A method and system for controlling one or more contactors of a rechargeable energy storage system (RESS) includes adjusting, via a controller, the respective actuating power provided to a respective one or more of the contactors, where adjusting of the actuating power is defined by the energized or non-energized condition of the vehicle and at least one parameter affecting holding and opening forces exerted on the respective contactor. In an example, the controller is configured to use feed forward factors defined by the at least one parameter and to adjust the dynamic actuating current by modulating the dynamic actuating current at a pulse width modulation (PWM) frequency defined by a feed forward window. The system may be configured as a plug-in electric vehicle including the rechargeable energy storage system and the controller.

Abstract: A sensing circuit, a vehicular battery pack using a sensing circuit, a method of protecting a circuit with a fuse and a method of providing battery power to a vehicle. The sensing circuit includes the fuse, which is made up of a main element and a sensing element such that the sensing element defines a pre-open detection capability through at least one of a dissimilar geometric profile or a different material choice from that of the main element. The sensing circuit also includes an electrical connector between one or more battery cells and an electronic control module so that the circuit provides indicia of the fusing event.

Abstract: A stator for an electric motor includes a plurality of pole pieces and a plurality of electrical windings associated with the pole pieces. Each winding includes a cable having an electrically conductive element. A lossy insulative material is located between the electrical windings and the associated pole pieces.