Ford Global Technolgoies, LLC

Casey Taylor Dunn

Siraj Siddiqui

Daniel Frank Sheldon

An electric machine assembly including a terminal assembly and three terminal lugs is provided. The terminal assembly may include three pairs of terminal leads. Each of the three terminal luges may define a pair of terminal lead through-holes and a pair of opposing radial sides. Each terminal lug may be compressed at one of the sides to deform a respective terminal lug and secure each of the pair of terminal leads within one of the pair of terminal lead through-holes. The assembly may further include a stator disposed within a housing and include end windings. Each of the terminal leads may include a base terminal portion. The terminal assembly and the stator may be arranged with one another such that each base terminal portion is aligned with one of the end windings for securing thereto. The assembly may further include three bridges.

Electric machine assembly and method to assemble

A stator of an electric machine has first and second hairpin winding terminals connected with a first electrical phase and extending axially away from end windings of the stator. A hairpin winding of a second electrical phase is located circumferentially between the first-phase terminals and spaces them from one another. A jumper has spaced-apart C-hooks oriented face-to-face relative to one another and wrapping around respective exposed ends of the first-phase hairpin winding terminals. The jumper forms a bridge spanning between the first-phase hairpin winding terminals and over the second-phase hairpin winding terminal. During manufacturing of the stator, the C-hooks are slid axially downward onto respective non-insulated ends of the first-phase stator hairpin winding terminals. The C-hooks abut against and are axially positioned relative to the first-phase terminals by ledges defined by insulative coatings that cover portions of the first-phase hairpin winding terminals.

Self-fixturing jumper bridge for electric machine stator

An electric machine includes a stator core and interconnected hairpins attached to the stator core and defining a path. A pair of the interconnected hairpins have first and second ends, respectively, and are circumferentially spaced apart from each other. A jumper is interconnected between the first and second ends. The jumper has a body defining first and second holes that receive the first and second ends, respectively. The first hole is defined by a perimeter having opposing first and second walls and opposing third and fourth walls.

Hairpin electric machine with self-supporting jumpers

An electric machine for an electrified vehicle includes a stator and a temperature sensor assembly. The temperature sensor assembly includes an elongated housing having an anchor portion disposed within the windings. The anchor portion includes a screw thread extending about an outer perimeter of the elongated housing, resilient tabs extending from the outer perimeter, and a temperature sensor housed within the anchor portion of the elongated housing.

Electric machine thermal management

An e-machine is disclosed that comprises a stator, a terminal block, and a plurality of interface conductors. The stator is disposed inside a housing in a wet portion of the housing that contains transmission fluid. The terminal block is attached to the housing and is electrically connected to an inverter system controller of the e-machine. The terminal block is disposed in a dry portion of the housing that does not contain transmission fluid. The plurality of interface conductors each include a hollow conductive body, a stator lead lug on a first end connected to windings of the stator, and a busbar on a second end connected to the terminal block. A seal is assembled at an intermediate location in a groove on an outer surface of the hollow conductive body. A plug is assembled inside the hollow conductive body.

Phase terminal interface

An electric machine for an electrified vehicle includes a stator including windings and a bridge extending across the windings and in engagement with the windings. The electric machine further includes a temperature sensor assembly secured to the bridge. The temperature sensor assembly includes a retention housing having a base and spaced apart retention arms extending from the base. The temperature sensor assembly further includes a temperature sensor disposed within the retention housing. An adhesive is disposed between the retention housing and the bridge.

A temperature sensor assembly for an electric machine includes an elongated housing including an anchor portion, a temperature sensor disposed in the anchor portion, and a retention body extending from the elongated housing opposite the anchor portion and including spaced apart retention arms. The temperature sensor assembly further includes a wire guide extending from the retention body and extending along a retention arm away from the elongated housing, and a lead wire extending from the temperature sensor and through the wire guide.

A terminal block includes a housing having sidewalls defining a cavity. One of the sidewalls defines a hole opening into the cavity. A conductor is supported in the cavity and is configured to electrically connect with an inverter. A terminal lug extends through the hole. The terminal lug includes a body having a first end disposed in the cavity and attached to the conductor and a second end external to the cavity and configured to attach to a terminal lead of an electric machine. The terminal lug further includes a support integrally formed with the body and disposed between the first and second ends to be located within the hole. A sealing member is attached to the support and is in sealing engagement with the hole to prevent fluid from entering the cavity.

Terminal block with sealing terminal lug

An electric machine includes a stator having hairpin windings with at least first and second phases and a neutral bridge attached to the at least first and second phases. The neutral bridge defines a planar body and a mounting feature extending from an upper surface of the body and cooperating with the body to define an opening. A temperature sensor of the electric machine includes an insertion portion having a sensing element. The insertion portion is received in the opening.

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Brownstown Charter Township, MI, United States of America

Casey Taylor Dunn