Ford Global Technolgoies, LLC

Cyrille Goldstein

Joel A Hetrick

Siraj Siddiqui

William David Guarino

Michael Coury

Jacob Krizan

Edward William Haran

Elizabeth Rose Bifano

Chun Tang

Kenneth G Kraft

Peter Alexander Szpara

An electric machine rotor includes a core, a first end plate, a second end plate, and a shaft. The core defines an internal cavity. The first and second end plates each define a central orifice and are respectively secured to opposing axial ends of the core. The shaft is disposed within the cavity and engages the first and second end plates within the central orifices to facilitate synchronized rotation of and torque transfer between the core and shaft.

Electric machine rotor

A motor for an electric vehicle includes a motor housing for receiving a stator. A plurality of caps each have an outer rim and a washer portion defining a bolt receiving opening. The outer rim of each of the caps is press-fit into the receptacles in the motor housing. The caps are each attached to the stator by one of the bolts. The heads of the bolts clamp the cap to the stator to retain one end of the stator. The outer rim holds the cap in the motor housing while the washer portion flexes axially in response to thermal expansion and contraction of the motor housing. A method is disclosed for assembling the stator into the motor housing.

Stator free end retainer

The rotor of a permanent magnet motor includes a stack of laminations. Each lamination is located with respect to a shaft using a key with a tangential fillet. Each lamination also includes a set of lightening holes having a shape designed to minimize hoop stresses and thereby increase the maximum permissible operating speed of the motor. Furthermore, the tightening holes are aligned with the key to minimize interactions of the respective stress concentrations.

Rotor lamination with key

An electric machine includes an outer housing and a stator secured to the outer housing and configured to induce an electromagnetic field. The electric machine also includes a rotor configured to output rotational movement in response to the electromagnetic field of the stator. The electric machine further includes at least one retention key configured to cooperate with a retention feature of the stator to engage a channel of the outer hosing to generate a circumferential force to resist movement of the stator relative to the housing.

Electric motor and construction methods thereof

An electrified vehicle assembly includes, among other things, an outer shaft that is rotatable about an axis. The outer shaft rotatably couples a motor of an electrified vehicle to a transmission component of the electrified vehicle. A shaft insert provides a conduit for a fluid and that blocks the fluid from flowing radially between the shaft insert and the outer shaft relative to the axis. The shaft insert includes a polymer-based material, a composite material, or both.

Shaft assembly for an electrified vehicle and shaft providing method

A vehicle transaxle includes a housing, an electric machine stator, a plurality of mounting plates, and a first set of fasteners. The housing has internal walls that define a cavity and an access opening to the cavity. The electric machine stator is disposed within the cavity between a first of the internal walls and the opening. The plurality of mounting plates secures a first longitudinal end of the stator to the housing proximate the opening. Each fastener of the first set of fasteners extends through one of the mounting plates, through the stator, and engages the first of the internal walls to secure a second longitudinal end of the stator to the first of the internal walls.

Hybrid/electric vehicle transmission

A vehicle transmission includes a housing, an electric machine stator, a support plate, and a plurality of fasteners. The housing has an internal rear wall and a side wall that define a cavity. The electric machine stator is disposed within the cavity. The support plate is disposed within the cavity. The support plate engages the internal side wall such that a press-fit engagement is formed between the support plate and the internal side wall. The electric machine is disposed between the support plate and the internal rear wall. The plurality of fasteners extends through the support plate, through the stator, and engages the rear internal wall to secure the stator to the housing.

A vehicle transmission includes a housing, an electric machine, a bracket, and a plurality of fasteners. The housing has internal rear and internal side walls that define a cavity. The electric machine stator and the bracket are disposed within the cavity. The bracket has a metallic inner ring and an elastomer outer ring. The elastomer outer ring engages the internal side wall. The electric machine stator is disposed between the bracket and the internal rear wall. The plurality of fasteners extends through the metallic inner ring, through the stator, and engages the rear internal wall to secure the stator to the housing.

An electric machine is provided. The electric machine may include a shaft and a rotor. The shaft may define a rotational axis and a coolant passage that is transverse to the axis. The rotor may be assembled to the shaft and define an outer periphery, an inner periphery, and a medial section extending therebetween. The medial section may define a coolant channel that defines an inner edge and a plurality of elongated fins extending therefrom. The plurality of elongated fins may be configured to transfer heat from the outer periphery to coolant flowing from the coolant passage through the coolant aperture.

Electric machine cooling passage with internal fin structure

An electric machine is provided. The electric machine may include a rotor disposed on a shaft and an endplate. The endplate may define a coolant capture ring. The coolant capture ring may have tapered side walls that extend from an outer portion of the endplate toward the shaft at a periphery thereof. The coolant capture ring may be configured to deflect coolant captured by the coolant capture ring and expelled by the shaft due to centrifugal forces associated with the rotation of the shaft.

Rotor endplate for electric machine

An exemplary shaft assembly includes an outer shaft rotatable about an axis, and a shaft insert that provides a conduit for a fluid and blocks the fluid from flowing radially between the shaft insert and the outer shaft relative to the axis. An exemplary shaft assembling method includes positioning a shaft insert within an outer shaft. The shaft insert has a fluid conduit and is configured to block fluid from communicating radially between the shaft insert and the outer shaft.

Motor shaft assembly and assembling method with an insert that provides a fluid conduit

An electric machine is disclosed. The electric machine may include a rotor and an endplate. The endplate may define an aperture, an inner locknut surface and a balance-ring surface. The locknut surface may extend from a periphery of the aperture to a first diameter. The balance-ring surface may extend from a second diameter that is greater than the first diameter to an outer periphery of the endplate. Before assembly, the balance-ring surface may be adjacent to the rotor and the locknut surface may be spaced apart from the rotor.

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Ferndale, MI, United States of America

Cyrille Goldstein