Gm Global Technolgoy Operations, Inc.

Russell K Steele

Andrew J Namou

Shifang Li

James F Crawford

Peter Kung Chiang

James E Tarchinski

Yue Fan

Alexander M Bilinski

Chandra S Namuduri

Rashmi Prasad

Brendan M Conlon

Daniel P Grenn

Garrett M Seeman

Andrew C Baughman

Shaochun Ye

Robert J Heydel

Brandon R Jones

Kris Sevel

Douglas S Cesiel

David J Mifsud

Emil Francu

Marc Reischmann

Marjorie A Bassham

Andrew M Zettel

Daniel J Davis

Stephen D Gurski

Michael E Barton

Rohit Singhal

A method of operating a motor vehicle includes a vehicle controller receiving, from a first feedback sensor of an HV component, a first feedback signal indicative of an electrical characteristic of the HV component, and then detecting an HV system fault if the first feedback signal is less than a predefined electrical threshold. Upon detecting the system fault, the controller commands the HV component to operate at a commanded set-point; after sending the command, the controller receives, from a second feedback sensor of the HV component, a second feedback signal indicative of an operating characteristic of the HV component. An HV pathway failure is detected if the second feedback signal is not equal to or within a predefined operating range of the commanded set-point. Upon detecting the pathway failure in an HV electrical pathway of the HV component, the vehicle controller transmits a command signal to take a remedial action.

Intelligent vehicle systems and control logic for intrusive detection of high-voltage pathway failures

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.

Active isolation detection using adaptive bias resistance

A rechargeable energy storage system (RESS) includes a battery controller and battery modules, each respective module having battery cells, a cell sense board, and a semiconductor switch. The switch is connected in parallel with the cells within the respective module, and configured to conduct an electrical current during a thermal runaway propagation (TRP) event in which one or more cells is in an open-circuit state. This action bypasses the module and enables electrical components to be powered by the RESS during the TRP event. A battery electric system includes a direct current ('DC') voltage bus, an electrical component connected thereto, the battery controller, and the RESS. A method for constructing the RESS includes connecting a respective semiconductor switch in parallel with the at least one battery cell of each respective one of the multiple battery modules, and electrically connecting the multiple battery modules together to construct the RESS.

Battery electric system having switchable architecture with thermal runaway protection

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

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.

Method and system for noise-tolerant RC response prediction

An electrical system includes cables, a DC charge connector, first and second battery modules, a splice device, and a controller. Each battery module has first, second, third, and fourth electrical connectors receiving a respective one of the cables. The battery modules are connected to each other via the cables, and further have first, second, third, and fourth switches that connect battery cell strings to one or more connectors. The charge connector is connected to one of the cables between the first electrical connectors. The splice device connects the charge connector to the first connector of the first battery module and to a pair of the cables. A charging current may be split between the battery modules. The controller selectively establishes parallel charging, parallel drive, and separate drive and charging modes for each battery module. The system may have an independent drive mode.

Vehicle and electrical system with dual battery modules

An electrical system connectable to an offboard power supply includes a battery pack, parallel DC-coupled conductive and inductive charging systems, and a controller. The controller initiates charging of the battery pack using analog low-voltage signals. A charging preference may prioritize charging via a designated one of the charging systems. Another electrical system includes a battery pack connected to a DC voltage bus, a charge coupler connectable to the offboard power supply to establish a plug-in charging connection, parallel DC-coupled conductive and inductive charging systems, and a controller. The controller commands charging using the analog low-voltage control signals, doing so via the conductive charging system when the charge coupler is plugged into the power supply and via the wireless charger when the charge coupler is not plugged into the power supply and the controller detects proximity of the system to the primary induction coil.

Dual inductive/conductive DC-coupled charging system

An off-board charging device disposed to electrically charge an electric energy storage system via an electrical charging system on-board a vehicle is described. This includes an electric machine electrically connected to the electric energy storage system and is disposed to supply propulsion effort to the vehicle. A method for controlling the off-board charging device includes determining severity of a drive cycle that occurs prior to a charging event for the electric energy storage system. A charging profile is determined based upon the severity of the drive cycle. A controller commands operation of the off-board charging device based upon the charging profile.

Method and apparatus to control an off-board charging device

A method of controlling a transmission having a gearbox and a pump operable to circulate a fluid through the gearbox, includes sensing an acceleration of the vehicle, and adjusting an operating state of the pump. The operating state of the pump is adjusted to change the operating state of the pump from an initial operating state, to an adjusted operating state, when the acceleration of the vehicle is greater than an acceleration threshold. When the acceleration of the vehicle decreases from being greater than the acceleration threshold to being below the acceleration threshold, the operating state of the pump is returned to the initial operating state. The operating state of the pump may include a speed of the pump, a control signal representing a fluid flow rate for the current speed of the pump, or a fluid flow circuit for supplying the fluid to the pump.

Method of controlling a transmission during high G-force maneuvers

A vehicle including a high-voltage electric battery assembly including first and second battery cell modules and DC/DC electric power converter assembly is described. The DC/DC electric power converter assembly selectively converts electric power from the first battery cell module and the second battery cell module. A second end of the DC/DC electric power converter is electrically connected to a low-voltage system. The low-voltage system includes a first subsystem configured to provide a critical vehicle operation. A controller includes algorithmic code executable to monitor the high-voltage battery assembly, including, upon detecting a fault in the first battery cell module of the high-voltage battery assembly, controlling the DC/DC electric power converter assembly to electrically convert electric power from the second battery cell module to low-voltage electric power that is transferred to the first subsystem.

Method and apparatus for controlling a DC/DC power converter

A multi-mode powertrain system including an internal combustion engine, a high-voltage electric machine and a high-voltage electric power system is described. A method for controlling the multi-mode powertrain system includes, in response to an operator initiating a jumpstart, electrically connecting the high-voltage electric power system to a remote electric power source and energizing contactors between the high-voltage electric power system and the remote electric power source. Electric power flow through an auxiliary power module electrically connected to the high-voltage electric power system that supplies electric power to an accessory device is minimized. Engine starting parameters are modified, and the internal combustion engine is started by controlling, via a controller, the high-voltage electric machine to spin the internal combustion engine, and controlling operation of the internal combustion engine based upon the modified engine starting parameters to effect starting.

Jumpstarting an internal combustion engine

Systems and methods disclosed herein provide for a distributed high-voltage bus for a battery system included in a vehicle. In certain embodiments, the systems and methods disclosed herein provide for a scalable high-voltage bus architecture utilizing a common high-voltage rail for powering vehicle systems and/or modules. Independent contactors may be utilized on the opposite rail to selective power high-voltage branches. In further embodiments, a common rail pre-charge circuit may be utilized allowing for independent pre-charging of HV branches and systems and/or modules coupled to the HV bus.

Distributed vehicle battery high-voltage bus systems and methods

A product for use with a vehicle may include a high voltage electrical storage system unit. An energy storage unit may supply power to a high voltage wakeup module. The high voltage wakeup module may connect and may disconnect a number of loads from the energy storage unit when the vehicle is operating or shut down.

Single battery architecture for electrification vehicle

A system and method for determining whether a resistor in a battery circuit on an electric vehicle cannot be used as a resistive heater for heating a cooling fluid for cooling the vehicle battery, but can used as a pre-charge resistor for starting the vehicle. A temperature sensor is provided proximate the resistor within the cooling fluid. The method turns on the resistor before turning on a coolant pump and samples the temperature at sample intervals over a predetermined period of time. The method then calculates an integral or differential of the sampled temperatures and compares that value with a calibrated threshold. If the temperature value is not greater than the threshold, meaning that the temperature indicates no cooling fluid is present, the algorithm disables the resistor for heating purposes, but maintains operation of the resistor for pre-charge purposes.

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Clinton Township, MI, United States of America

Russell K Steele