Ford Global Technolgoies, LLC

Chuan Deng

Guohua Du

Yigang Yuan

Joy Gong

Xusheng Zhang

Kun Zhuge

Alvin Yuan

Leila Du

An electric machine includes a stator rotatably supporting a rotor, the rotor includes a stacked rotor laminations forming a rotor core with cavities having magnets arranged in the cavities through at least two adjacent rotor laminations and parallel to a rotor central axis, each lamination including an outer edge having grooves or scallops arranged asymmetrically about the circumference to reduce torque ripple. At least one groove or scallop may be arranged along a q-axis and at least one groove or scallop may be arranged between a q-axis and a d-axis of the rotor core. The laminations may be substantially identical with a first group of laminations flipped or rotated about a diametric axis relative to a second group of laminations. An electrified vehicle includes an electric machine powered by a traction battery, the electric machine having a rotor core with stacked rotor laminations having a scalloped outer edge.

Electric machine and vehicle having asymmetric rotor laminations

A stator for an electric machine includes slots for accommodating windings, the slots having a slot neck portion and a filling portion and extending radially between an inner circumference and an outer circumference of the stator, and including regular slots and misplaced slots. The slot neck portion of the misplaced slots has a dimension different from that of the regular slots. The plurality of slots and windings establish a plurality of phases, each phase occupying at least two adjacent slots, and the at least two adjacent slots include a regular slot and a misplaced slot resulting in reduced torque ripple and an associated reduction in vehicle NVH.

Electric machine stator and method for reducing torque ripple of electric machine

An electrical connector for a vehicle provides integrated noise suppression and includes a housing having openings at both ends, conductors extending through the openings, a magnetic ring surrounding but spaced from the conductors, capacitors spaced from the magnetic ring and coupled to the conductors, and insulating filler disposed within the housing and contacting the magnetic ring and the capacitors.

Electrified vehicle connector assembly with integrated noise suppression

An electric machine rotor including a rotor core having a plurality of magnets and several pairs of elongated slots circumferentially distributed on the rotor core. Each pair of elongated slots jointly forms a V-shaped configuration with an opening facing an outer periphery of the rotor core. Each elongated slot includes a mounting portion that matches the shape of the magnet and an end hole located at an end of the elongated slot pointing to the outer periphery. The end hole includes a main body area and a lobe area, and the lobe area extends from the main body area toward outside of the V-shaped configuration until it is partially located outside a side extension line of the mounting portion.

Electric machine rotor

An electric machine stator includes a stator core having annular stator laminations arranged in a stack with each lamination includes a plurality of stator teeth, adjacent teeth defining corresponding tooth slots on an inner periphery. Each stator tooth slot includes a winding area and an opening area leading to the inner periphery and including a first side and a second side. The first side and the second side each have an inner and outer tooth top, the inner and outer tooth top of the first side and the inner and outer tooth top of the second side are respectively symmetrical with respect to a center line of the opening area, and the first side and the second side are asymmetric with respect to the center line.

Electric machine stator and vehicle electric machine containing the same

There is provided a current transferring device for an electric machine comprising a rotary bearing member fixed in a rotor shaft and rotating with it and a non-rotary component. The rotary bearing member includes a first compartment filled with a conducting fluid and having a first opening and a rotor positive connector that is in electrical contact with the conducting fluid therein and electrically connected to a rotor positive pole, and a second compartment filled with a conducting fluid and electrically insulated from the first compartment and having a second opening and a rotor negative connector that is in electrical contact with the conducting fluid therein and electrically connected to a rotor negative pole. The non-rotary component closes the first and second openings.

Current transferring device for an electric machine and an electric machine with the same, and a vehicle

An electric machine rotor includes a rotor core having pairs of magnets circumferentially distributed around the rotor core, each magnet pair forming a V-shaped configuration with an opening facing an outer periphery of the rotor core, and first and second slots inside the V-shaped configuration that form a magnetic bridge. Sides of the magnetic bridge are angled toward the outer periphery.

Electric machine rotor and vehicle electric machine containing the same

A motor rotor may include a body having axially extending first and second magnets embedded into the body, the first magnet and the second magnet being arranged at an angle and spaced apart by an axially extending magnetic shielding component. The first magnet includes a first surface away from a central axis of the rotor body and a second surface facing the central axis. The second magnet includes a third surface away from the central axis and a fourth surface facing the central axis, wherein the first surface and the third surface and extension surfaces thereof define a first area of the body part away from the central axis and a second area of the body part close to the central axis.

Motor rotor

A stator core for an electric motor may include a main body part formed by a plurality of stacked electromagnetic steel sheets, the main body part being provided with at least a first through hole extending axially with a first pin located in the first through hole. A first end cover is located at a first end of the main body part and connected to a first pin end of the first pin. A second end cover is located at a second end of the main body part and connected to a second pin end of the first pin. The connections of the first end cover and the second end cover to the first pin generate tensile stresses in the main body part to reduce core losses.

Stator core of motor

A motor and stator include first and second laminations arranged adjacently in the axial direction. The laminations include sub-yoke parts and first tooth parts. The sub-yoke parts are spliced through a yoke engaging part to form a substantially annular yoke part. The tooth parts are assembled on an inner edge of the yoke part through a tooth engaging part. A first tooth engaging part and a second tooth engaging part are superposed in the axial direction, the first tooth engaging part being different from the second tooth engaging part. A method of manufacturing a stator for a motor is also disclosed.

Electric machine cooling with rotor having cooling pipe

A stator for a motor includes laminations arranged axially adjacently. A first lamination includes sub-yoke parts and tooth parts. The sub-yoke parts are spliced through a first yoke engaging part to form an annular first yoke part. The first tooth parts are assembled on an inner edge of the first yoke part through a first tooth engaging part. The second lamination includes sub-yoke parts and tooth parts. The sub-yoke parts are spliced through a second yoke engaging part to form an annular second yoke part. The second tooth parts are assembled on an inner edge of the second yoke part through a second tooth engaging part. The first and second tooth engaging parts are superposed in the axial direction. A method of manufacturing a stator for a motor is also described.

Stator for motor and method of manufacturing

An electric machine operable as a motor or generator includes a stator having a body portion substantially in the shape of a hollow column with an outer wall and an inner wall. The body portion has a plurality of first slots and a plurality of second slots each running through the body portion in a longitudinal direction. The plurality of first slots are distributed in a circumferential direction between the outer wall and the inner wall, and the first slots are circumferentially closed slots. The plurality of second slots are distributed in the circumferential direction between the first slots and the inner wall, and the second slots are circumferentially closed slots and are spaced apart from the first slots.

Stator for motor and motor

One or a plurality of embodiments of the present application provide a winding method for a stator winding. The method comprises positioning a first wire in a first direction according to a first rule, wherein the first rule is continuously positioning the first wire from a first layer in the first direction at a spacing of R slots in a layer number ascending manner until passing through an Mth layer; in the Mth layer, subjecting the first wire to pass a first same-layer transition and pass through a next slot having a spacing of R; positioning the first wire in a second direction according to a second rule, wherein the second rule comprises positioning the first wire at the spacing of R slots in a layer number descending manner until passing through the first layer; and in the first layer, subjecting the first wire to pass a second same-layer transition and pass through a next slot having the spacing of R, wherein the first wire advances in the same direction in the first same-layer transition and the second same-layer transition; and advancing the first wire by repeating following the first rule, passing the first same-layer transition, following the second rule, and passing the second same-layer transition until the first wire fills up the M layers of the stator without crossing itself, where M is a total number of layers of the first wire in stator slots.

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Jiangsu, China

Chuan Deng