Ford Global Technolgoies, LLC

Flexsys, Inc.

Other

Wisconsin Alumni Research Foundation

University of Michigan

Fourth and Long, Inc.

Joel A Hetrick

Sridhar Kota

Jacob Krizan

Cyrille Goldstein

Chun Tang

Gregory F Ervin

Franco Leonardi

Shailesh Shrikant Kozarekar

Akash Changarankumarath Pradeepkumar

Adeeb Ahmed

Brian Christian Orr

Singar Rathnam

Kyi Shin Shiah

Edward William Haran

Elizabeth Rose Bifano

Qubo Li

Yogesh B Gianchandani

Wei Wu

Daniel M Saban

Fang Deng

Murtuza Lokhandwalla

M Steven Rodgers

Alfredo R Munoz

Dengfu Zhang

Seong Taek Lee

Joshua D Simon

Devan James Anderson

Huifen Qiu

Philip Totaro

Janne Kinnunen

Larry Li-Yang Chu

Thomas Gettinger

Dexiang Dallis Sun

An electric machine includes windings, a terminal block, and terminal connectors. The windings have lead ends and neutral ends. The terminal block has a plurality of bus bars, a neutral bar, and an insulating material. Each bus bar is connected to one or more of the lead ends. The neutral bar is connected to one or more of the neutral ends. The insulating material encapsulates the plurality of bus bars and the neutral bar, defines a plurality of orifices, and defines a plurality of slots. Each lead end extends through one of the orifices from the outer boundary to one of the bus bars. Each neutral end extends through one of the orifices from the outer boundary to neutral bar. Each terminal connector extends through one of the slots from the outer boundary to one of the bus bars.

Electric machine

A stacked plurality of alternating laminations and adhesive layers of a rotor are arranged such that each of the adhesive layers bonds an outer periphery of an adjacent pair of the laminations together. Each of the laminations includes a plurality of interlocks, disposed about a central region of the lamination radially inside the outer periphery and lacking presence of any of the adhesive layers, that engage a same adjacent one of the laminations.

Hybrid interlock and adhesive rotor cores

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 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, and stator include stator teeth extending from a yoke portion toward a rotor and defining slots between adjacent teeth with windings positioned within the slots, wherein the teeth form pockets at connections to the yoke portion. Electrically insulating slot paper may line at least three sides of the slots. The pockets may extend into the teeth or the yoke portion where the teeth extend from the yoke portion, and may be filled with an electrically insulating compound that secures the insulating slot paper lining and electrically conductive rectangular windings within the slots.

Electrified vehicle having electric machine stator with slot pocket

An electric machine includes a cylindrical stator core and a cylindrical housing having an inner diameter. The core has an outer surface and a plurality of projections extending therefrom. An outer diameter of the core measured between tips of diametrically opposing projections is greater than the inner diameter. The core is disposed in the housing with the tips engaging the inner diameter to create an interference fit between the core and housing to reduce housing resonance.

Electric machine with reduced housing resonance

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.

Hairpin winding electric machine

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

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.

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 electric machine may include a plurality of sections, each defining a permanent magnet pocket and a field formation chamber. The sections may be stacked to form a rotor such that when walls of the permanent magnet pockets are aligned from end to end, walls of the chambers of at least some of the sections are offset. An adjacent pair of the sections may have different chamber to pocket relative positions to define different pole arc angles. A difference between the first pole arc angle and the second pole arc angle may be equal to a slot pitch of a stator of the electric machine. The slot pitch may be 7.5 mechanical degrees. The chamber may be defined on a radially outward edge of the pocket. The chamber may taper in a radially outward direction.

Electric machine rotor

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 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.

Growing community of inventors

Madison, WI, United States of America

Joel A Hetrick