Ford Global Technolgoies, LLC

Masahiro Kimoto

John Sturza

Patrick Daniel Maguire

Benjamin A Tabatowski-Bush

Ray C Siciak

Philip Michael Gonzales

Hari Krishna Addanki

Debbi Callicoat

Vineeth Seshadri Kallur

Thomas Joseph Turgeon

Rajesh Narayanan

Suriyaprakash Ayyangar Janarthanam

Derek Hartl

Wesley Burkman

David Anthony Symanow

Josephine S Lee

Francisco Fernandez-Galindo

Eid Farha

Kevin A Montgomery

Robert Bolduc

Abdul Lateef

Tsung-Han Tsai

Kevin Lloyd Newman

Deborah E Callicoat

Bradley Arnold Lammers

Temam Kedir

Ken Jon Cunningham

Leann Marie Vernon

Doug G Hughes

Carlos Ayala

Pratyaksh Kamath

Darin Joseph Bremmer

A motor vehicle according to an exemplary aspect of the present disclosure includes, among other things, a frame including a rail and an electrical distribution system routed at least partially through the rail. A method is also disclosed.

Vehicle with electrical distribution system routed through frame

An exemplary assembly includes an array plate, and an electronic component held within a cavity of the array plate. An exemplary method includes housing an electronic component within a cavity of an array plate, and holding a battery cell of an array with the array plate.

Electrified vehicle array plate that houses at least one electronic module

An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.

Busbar forming method and folded busbar

A vehicle includes main contactors powered via a low voltage bus and disposed electrically between a traction battery and a high voltage bus, and a controller. The controller, responsive to the contactors remaining open following activation of the low voltage bus and reported voltage values associated with the high voltage bus being less than a threshold, operates a horn of the vehicle.

Service disconnect notification strategy

Method and apparatus are disclosed for controlling a high voltage power supply. An example vehicle includes first and second power supply buses, a high voltage power supply coupled to the first and second power supply buses, and a high voltage controller. The high voltage controller is configured to control the high voltage power supply, detect a short circuit on the first power supply bus, and responsively change a power source of the high voltage controller by activating an opto-isolator and one or more smart FETs.

Redundant vehicle power supply control systems and methods

An example electric vehicle battery thermocouple includes a temperature sense lead of a first material, and an electric vehicle battery component of a second material different than the first material.

Electric vehicle battery thermocouple

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.

High voltage battery contactor arrangement for DC fast charging

A vehicle power system may include a battery array having at least one battery with a bus bar connected to an electrical bus. The power system may also include a conductive lead of a sensor welded to the bus bar to form a joint defined by a plurality of stitches, a net cross-sectional area of the plurality being less than a cross-sectional area of the lead such that short-circuit current from the battery array melts the joint to protect the sensor.

Sensor fuse for an electric battery array

An exemplary traction battery mounting assembly includes a traction battery and a damper securing the traction battery to a vehicle frame such that the traction battery can move together relative to the vehicle frame when secured to the vehicle frame. An exemplary traction battery securing method includes securing a traction battery in an installed position where the traction battery is mounted to a vehicle frame. The traction battery is moveable relative to the vehicle frame when in the installed position.

Traction battery mounting assembly and securing method

A vehicle having: vehicle structure including a pair of opposed sides and a rear, with a floor extending horizontally between the sides and rear; a battery-pack mounted above the floor; a fan assembly having a housing with a motor mounted therein directly behind the battery-pack, with the housing including a pair of flanges having U-slots with slot openings facing downward; and fasteners extending horizontally through the U-slots and secured to the battery-pack.

Battery cooling fan mounting

A method according to an exemplary aspect of the present disclosure includes, among other things, activating hazard lights of an electrified vehicle in response to a high voltage battery disconnect event.

Vehicle system and method for activating hazard lights during battery disconnect events

An automotive vehicle high voltage bus is connected to a power source by a circuit having a main contactor and a precharge contactor. To energize the bus, the precharge contactor is closed and then the main contactor is closed. Upon completion of precharging, the main contactor is opened and energization of the bus is complete.

Energizing an automotive vehicle high voltage bus using a single main contactor

An example electric vehicle battery thermocouple includes a temperature sense lead of a first material, and an electric vehicle battery component of a second material different than the first material. In an exemplary embodiment, the electric vehicle battery component includes a voltage sense lead and a bus bar. In another exemplary embodiment, the electric vehicle battery component includes a voltage sense lead and a terminal. In yet another exemplary embodiment, the electric vehicle battery component includes a voltage sense lead.

An example contactor weld detection method for an electric vehicle includes detecting that a contactor is welded closed when the contactor is commanded closed.

Growing community of inventors

Plymouth, MI, United States of America

Masahiro Kimoto