Ford Global Technolgoies, LLC

Ford Motor Company Limited

Franco Leonardi

Michael W Degner

Prasad Dev Hanumalagutti

Feng Liang

Wanfeng Li

Chun Tang

Edward Chan-Jiun Jih

John Matthew Ginder

Robert C McCune

Becky Sue Morris

John Michael Miller

Wei Wu

Leyi Zhu

Chuanbing Rong

Man Prakash Gupta

Joel A Hetrick

Alfredo R Munoz

Jacob Krizan

Brian Christian Orr

Alan John Gillard

Christopher M Wolf

Henry Heping Huang

Kewei Xiao

Benedikt Groschup

Steven Gerald Thomas

S George Luckey, Jr

Guangyin Lei

David Jeffeory Berels

Daniel Richard Luedtke

Xiao Guang Yang

Mark Allan Lippman

Ronald David Brost

Dengfu Zhang

Myung Ki Sung

Ji Wu

Chris Wolf

Singar Rathnam

Ronald C Elder

Patrick McCleer

Seth Avery

Dean Richard Canini

Gary Thomas Martini

Christopher White

Steven White

Matthew Meier

A rotor for an electric machine includes a core comprised of stacked laminations that define pockets between a hub portion and a pole portion. Each of the pockets are configured to receive magnetic material and define center cavities between regions of magnetic material to eliminate a flux leakage path between the magnetic materials. A cured mixture including an epoxy and a magnetic powder is disposed within the center cavities. The magnetic material may include sintered magnets and a cured mixture.

Adhesive mixture including hard magnetic material for e-machine rotor

Methods and systems for demagnetizing a rotor. The method includes, in one example, adjusting a position of magnetic poles mounted on a frame in a demagnetization system in relation to a first electric machine rotor, and decreasing the magnetization of the first electric machine rotor via operation of the demagnetization system to generate an electromagnetic field.

Systems and methods for demagnetization of a permanent magnet rotor

An electric machine for an electrified vehicle includes a stator core configured to receive a plurality of windings. The stator core including a plurality of interchangeable stacked laminations arranged in sub-stacks. The sub-stacks having an outer diameter surface divided into circumferential quadrants, each quadrant having a cutout extending inwardly at a predetermined depth and radial position to define a serpentine cooling path on the outer surface of at least a portion of the sub-stacks. The sub-stacks are circumferentially rotated relative to each other such that two quadrants have a first cutout orientation, and the two other quadrants have a second cutout orientation, the first cutout orientation is different than the second cutout orientation and when rotated in sequence each cutout aligns to form the continuous serpentine cooling path in a quadrant of the stator core.

Stator with serpentine coolant path on the outer surface

An electric machine includes a stator core defining slots having a number of radial positions. A winding is disposed in the core and has three phases, each of the phases having at least two parallel paths including hurdle-shaped conductors interconnected to form at least two continuous circuits between a terminal and a neutral. Each of the hurdle-shaped conductors have first and second uprights disposed in a different one of the slots and a bridge connecting between the uprights and extending circumferentially over an end surface of the core, wherein the bridges are stacked one on top of the other such that the winding has upper and lower layers. The bridges have variable thickness such that a number of bridges, at each of the upper and lower layers, extending over one of the slots exceeds the number of radial positions of that slot.

Electric machine end winding design without conductor overlap

Permanent magnets and method of making the same are provided. The magnets include a magnetic layer having an insulation layer disposed thereon. The insulation layer is formed via additive manufacturing techniques such as laser melting such that it has discrete phases including a magnetic phase and an insulating phase.

Additive manufacturing of ND—FE—B magnets with insulating layers

An electric machine including a stator core having an outer circumferential surface and an axial row of raised projections that extend radially outboard from the outer surface. The raised projections are axially spaced from each other to define circumferential channels therebetween. A housing defines a cavity that receives the stator core. The housing has an inner circumferential surface in contact with the raised projections and radially spaced from the outer surface of the core to define a void space in fluid communication with the channels. The void space and the channels cooperate to form a fluid circuit that overlays the outer circumferential surface such that the fluid is in direct contact with the stator core.

Electric machine thermal management

A core for an electrical apparatus includes a plurality of electrical steel sheets having a ferromagnetic or ferrimagnetic coating applied to both sides of the electrical steel sheets. The electrical steel sheets are arranged in a stack to form a laminated stack. The ferromagnetic or ferrimagnetic coating is applied to both sides of the electrical steel sheets. The coating may comprise MnZn ferrites, NiZn ferrites, MgMnZn ferrites, CoNiZn ferrites, Co ferrites, Ni ferrites, Yttrium iron garnets (Y3Fe5O12) or other ferromagnetic or ferrimagnetic coating materials.

Electrical steel lamination stacks with magnetic insulator coating for electrical apparatus cores

A vehicle, electric machine, and method of manufacturing an electric machine include a stator having teeth extending from a yoke portion toward a rotor and defining slots between adjacent teeth with windings positioned within the slots, wherein the slots are coated with an electrically insulating material having an arcuate surface exiting the slots and extending at least partially over the teeth on at least one end face of the stator to form a winding guide for bending/positioning the windings. The winding guide may be formed by a molded epoxy that replaces insulating paper slot liners while providing a template for forming the hairpin bends of end windings.

Electrified vehicle having electric machine stator with embedded wire support overmold

A method of processing an anisotropic permanent magnet includes forming anisotropic flakes from a hulk magnet alloy, each of the anisotropic flakes having an easy magnetization direction with respect to a surface of the flake and combining the anisotropic flakes with a binder to form a mixture. The method further includes extruding or rolling the mixture without applying a magnetic field such that the easy magnetization directions of the anisotropic flakes align to form one or more layers having a magnetization direction aligned with the easy magnetization directions of the anisotropic flakes, and producing the anisotropic permanent magnet from the layers having the magnetization direction such that the anisotropic permanent magnet has a magnetization with a specific orientation.

Processing of anisotropic permanent magnet without magnetic field

Permanent magnets and method of making the same are provided. The magnets include a magnetic layer having an insulation layer disposed thereon. The insulation layer is formed via additive manufacturing techniques such as laser melting such that that it has discrete phases including a magnetic phase and an insulating phase.

Additive manufacturing of Nd-Fe-B magnets with insulating layers

A vehicle electric machine includes a stator core having an inner diameter defining a plurality of slots, an outer diameter, and a plurality of mounting ears disposed radially outboard of the outer diameter. At least one of the mounting ears defines a cooling channel extending in an axial direction of the stator core. A radial distance between a center of the stator core and the cooling channel is greater than a radial distance between the center and the outer diameter. The machine further includes windings having portions disposed in the slots and end windings adjacent to an end face of the stator core.

Electric machine for vehicle

A stator includes a plurality of same laminations each defining a piloting tab on a perimeter thereof, and stacked to form a stator body and such that the piloting tabs define at least two axially extending serrated edge portions spaced apart from one another around a perimeter of the stator body or at least two sets of axially aligned housing contact pads spaced apart from one another around the perimeter.

Stator with piloting supports

A vehicle electric machine includes a housing and a stator having windings and a stator core. The core defines a plurality of axially extending cooling channels each having an entrance port at one end of the stator and an exit port at the other end of the stator. An end cover is connected to a first end of the housing defining a recessed cavity configured to receive the windings and defines an arcuate inlet manifold channel that extends in a circumferential direction of the stator to partially circumscribe the first cavity and that is in fluid communication with first ones of the axial cooling channels.

An electric machine includes a housing, a stator, an oil film, and at least one first seal. The housing has an internal surface defining an internal cavity. The stator has an outer peripheral surface and is disposed within the internal cavity such that a clearance gap is defined between an outer peripheral surface and the internal surface. The oil film is disposed within the clearance gap and is in contact with the internal surface and the outer peripheral surface. The at least one first seal is disposed along a first end of the stator and is configured to retain the oil film within the clearance gap along the first end of the stator.

Electric machine

This disclosure relates to thermal management for an electric machine, such as an electric motor, of an electrified vehicle. An example assembly includes a stator having a core and a jacket at least partially surrounding the core. The jacket radially encloses a slot and is configured to permit fluid to flow within the slot from a first face of the stator to a second face of the stator. The assembly further includes a first end cover covering the first face of the stator. The first end cover has an inlet port and is configured to direct fluid from the inlet into the slot. Further, the assembly includes a second end cover covering the second face of the stator and configured to direct fluid that exits the slot.

End covers configured to direct fluid for thermal management of electric machine for electrified vehicle

Growing community of inventors

Dearborn Heights, MI, United States of America

Franco Leonardi