Gm Global Technolgoy Operations, Inc.

Daimler Chrysler Ag

Daimlerchrysler Corporation

Hitachi Cable Indiana, Inc.

Edward L Kaiser

Khwaja M Rahman

Peter James Savagian

Sinisa Jurkovic

Joel E Mowatt

William S Reed

Peter Bostwick

Matthew D Laba

Paul Buchholz

James Allen Raszkowski

Xiaohui Du

Micah Joel Fuchs

Ryan Van Tiem

John C Morgante

Song He

Paul F Turnbull

Anthony P Tata

Kevin P Coleman

Kyle Kenneth Kinsey

Chandra S Namuduri

Suresh Gopalakrishnan

John D Campbell

Margarita P Thompson

Mark P Adams

Amanda Luedtke

David A Galey

Elizabeth Pepper

Alan G Holmes

Farzad Samie

Thomas W Nehl

Derek F Lahr

John Stilianos Agapiou

John A Diemer

Michael D Foster

Hongliang Wang

Arthur L McGrew, Jr

Alexandru Rajala

Fredrick R Poskie

William T Ivan

Wenying Yang

Timothy J Alfermann

Steven Lee Hayslett

Kent A Miller

Robert T Dawsey

David J Trzcinski

Richard A Pashnik

Frederick W Rhoads

Xu Han

Xinyu Zhou

Yew Sum Leong

Mohammad Faizul Momen

Qiang Niu

Grantland I Kingman

James W Haynes

Rebecca K Risko Cattell

Rolf Blissenbach

Michael C Muir

Mithun Sunny

Pavan Kumar Patruni

Cheongun Han

Matthew J Bozich

Xuan Q Tran

Richard Robertson

Michael H Standing

Frederick R Poskie

Caroline Bolt

Presented are direct liquid cooling systems for regulating magnet temperature of electric machines, methods for making/using such systems, and motor vehicles equipped with traction motors having magnets cooled by such systems. An electric machine includes a stator assembly that is located inside a protective outer housing. The stator assembly includes one or more electromagnetic windings mounted onto a stator core. A rotor assembly is rotatably attached to the housing, coaxial with and spaced from the stator assembly. The rotor assembly includes one or more permanent magnets mounted to a rotor core. The rotor core includes one or more radially elongated feed grooves that are fluidly connected to one or more axially elongated feed channels. The rotor feed groove(s) fluidly connect to a direct liquid cooling system to receive therefrom a liquid coolant. Each rotor feed channel transports the liquid coolant into direct contact with a target surface of a magnet.

Direct liquid cooling systems and methods for magnets of interior permanent magnet electric machines

A method of incorporating additive domains in a rare earth magnet, a system for incorporating additive domains in a rare earth magnet, and a traction motor including a rare earth magnet. Inert gas and a plurality of coarse neodymium-iron-boron (NdFeB) particles are introduced into the chamber of a jet mill. The plurality of coarse NdFeB particles impact each other producing a plurality of refined NdFeB particles. The plurality of refined NdFeB particles also impact a target including a target material and transfer a portion of the target material onto a surface of the refined NdFeB particles. The plurality of refined NdFeB particles including the target material are separated from the plurality of coarse NdFeB particles and collected to form a rare earth magnet.

Method and systems for uniform distribution of additive domains in the grain boundary of magnets

An exposed terminal for a wire conductor, and a process for preparing the exposed terminal includes executing, via a mechanical device, a mechanical ablation process to remove the insulative material from an outer surface of the plurality of square edges along a predefined length of the portion of the wire conductor. The process also includes executing, via a laser tool, a laser ablation process to remove the insulative material from the first pair of opposed faces along the predefined length of the portion of the wire conductor; and executing, via the laser tool, the laser ablation process to remove the insulative material from the second pair of opposed faces along the predefined length of the portion of the wire conductor.

Method and system for preparing a terminal for an insulated wire conductor

A hairpin conductor includes two wire segments each having respective first and second ends and a respective middle region. The segments are disposed in a side-by-side orientation such that their first ends are proximate each other and their second ends are proximate each other. The first ends are welded to each other and the second ends are welded to each other, or the middle regions are welded to each other, thereby providing a welded wire assembly, which is bent such that the two wire segments are bent equally to form the hairpin conductor. The hairpin conductor has a primary bend in the middle regions to form an apex thereat and first and second secondary bends in the two wire segments nearer to the apex than to the first and second ends to form respective first and second shoulders thereat. A method of forming the hairpin conductor is also presented.

Hairpin conductor for an electric motor stator and method of forming the hairpin conductor

A motor stator includes a plurality of stacked annular stator laminates defining a stator core having an inner circumference, an outer circumference, a plurality of stator teeth on the inner circumference, and a plurality of ears extending outward from the outer circumference with a respective bolt hole defined in each ear. A first set of the stator laminates includes a plurality of coolant openings therethrough, wherein the coolant openings of adjacent stator laminates communicate with one another in order to define cooling channels inside the stator core. A second set of the stator laminates each include one or more generally radially extending first openings therethrough, wherein the first openings of adjacent stator laminates communicate with one another to define one or more first radial channel segments inside the stator core for providing radial coolant flow between one or more bolt holes and one or more cooling channels.

Motor stator coolant distribution via internal channels

Presented are electric machines with optimized stator tooth geometries and multi-gauge stator conductors, methods for making/using such electric machines, and motor vehicles equipped with such electric machines. An electric machine includes a housing, a rotor assembly rotatably attached to the housing, and a stator assembly coaxial with and separated by an airgap from the rotor assembly. The rotor assembly includes one or more magnets mounted to a rotor core. The stator assembly includes a stator core with multiple axially elongated, circumferentially spaced stator slots, multiple radially aligned stator teeth interleaved between and separating the slots, and multiple electromagnetic windings wound through the slots. Each stator tooth has an elongated tooth body with a tooth head at a radial end of a tooth root, which attaches to a cylindrical hub of the stator core. The tooth head has an axial cross-section with a trapezoidal crown integral with a rectangular tip.

Stator tooth and winding conductor designs for electric machines

A rotor core for an electric machine of an automobile includes a core stack including a plurality of lamination plates, each lamination plate including a plurality of apertures formed therein, the apertures of each of the lamination plates axially aligned to define a plurality of magnet slots extending axially through the core stack, a plurality of magnets stacked axially within each of the plurality of magnet slots along a length of the core stack, at least one of the plurality of magnet slots including a cavity extending axially along the length of the core stack, and a wedge inserted within the cavity adapted to apply a lateral force onto the plurality of magnets within the at least one magnet slot to secure the plurality of magnets within the at least one magnet slot.

Preloading magnets in a rotor core

An electric machine may include a substantially annular stator stack having a plurality of laminations which include mounting ears. A fraction of the laminations may be oriented such that the mounting ears are angularly offset from the others. The stator may be secured to a housing at both mounting ear locations thus improving structural rigidity and enhancing performance.

Electric machine and method for manufacture

An electric machine includes a machine rotor circumscribed by a machine stator, and having a rotor shaft, rotor stack, and end cap which rotate about an axis. The end cap includes lobes equal in number to a number of pole pairs of the machine rotor. A position sensor assembly has a predetermined alignment with the machine rotor and stator. The sensor assembly includes a sensor rotor formed by the lobes and a sensor stator having a printed circuit board with conductive sine and cosine traces. Machine rotor rotation causes the sensor assembly to output an unmodulated sine and cosine signals to a controller, which then calculates a calibrated reference angle. A magnetic axis of an electrical phase of the machine is aligned with and bisects a peak of the sine trace. A direct axis of the machine rotor aligns with an edge of a lobe.

Electric machine with inductive position sensor assembly and method for assembling and aligning the same

A stator assembly includes a plurality of stator slots having multiple respective slot layers and a plurality of hairpins. The plurality of hairpins have a respective first leg positioned in one of the multiple respective slot layers and a respective second leg positioned in another of the multiple respective slot layers. A first set of n adjacent slots of the plurality of stator slots is configured to accommodate the plurality of hairpins carrying a current in a first phase, n being an integer. The plurality of hairpins is configured in respective conductor layers (L, L. . . ) having a plurality of respective turn locations defining n respective turn positions. The plurality of hairpins is configured to occupy the n respective turn positions an equal number of times such that the respective conductor layers (L, L. . . ) are electrically balanced.

Stator assembly with electrically balanced conductor layers

A stator for an electromagnetic machine includes a first lamination stack defining a first cavity therein and having a central longitudinal axis. The first lamination stack includes a first plurality of mounting ears disposed opposite the first cavity and each spaced apart from one another about the central longitudinal axis. The stator further includes a second lamination stack abutting the first lamination stack and defining a second cavity therein aligned with the first cavity along the central longitudinal axis. The second lamination stack includes a second plurality of mounting ears disposed opposite the second cavity and each spaced apart from the first plurality of mounting ears and from one another about the central longitudinal axis. An electromagnetic machine including the stator and a device including the electromagnetic machine are also described.

Stator having skewed mounting ears

An electromagnetic machine includes a motor housing defining a cavity therein, and a stator disposed within the cavity. The stator has an external surface and a plurality of mounting ears each configured to receive a fastener and extending from the external surface towards the motor housing. The assembly includes a tunable insert ring disposed between the motor housing and the stator. The tunable insert ring and the stator define at least one cooling channel therebetween. The tunable insert ring encircles the external surface and includes a plurality of projections each extending towards and disposed in contact with the stator to thereby stiffen the electromagnetic machine and minimize vibration of the stator within the motor housing. A device including the electromagnetic machine is also described.

Electromagnetic machine and tunable insert ring

A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.

Distributed connection ring assembly for stator assembly

An electric device and a stator assembly for the electric device includes a stator core defining a plurality of slots spaced from each other. The stator assembly includes a plurality of bar conductors disposed in each of the slots and arranged to present a first winding path, a second winding path and a third winding path. A first set of the bar conductors of the first, second and third winding paths are configured to receive current in a parallel circuit arrangement. The stator assembly also includes a plurality of electrical jumpers electrically connected to a predetermined number of the bar conductors such that an amount of current flowing through the first winding path and the third winding path is substantially the same and an amount of current flowing through the second winding path is different from the amount of current flowing through the first and third winding paths.

Electric device and a stator assembly for the electric device

An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.

Apparatus for injection molding rotor magnets

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Orion, MI, United States of America

Edward L Kaiser