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 vehicle includes a system that performs method operating a battery pack of the vehicle. The system includes one or more sensors and a processor. The one or more sensors obtain a measured value of a battery parameter of the battery pack. The processor is configured to calculate an expected value of the battery parameter from a model of the battery pack, compare the measured value to the expected value to determine a blown fuse condition of the battery pack, determine an available current from the battery pack based on the blown fuse condition, and control an operational state of the vehicle based on the available current.

Abstract: An example method includes receiving, at a module management unit (MMU) associated with a battery cell, a battery cell parameter measurement associated with the battery cell. The MMU in is communication with a battery radio frequency module via a first link. The method further includes performing, by the MMU, a first function based at least in part on the battery cell parameter measurement to generate a first signal, and transmitting, from the MMU, the first signal to the battery radio frequency module via the first link. The method further includes performing, by the battery radio frequency module, a second function based at least in part on the first signal to generate a second signal. The method further includes transmitting, from the battery radio frequency module, the second signal to a controller, and performing, by the controller, a third function based at least in part on the second signal.

Abstract: A trip energy estimation system includes a memory and a control module. The memory stores average traffic speed, average traffic acceleration, driver speed, and driver acceleration data. The control module executes an algorithm to estimate an amount of energy for an electric vehicle to travel between two locations. The algorithm includes: determining, based on the average traffic speed data and the average traffic acceleration data, a baseline amount of energy for the electric vehicle to travel between the two locations; determining, based on the driver speed data and the driver acceleration data, a dynamic amount of energy corresponding to at least one of stop and go events, over speeding, or under speeding; and determining a total amount of energy based on the baseline amount of energy and the dynamic amount of energy. The control module, based on the total amount of energy, performs an operation including indicating a trip estimate.

Abstract: A vehicle includes a system operating a method of controlling a temperature at a battery cell of the vehicle. The system includes the battery cell, a temperature sensor and a processor. The battery cell has a tab for flow of current to and from the battery cell. The temperature sensor is configured to measure a cell temperature of the battery cell at a location away from the tab. The processor is configured to predict a tab temperature from the cell temperature, and control a power supplied to a load from the battery cell based on the tab temperature.

Abstract: A method and apparatus for electric motor control includes a model predictive controller operating in a d-q reference frame to provide d-q reference frame voltage command signals that counteract a magnetic cross coupling within the motor.

Abstract: A method and apparatus for electric motor control includes a model predictive controller operating in a d-q reference frame to provide d-q reference frame voltage command signals that counteract a magnetic cross coupling within the motor.

Abstract: A mixed chemistry battery including a sensing cell having a first chemistry, a battery cell having a second chemistry that is different than the first chemistry, where the battery cell is connected to the sensing cell in series. The mixed chemistry battery also includes a battery monitoring system configured to monitor a current flow through the sensing cell and the battery cell and to calculate a state-of-charge (SOC) of the sensing cell. The battery monitoring system is further configured to calculate a SOC of the battery cell based at least in part on the SOC of the sensing cell.

Abstract: A system in a vehicle includes a controller to implement a neural network to provide current commands based on inputs. The inputs include a torque input. The system also includes a current controller to provide a three-phase voltage through an inverter based on the current commands from the controller. An electric traction motor provides drive power to a transmission of the vehicle based on injection of the three-phase voltage. The current commands resulting from implementation of the neural network are corrected based on estimated torque resulting from the injection of the three-phase voltage to the electric traction motor.

Abstract: A method for detecting thermal runaway of a cell includes: positioning a battery pack having multiple cells in an automobile vehicle; measuring a cell voltage of the multiple cells at a predetermined sample rate; and identifying if the cell voltage decreases and modulates coincident with a cell surface temperature increase indicating initiation of a cell short.

Abstract: A trip energy estimation system for a vehicle includes a traffic speed module configured to determine an average traffic speed along a projected route, a path information module configured to output path information indicating route features along the projected route, a perceived speed module configured to output a perceived vehicle speed along the projected route based on the average traffic speed and the path information, and a dynamic driving module configured to calculate and output a predicted driver speed based on the perceived vehicle speed and a feedback input indicative of the predicted driver speed. The dynamic driving module is configured to execute a machine learning algorithm to calculate the predicted driver speed.

Abstract: A power control system comprises a battery system including N battery packs. A plurality of contactors selectively connects N battery packs of a battery system in a first configuration supplying a first voltage level, a second configuration supplying a second voltage level, and a disconnected configuration. M power inverters connect the battery system to M electric machines, respectively. A controller is configured to determine when to transition between the first configuration and the second configuration. The controller is configured to transition between the first configuration and the second configuration by causing one of a positive torque transient and a negative torque transient to be generated by at least one of the M electric machines, transitioning the battery system from one of the first configuration and the second configuration to the disconnected configuration, and transitioning from the disconnected configuration to the other one of the first configuration and the second configuration.

Abstract: A motor drive system of a vehicle includes: an inverter that receives power from a power source via a bus, where the inverter is connected to a motor of the vehicle; a driver that drives the inverter; a filter that filters a current signal received from the bus to generate a filtered signal; and a control module that operates in an impedance determination mode. The impedance determination mode includes: based on the filtered signal, controlling the driver and the inverter to generate a pulsed signal applied to the power source; determining a current level and a voltage of the power source due to generation of the pulsed signal, and determining impedance based on the current level and the voltage. The control modules are configured to: determine a characterization parameter of the power source based on the impedance; and perform a control operation or a countermeasure based on the characterization parameter.

Abstract: A charging system includes: a charge port that receives shore power; a DC-to-DC converter or a motor inverter circuit; switches that connect the charge port and the DC-to-DC converter or the motor inverter circuit to battery packs; and a control module. The control module: determines open circuit voltages or states of charges of the battery packs; based on the open circuit voltages or the states of charges of the battery packs, determines whether to connect at least one of the battery packs to the charge port, the DC-to-DC converter, and the motor inverter circuit; and based on the determination of whether to connect at least one of the battery packs, control states of the switches to charge the at least one of the battery packs by selectively connecting the at least one of the battery packs to (a) the charge port, or (b) the DC-to-DC converter or motor inverter circuit.

Abstract: A motor drive system of a vehicle includes: an inverter that receives power from a power source via a bus, where the inverter is connected to a motor of the vehicle; a driver that drives the inverter; a filter that filters a current signal received from the bus to generate a filtered signal; and a control module that operates in an impedance determination mode. The impedance determination mode includes: based on the filtered signal, controlling the driver and the inverter to generate a pulsed signal applied to the power source; determining a current level and a voltage of the power source due to generation of the pulsed signal, and determining impedance based on the current level and the voltage. The control modules are configured to: determine a characterization parameter of the power source based on the impedance; and perform a control operation or a countermeasure based on the characterization parameter.

Abstract: A system for self-discharge prognostics for vehicle battery cells with an internal short circuit includes a plurality of battery cells and a voltage sensor providing open-circuit voltage data over time for each battery cell. The system further includes a computerized prognostic controller operating programming to monitor the open-circuit voltage data over time for each of the plurality of battery cells and evaluate a voltage drop rate through a time window for each of the plurality of battery cells based upon the open-circuit voltage data. The controller further identifies one of the plurality of battery cells to include the internal short circuit based upon the voltage drop rate and signals an alert based upon the one of the plurality of battery cells including the internal short circuit.

Abstract: Systems and methods for diagnosing health of a battery using in-vehicle impedance analysis. The method includes receiving a sensed current measurement for a cell of the battery; generating a current profile as a function of the sensed current measurement, including pulses to a peak current, the pulses having a pulse frequency (w); applying a current with the current profile to the cell; for each pulse in the current profile, receiving a voltage measurement for the cell that is responsive to the pulse, calculating an impedance for the cell responsive thereto, the impedance comprising a real component at the pulse frequency (RZw), and an imaginary component at the pulse frequency (IZw), identifying a battery health problem when either RZw exceeds a preprogrammed first threshold for the pulse frequency, or when IZw exceeds a preprogrammed second threshold for the pulse frequency, and storing the RZw and the IZw for the cell.

Abstract: A trip energy estimation system includes a memory and a control module. The memory stores average traffic speed, average traffic acceleration, driver speed, and driver acceleration data. The control module executes an algorithm to estimate an amount of energy for an electric vehicle to travel between two locations. The algorithm includes: determining, based on the average traffic speed data and the average traffic acceleration data, a baseline amount of energy for the electric vehicle to travel between the two locations; determining, based on the driver speed data and the driver acceleration data, a dynamic amount of energy corresponding to at least one of stop and go events, over speeding, or under speeding; and determining a total amount of energy based on the baseline amount of energy and the dynamic amount of energy. The control module, based on the total amount of energy, performs an operation including indicating a trip estimate.

Abstract: A monitoring system for a battery system includes a battery system including a battery pack. The battery pack includes M battery modules, where M is an integer greater than zero. Each of the M battery modules includes C battery cells, where C is an integer greater than one. T temperature sensors configured to generate sensed temperatures of the M battery modules, where T is greater than or equal to M and less than M times C. A battery management module configured to perform battery impedance measurements on the C battery cells of the M battery modules; generate estimated temperatures for each of the C battery cells of the M battery modules based on the battery impedance measurements; and selectively detect at least one of the C battery cells having a cell outlier temperature based on the estimated temperatures of the C battery cells.

Abstract: A battery system for a vehicle includes a plurality of battery modules, each of the plurality of battery modules including a respective management module, and a master management module configured to communicate with the management modules and with a battery control module. Each of the management modules includes a communication interface configured to transmit data to the master management module and receive data from the master management module and a diagnostic module configured to monitor operating parameters of a respective one of the plurality of battery modules, detect a fault associated with the respective one of the plurality of battery modules based on the operating parameters, and selectively output a signal indicative of the detected fault.