Gm Global Technolgoy Operations, Inc.

Electronic Data Systems Corporation

Daniel P Grenn

Andrew M Zettel

Mark D Carr

Voytek A Novak

Wenbo Wang

Michael J Lucido

John F Van Gilder

Andrew C Baughman

Andrew J Farah

Ronald Joseph Kubani

Hamid M Esfahan

David J Mifsud

Jeffrey S Richards

Sara Safaeian

Larry T Nitz

Richard B Jess

Wei D Wang

Mark Henry Costin

Shifang Li

Peter E Wu

Joseph M Stempnik

Leonard G Wozniak

Aniket P Kothari

Jon C Miller

Richard A Marsh

Garrett M Seeman

Vincent A White

Russell K Steele

Shaochun Ye

Ian J Macewen

Ian J Mac Ewen

Ronald W Van Diepen

Michael A Turley

Marek L Wilmanowicz

Bryan D Lehman

Walter M Lazar, Ii

Rick H Schroeder

Matthew S Stout

Vivekananda Shripathy

Michael J Taljonick

Jeanette C Kurnik

Jayanthi Padmanabhan

Tracey A Bagley-Reed

Sandra J Nelson

Gary J Wallo

Kathy D Rose

Joseph Bisbing

Jerry L Brink

Presented are traction battery pack balancing systems, methods for making/operating such systems, and multi-pack, electric-drive motor vehicles with battery pack balancing capabilities. A method for controlling operation of a motor vehicle includes a vehicle controller: receiving a key-off command signal to power off the motor vehicle; determining if a difference between corresponding electrical characteristics of first and second traction battery packs is greater than a calibrated characteristic differential threshold; determining if a difference between corresponding battery pack capacities of the first and second traction battery packs is greater than a calibrated capacity differential threshold; and, responsive to the characteristic difference not being greater than the calibrated characteristic differential threshold and the capacity difference being greater than the calibrated capacity differential threshold, transmitting a key-on command signal to power on the motor vehicle, and a pack balancing command signal to reduce the capacity difference to below the calibrated capacity differential threshold.

Battery pack balancing systems and control logic for multi-pack electric-drive motor vehicles

A vehicle including an energy storage device and a powertrain system configured to effect regenerative braking is described. A method for controlling the vehicle includes determining an expected increase in a state of charge of the energy storage device achieved through opportunity charging by employing regenerative braking during an anticipated next trip of the vehicle. A preferred setpoint for the state of charge of the energy storage device is determined based upon the expected increase in the state of charge achieved through opportunity charging, and charging of the energy storage device is controlled during a remote charging event based upon the preferred setpoint for the state of charge of the energy storage device.

Method and apparatus for recharging an energy storage device on a vehicle

Methods of controlling a contactor in a high voltage electrical circuit of a vehicle include delaying a contactor opening if a valid open command is not received, inhibiting closing of a contactor if a low voltage circuit voltage is not sufficient to close the contactor, and determining a fault in the opening of a contactor based on voltages sensed on the contacts of the contactor.

Methods of operating contactors in high voltage circuits of vehicles

A method of controlling positive and negative contactors in a high voltage electrical system includes sensing current flowing through each contactor prior to opening of the contactor and/or after closing of the contactor. A negative contactor weighted value is computed based at least partially on the sensed current flowing through the negative contactor during opening and/or closing. A positive contactor weighted value is computed based at least partially on the sensed current flowing through the positive contactor during opening and/or closing. The order of opening and/or closing of the contactors is determined utilizing at least one of the negative contactor weighted value and the positive contactor weighted value.

Methods of determining the order of operating contactors in high voltage circuits

A system according to the principles of the present disclosure includes a first reprogramming identification module and a first diagnostic module. The first reprogramming identification module identifies when a first control module of a vehicle is reprogrammed. The first diagnostic module sets a first diagnostic trouble code (DTC) when the first control module is reprogrammed and selectively clears the first DTC when an instruction to clear a second DTC stored in a second control module of the vehicle is received.

System and method for clearing a readiness bit when a control module of a vehicle is reprogrammed

A method of identifying a non-communicative battery Cell Sensing Board (CSB) within a plurality of battery CSBs arranged in a serial chain includes sequentially reconfiguring the serial chain of the battery CSBs to sequentially define each of the plurality of battery CSBs as a last battery CSB in a temporary test serial chain. Communication with the last battery CSB of each temporary test serial chain is sequentially established with a loopback feature of the battery CSBs. When a disruption in communication between the battery system manager controller and the last battery CSB of the current temporary test serial chain is detected, the last battery CSB of the current temporary test serial chain is identified as the non-communicative battery CSB.

Detection diagnostic for communication loss between a battery system manager controller and a plurality of battery cell sensing boards

A system and method for providing a user of a hybrid electric vehicle (HEV) more flexibility and control regarding the selection of heating modes, without adversely affecting vehicle engine emissions. According to one embodiment, when the HEV is in a normal heating mode, the user is able to switch to an economy or deferred heating mode, so long as the switch takes place during the following ignition cycle. When the HEV is in an economy heating mode the user is able to switch to a normal heating mode right away, but is only allowed to do so once per ignition cycle. In both instances, the switch between heating modes is initiated by the user through a non-emissions related system, such as a vehicle infotainment module or climate control module.

System and method for controlling heating modes for hybrid electric vehicle (HEV)

A method of monitoring a performance level of a battery of a vehicle having an electronic control unit (ECU) includes enabling a charging diagnostic module (CDM) and determining, with the CDM, a charging status of the battery. The method also includes enabling a discharging diagnostic module (DDM) and determining, with the DDM, a discharging status of the battery. The charging status and the discharging status are recorded in a memory location of the ECU.

System and method of monitoring a performance level of a battery

In accordance with exemplary embodiments, battery capacity of an electric vehicle can be automatically determined. In an exemplary method, an instruction is received to determine a battery capacity value and one or more vehicle accessories are activated to discharge the battery to a first charge level. When the first charge level is reached, a generator in the vehicle is started and used to charge the battery to a second charge level, after which the battery capacity value can be determined and stored. In accordance with the exemplary embodiments, the vehicle comprises a controller adapted to cause a battery to be discharged and charged to determine a capacity value of the battery. A plurality of accessories are configured to activate and deactivate responsive to the controller to discharge the battery, while a generator is responsive to the controller to charge the battery so that the controller can determine the battery capacity value.

System and method for determining battery capacity in an electric vehicle

A method for isolating voltage sensor errors from contactor errors in an electrical system includes measuring a voltage between ground and a voltage bus rail when a contactor is open, and comparing the measured voltage to a first threshold voltage corresponding to a calibrated voltage reading that is expected when the contactor is closed. A first diagnostic code is recorded with a stuck-in-range status for the sensor when the measured voltage is greater than 0 and less than the first threshold voltage. A second diagnostic code is recorded with a stuck-closed status for the contactor when the measured voltage is equal to the first threshold voltage. The measured voltage may be compared to a second threshold voltage that exceeds the first threshold voltage, with a third diagnostic code recorded with a shorted value for the sensor when the measured voltage exceeds the first threshold voltage or is less than 0.

Method and system for isolating voltage sensor and contactor faults in an electrical system

A fault diagnostic system of a vehicle includes: a global positioning system (GPS) receiver and a diagnostic module. The GPS receiver determines a location of the vehicle. The diagnostic module diagnoses a fault in a component of the vehicle. In response to the diagnosis of the fault, the diagnostic module stores diagnostic data in a computer readable medium. The diagnostic data includes both a predetermined diagnostic trouble code associated with the fault diagnosed and the location of the vehicle when the fault was diagnosed.

Vehicle location and fault diagnostic systems and methods

Methods, program products, and vehicles are provided for providing diagnostics for a smart sensor, such as a direct current (DC) converter, for a vehicle. A result of a diagnostic test is received from the smart sensor at a first time. A sequence indicator is retrieved from memory. The sequence indicator pertains to a second time in which the diagnostic test is expected to be completed by the smart sensor. A health assessment is provided using the result via a processor, provided that the second time does not precede the first time. The health assessments may be linked individually to a diagnostic trouble code, or may be grouped together and linked as a group to a diagnostic trouble code. Multiple smart sensor health assessments may be grouped and linked to diagnostic trouble codes.

Diagnostics for smart sensors of vehicles

Methods, program products, hybrid, and non-hybrid vehicles are provided for providing diagnostics for a direct current (DC) converter of the hybrid, and non-hybrid vehicle. The vehicle includes an engine, a rechargeable energy storage system (RESS), the direct current (DC) converter, and a controller. The engine is automatically turned on and off based on driver inputs in accordance with an auto-stop feature. The RESS at least facilitates turning on the engine. The DC converter is coupled to the RESS. The controller is coupled to the DC converter, and is configured to determine a status of the engine, receive a DC converter voltage value from the DC converter, and provide diagnostics for the DC converter based on the engine status, RESS voltage, and the DC converter voltage.

DC converter diagnostics for vehicles

A method and control module for determining a sensor error includes a time-based diagnostic module generating a time-based diagnostic for a sensor and an event-based diagnostic module generating an event-based diagnostic for the sensor. A synchronizing module synchronizes the time-based diagnostic and the event-based diagnostic to obtain a diagnostic result. A fault indicator module generates a fault signal in response to the diagnostic result.

Control system and method for sensor signal out of range detection

A distributed on-board diagnostic (OBD) architecture for a control system of a vehicle includes a plurality of control modules that are in communication with one another and a designated master OBD control module that is one of the plurality of control modules. The master OBD control module performs functions that a remainder of the plurality of control modules are incapable of performing including at least one of arbitrating a malfunction indicator lamp (MIL) state, arbitrating and storing OBD freeze frame data and determining OBD status flags of the remainder of the plurality of control modules.

Distributed diagnostics architecture

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Highland, MI, United States of America

Daniel P Grenn