Gm Global Technology Operations LLC

Chengwu Duan

Jian Yao

Chunhao J Lee

Lei Hao

Norman K Bucknor

Dongxu Li

Farzad Samie

Yusheng Zou

Zhen Gao

Lei Li

Alireza Fatemi

Chandra S Namuduri

Anil Kumar Sachdev

Derek F Lahr

Mingyuan Zhang

Suresh Gopalakrishnan

Chi-Kuan Kao

Yongsheng He

Ming Liu

David Sun

Alan G Holmes

Thomas W Nehl

Anthony M Coppola

Venkata Prasad Atluri

Chih-Hung Yen

Neeraj S Shidore

Dewen Kong

David J Cleary

SeungHwan Keum

Michael A Potter

Peggy Wang

Jingyuan Liu

Mohammad Hotait

Samantha Gunter Miller

Denghao Fan

Vincent Fedida

Robert J Gonzalez

Zhimin Liu

A cooling system includes a housing configured to enclose an electric vehicle component immersed in cooling fluid and to define a first volume. A variable volume member defines a second volume that varies in response to a first signal. A combined volume is defined by the first volume and the second volume. Heat causes the cooling fluid to transition between a liquid state and a vapor state in the combined volume. A pressure sensor is configured to sense a pressure in the combined volume. A condenser is configured to cause the cooling fluid to transition from the vapor state back to the liquid state. A controller includes a volume adjustment module configured to generate the first signal to vary the second volume of the variable volume member to adjust the combined volume in response to the pressure and a first temperature of the electric vehicle component.

Active and passive heat flux control systems for two-phase immersive cooling for high power density electric vehicle components

An axial flux motor assembly is disclosed and includes: an axial flux motor comprising a rotor, and a first stator; and a power inverter assembly. The power module assembly includes: a printed circuit board; a control module mounted on the printed circuit board; power module assemblies connected to the printed circuit board and controlled by the control module; and a cold plate. The cold plate is disposed between the first stator and the power module assemblies and includes a first side and a second side, which is opposite the first side. The cold plate cools the power module assemblies via the first side and the first stator via the second side.

Axial flux motor assemblies with integrated power electronics and double-sided cooling

An example rotor includes a rotor yoke having an outer circumference and an inner circumference. The rotor further includes a plurality of rotor ribs on a surface the rotor yoke and extending between the outer circumference and the inner circumference. The rotor further includes a plurality of magnets, each of the plurality of magnets being disposed adjacent to and between two of the plurality of rotor ribs.

Rotors for electric motors

An axial flux motor includes: a ring-shaped stator, a ring-shaped rotor and a planetary gear set. The ring-shaped stator includes a stator core and segments arranged on the stator core, where each of the segments includes a laminated stack and windings wrapped around the laminated stack. The ring-shaped rotor defines an inner open area and including a body and permanent magnets arranged on the body adjacent to and spaced from the segments. The planetary gear set is disposed within the inner open area and configured to receive an input torque from the rotor and provide an output torque, which is greater than the input torque.

Integrated axial flux motor assemblies including planetary gearsets

An electric machine includes a housing having an inner surface; and a stator including a stator core mounted in the housing. The stator core includes a plurality of stator windings, a thermal bridge extends between the stator core and the inner surface of the housing. The thermal bridge is formed from a non-magnetic material and includes a plurality of individual thermal bridge elements.

Thermal bridge for an electric machine

A power control system for a vehicle includes a charge port and a contactor connected to the charge port and including a first plurality of switches. An energy storage system includes a second plurality of switches and one or more battery packs. A bi-directional DC-DC converter is connected between the energy storage system and a plurality of vehicle loads. A controller is configured to control states of the first and second plurality of switches to configure in a plurality of modes including a range improvement mode, a first charging mode to perform charging at a first voltage level, a second charging mode to perform charging at a second voltage level, a battery preconditioning mode; and an accessory load support mode.

Multi-function DC-DC converter for battery electric vehicles

Presented are torque converters (TC) with hydraulic systems for converter feed and clutch control, methods for making/operating such TC assemblies, and vehicles equipped with such TC assemblies. A TC assembly includes a housing that drivingly connects to an electric motor, and an output member that drivingly connects to a multi-gear transmission. Rotatable within the TC housing are a turbine attached to the TC output member and an impeller juxtaposed with the turbine. A lockup clutch disposed inside the TC housing, between the turbine and housing, is operable to lock the housing to the output member. A disconnect clutch disposed inside the housing, between the impeller and housing, is operable to lock the housing to the impeller. A pump is attached to the TC housing and drivingly connected to the motor for feeding fluid into the housing to increase pressure within the TC chamber and activate the lockup and disconnect clutches.

Hydraulic system and control logic for torque converter assemblies

An electrical system can include a rechargeable energy storage system (RESS) and a direct current to direct current (DC-DC) converter. The DC-DC converter is connected to the RESS and configured to connect to a DC charging station. The DC-DC converter is configured to selectively connect the RESS to the DC charging station such that a charging current is selectively provided to the RESS during a recharging operation.

Controlling a DC-DC converter for DC charging

A mixed chemistry battery is provided. The mixed chemistry battery includes a reference module having a first chemistry and a battery module having a second chemistry that is different that the first chemistry, the battery module is connected to the reference module in series. The mixed chemistry battery also includes a battery monitoring system configured to monitor an open circuit voltage of the reference module, an open circuit voltage of the battery module, and a current flow through the reference module and the battery module. The battery monitoring system is further configured to calculate a state-of-charge (SOC) and state-of-health (SOH) of the battery module based at least in part on a SOC of the reference module.

State of charge and state of health assessment of a mixed chemistry battery

A bi-material permanent magnet for an electric machine includes a core including a first magnetic material and a shell portion located on the core and made of a second magnetic material. The first magnetic material comprises a magnet material with an energy less than 20 Mega Gauss Oersteds (MGOe). The second magnetic material comprises a magnet material with an energy greater than 30 MGOe.

Bi-material permanent magnets for electric machines

A system for bypassing a torque converter in a powertrain is provided. The system includes a torque generating device including an output shaft and a transmission assembly. The transmission assembly includes a transmission output shaft and a torque converter, a torque converter bypass shaft. The transmission assembly further includes a disconnect clutch selectively coupling the torque converter with the torque generating device and a torque converter clutch selectively coupling the torque converter bypass shaft with the torque generating device. Engaging the disconnect clutch and disengaging the torque converter clutch enables the torque generating device to transmit torque to the transmission output shaft through the torque converter. Engaging the torque converter clutch and disengaging the disconnect clutch enables the torque generating device to transmit torque to the transmission output shaft through the torque converter bypass shaft.

System and method for bypassing a torque converter in a powertrain

A stator assembly for an axial flux motor includes a heat exchanger jacket configured to circulate a heat transfer liquid. A stator also includes a plurality of stator cores each having a conductive winding, an electrically insulating material disposed over at least a portion of the conductive wire winding, and a molded soft magnetic composite (SMC) material. The heat exchanger jacket is disposed circumferentially around at least a portion of a perimeter of the stator. Each stator core defines a peripheral surface configured to contact the heat exchanger jacket and at least a portion of the peripheral surface is defined by the molded soft magnetic composite (SMC) material. Methods of making a molded soft magnetic composite (SMC) material stator core are also provided.

Direct contact cooling of axial flux motor stator

A system for a power take-off mechanism for a powertrain system is provided. The system includes an electrically powered torque generating device including a torque generating device output shaft and a transmission output shaft receiving mechanical power from the torque generating device output shaft. The system further includes a clutch selectively disengaging the transmission output shaft from the torque generating device output shaft and a power take-off module receiving mechanical power from the torque generating device.

System for a power take off mechanism for a powertrain system

An axial flux electric machine comprises a stator including a plurality of stator core segments each comprising a lamination comprising a plurality of layers. A first soft magnetic composite (SMC) portion is arranged adjacent to the plurality of layers of the lamination. An insulating layer arranged between circumferential side surfaces of the plurality of layers of the lamination and the first SMC portion. A rotor is arranged axially adjacent to the stator and including a plurality of permanent magnets. The rotor and stator are configured to generate magnetic flux that is aligned parallel to an axis of rotation of the rotor.

Axial flux electric machine including insulated hybrid stator core with soft magnetic composite portions and laminated layers

A method for controlling an electric drive unit (EDU) having a motor-driven torque converter includes receiving a request signal indicative of a requested output torque of the EDU, and operating the motor at a target motor speed using the requested output torque. The target motor speed minimizes system losses while achieving the requested output torque. When the requested output torque remains below a calibrated threshold and a turbine speed is less than a corner speed of the motor, a torque converter clutch (TCC) transitions to or remains in a locked state. The controller commands the TCC to transition to an unlocked state to reach the target motor speed, thereby selectively enabling torque multiplication. A powertrain system includes a driven load and the EDU. A computer readable storage medium may include executable instructions for performing the method.

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Shanghai, China

Chengwu Duan