Ford Global Technolgoies, LLC

Jacob Krizan

Chun Tang

Joel A Hetrick

Adeeb Ahmed

Michael W Degner

Franco Leonardi

Cyrille Goldstein

Kyi Shin Shiah

Andrew Kasha

Shehan Haputhanthri

Prasad Venkiteswaran

Matthew Joseph

Huifen Qiu

An electric machine rotor that is configured to rotate about a first axis includes a plurality of plates and plurality of permanent magnets. The plurality of plates are stacked along the first axis. Each of the plates defines V-shaped pairs of cavities. Each V-shaped pair of cavities defines a pole arc angle. Each cavity has a permanent magnet pocket and a magnetic field guide chamber extending radially outward from the permanent magnet pocket relative to the first axis. Offset angles between the magnetic field guide chambers and the permanent magnet pockets vary within each plate. The plates are stacked such that the permanent magnet pockets between adjacent plates are axially aligned and such that the magnetic field guide chambers between adjacent plates are axially offset. Each permanent magnet extends through a set of permanent magnet pockets.

Electric machine rotor

An electric machine rotor includes a plurality of plates stacked along an axis of rotation. Each of the plates defines a plurality of cavities. Each cavity defines a pole arc angle, has at least one permanent magnet pocket, and has magnetic field guide chambers extending outward from the at least one permanent magnet pocket. Offset angles between the magnetic field guide chambers and the at least one permanent magnet pockets vary between at least two of the cavities of the plurality of cavities within each plate such that each plate defines at least two different pole arc angles. The plates are stacked such that the at least one permanent magnet pockets between adjacent plates are axially aligned and such that the magnetic field guide chambers between adjacent plates are axially offset.

An electric machine includes a stator and a rotor. The stator defines a central orifice and has an inner diameter. The rotor has an outer diameter and is disposed within the stator. An airgap is defined between inner diameter and the outer diameter. The rotor defines a plurality of cavities. The rotor has magnets disposed within each of the cavities. The magnets define a plurality of pole arc angles. Each pole arc angle is centered about a D-axis. The rotor has an outer periphery. The outer periphery forms smooth spline curves positioned within each pole arc angle. The smooth spline curves deviate radially inward relative to the outer diameter.

Electric machine

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.

An electric machine includes a stator core defining slots and a winding disposed in the core and having three phases. Each of the phases has at least two parallel paths including hairpins interconnected to form at least two continuous circuits between a terminal and a neutral. The hairpins of each path include: a first type of hairpins (first hairpins) each having first and second legs spaced apart by a span of five slots; a second type of hairpins (second hairpins) each having first and second legs spaced apart by a span of seven slots; and a third type of hairpins (first hairpins) each having first and second legs spaced apart by a span of five or seven slots.

Hairpin winding electric machine

An electric machine includes a stator core defining circumferentially arranged slots alternating between odd and even slots. Each slot has radial pin positions arranged in adjacent pairs to define radial layers. A hairpin winding includes a first path of interconnected hairpins that is disposed in the stator core such that, for each of the radial layers, the first path is disposed in the odd slots and the even slots a same number of times.

An electric machine includes a stator having teeth that define open slots and slot closers disposed in the slots. Each slot closers includes a flux bridge surrounded by a nonmagnetic case. The slot closer is disposed between adjacent ones of the teeth with the case engaging and spanning the adjacent teeth. The case forms nonmagnetic gaps between the flux bridge and the adjacent teeth, respectively, to reduce potential for torque ripple.

Electric machine with slot closers

An electric machine includes a stator core defining circumferentially-arranged slots each having radial pin positions arranged to define radial layers and a hairpin winding including a first path of interconnected hairpins disposed in the stator core. The hairpins are arranged such that a leg portion of each hairpin is routed through a radial pin position of each slot wherein at least one uniquely-pitched hairpin is provided along the first path to induce a first shift in a trailing portion of the first path.

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 electric machine includes a rotor including a channel defined between a pair of magnets and a bridge assembly within the channel. The bridge assembly includes a bridge element and a spring arranged to bias the bridge element toward a center of the rotor such that responsive to spinning of the rotor, the bridge element moves radially away from the center against a force of the spring to alter a magnetic flux pattern associated with the magnets.

Variable flux bridge for rotor of an electric machine

An electric machine includes a stator core defining slots and a hairpin winding path disposed in the slots. The winding path includes first and second hairpins having legs with same slot spans and twist with same slot spans. The hairpins are installed in the core such that one of the twists of the first hairpin crisscrosses with one of the twists of the second hairpin. A reverse jumper joins the twists that crisscross.

A stator for a hybrid electric vehicle combines the best features of complete stators and segmented stators. The bobbins of a complete stator are modified to effectively widen the teeth and thereby reduce torque ripple. Each resin bobbin includes cavities on either side of the tooth. The cavities are filled with a magnetically conductive insert. In some embodiments, a single wedge shaped insert is installed on each side of each tooth. In other embodiments, multiple inserts of varying cross sectional area are installed on each side of each tooth.

Stator having bobbin-embedded tooth tips

A vehicle includes an electric machine having independently selectable delta and wye windings. The electric machine has a lower torque producing limit with one of the windings than an other of the windings at a given speed. The vehicle includes a controller configured to select the other of the windings such that torque of the electric machine increases without increasing the given speed. The selection is responsive to operating with the one of the windings and a torque demand greater than the lower torque producing limit.

Wye-Delta eDrive system for electric vehicles

A vehicle electric machine assembly including a stator core, a rotor, and a bridge is provided. The stator core defines a cavity. The rotor is disposed within the cavity and may include a channel defined between two magnets. The bridge is disposed within the channel for translation between at least a first and a second position. The translation of the bridge adjusts a path of magnetic flux from the rotor to the stator core based on the bridge position. The bridge may be of a ferromagnetic material. The assembly may further include a first non-magnetic guide mounted on a first side of the channel at a substantially central channel region and a second magnetic guide mounted on a second side of the channel at the substantially central channel region.

An electric machine assembly for an electrified vehicle including a stator core, a rotor, a first pair of magnets, a second pair of magnets, and a variable flux magnet is provided. The stator core defines a cavity. The rotor is disposed within the cavity for rotation and includes a bridge. Each of the first pair of magnets may be mounted to the rotor and spaced from one another on either side of a first D-axis. Each of the second pair of magnets may be mounted to the rotor and spaced from one another on either side of a second D-axis. The first D-axis and the second D-axis are spaced from one another on either side of a Q-axis. The variable flux magnet is embedded in the bridge and located on the rotor to influence current associated with the Q-axis to control torque output of the rotor, and to pulse D-axis current to control a magnetization of the bridge.

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Farmington Hills, MI, United States of America

Jacob Krizan