Remy Technologies, LLC

Borgwarner Inc.

Gm Global Technolgoy Operations, Inc.

Remy International, Inc.

Delphi Technologies, Inc.

Delco Remy International, Inc.

Remy Power Products, L.l.c.

Michael D Bradfield

Michael McCord

Thomas R Sowash

Stephen P Santichen

Attila Nagy

Jack Douglas Harmon

David Maley

Samuel Edrington

Brad L Auler

Kirk E Neet

Michael Timothy York

Joel Michael Gray

Chris Bledsoe

Jorge Esteban Silva

Debabrata Sarkar

Daniel B Teixeira

Richard W Huibregtse

David L Wright

Steven Hayslett

Roger A Hartman

Matthew Vanderlip

Chirs Bledsoe

Olen L Phillips

A rotating electric machine receiving a flow of fluid at a rotor includes a stator having stator slots and a plurality of stator windings for receiving electrical current; the rotor, concentrically received within the stator, including: at least one axially-extending fluid channel in fluid communication with an end face of the rotor and an opposite end face of the rotor, wherein the axially-extending fluid channel is configured to receive fluid applied by a fluid outlet spaced a distance from the end face of the rotor.

Decoupled oil feed for internal rotor cooling

An electric machine includes a housing having an inner surface, an upper portion, and a bottom portion. The bottom portion supports a coolant inlet, and a coolant outlet. A stator is mounted in the housing. The stator includes a plurality of stator laminations having a first end turn and a second end turn. The plurality of stator laminations includes a coolant flow path having a plurality of coolant channels that extend circumferentially about the stator. A first portion of the plurality of coolant channels direct a coolant circumferentially about the stator in a clockwise direction and a second portion of the plurality of coolant channels direct the coolant circumferentially about the stator in a counter-clockwise direction. The coolant flow path includes a first outlet and a second outlet. The first outlet directs onto the first end turn, and the second outlet directs coolant onto the second end turn.

Integrated stator cooling jacket system

An electric machine includes a stator formed from a plurality of stator laminations arranged in a first lamination group and a second lamination group. The first lamination group and the second lamination group form a tortuous flow path that extends across the stator. The first lamination group includes at least two of the plurality of stator laminations joined together. The at least two of the plurality of stator laminations include a first plurality of cooling channel defining members. The second lamination group includes a second plurality of stator teeth and a second plurality of cooling channel defining members. The second plurality of cooling channel defining members of the second lamination group are circumferentially offset from corresponding ones of the first plurality of cooling channel defining members of the first lamination group.

A drive module for a vehicle including an electric machine, an inverter, a gearing assembly, and a cooling system. A first housing member thermally coupled with the inverter has a first set of heat exchange surfaces and a second housing member thermally coupled with the electric machine has a second set of heat exchange surfaces. The first and second sets of heat exchange surfaces each project into an interior volume cooled by an externally supplied liquid coolant which thereby defines a heat exchanger. A lower oil sump for collecting oil used to cool the electric machine may also include heat exchange surfaces projecting into the same heat exchanger. The gearbox may include an elevated oil sump which is supplied by the same oil pump circulating oil on the electric machine wherein the elevated oil sump gravity feeds oil onto selected surfaces within the gearbox.

Drive module with improved efficiency

A wound field rotor includes a shaft having an outer surface, an inner surface defining a flow path, and an opening defining a passage extending from the flow path through the outer surface. A plurality of laminations is mounted to the outer surface. The plurality of laminations includes an inner annular surface disposed on the shaft and an outer annular surface defining a plurality of rotor teeth. A plurality of field windings is disposed about corresponding ones of the plurality of rotor teeth. A first portion of the plurality of rotor laminations includes a first passage portion that extends from the inner annular surface radially outwardly and is fluidically connected to the passage, and a second portion of the plurality or rotor laminations adjacent the first portion includes a second passage portion that includes a first end that registers with the first passage portion and a second end.

Cooling system for an electric machine having a wound field rotor

An electric machine includes a stator formed from a plurality of stator laminations arranged in a first lamination group and a second lamination group that is circumferentially off-set from the first lamination group. The first lamination group and the second lamination group forming a tortuous flow path that extends axially across the stator. Each of the plurality of stator laminations of the first lamination group includes a body having an inner surface section and an outer surface section. The inner surface section includes a plurality of stator teeth. A plurality of cooling channel defining members is integrally formed with and extend radially outwardly from the outer surface section. Each of the plurality of cooling channel defining members being spaced from others of the plurality of cooling channel defining members by a corresponding gap.

An electric drive unit with an electric motor, a differential assembly, a transmission that transmits rotary power from the electric motor to the differential assembly, and a pair of output shafts that are rotatably coupled to respective differential output members of the differential assembly. The electric drive unit is configured to provide low cost, reliable cooling and/or lubrication to various components of the electric drive unit.

Electric drive unit with integrated, variable flow, low-pressure oil cooling system

An electric machine including a rotor and a stator positioned about the rotor. The stator includes a stator core having a plurality of stator teeth and a plurality of stator windings supported by the stator core about the plurality of stator teeth. The plurality of stator windings include a first end turn and a second end turn. The stator includes a plurality of interlocking insulators extending about corresponding ones of the plurality of stator teeth. Each of the plurality of interlocking insulators includes a first base portion extending circumferentially outwardly in a first direction and a second base portion extending circumferentially outwardly in a second direction. The first base portion being configured to inter-engage with a second base portion on an adjacent interlocking insulator to form a coolant passage and a coolant barrier about the air gap.

Oil cooling system for a stator of an electric machine

A pole piece () for a rotor () of a rotary electric machine () includes a hub portion () and a plurality of pole segments () distributed evenly about the hub portion (). The pole segments each have a base () that is connected to the hub portion () and a tip () that is disposed axially opposite the base () along an axis () of the pole piece (). Each pole segment () defines circumferentially opposite side surfaces () that extend between the base () and the tip (). Each pole segment () also defines radially opposite outer and inner surfaces () that extend between the side surfaces (). A groove is recessed in the side surfaces () of each pole segment (). A radially innermost portion () of the groove () is arranged proximate to the radially outer surface.

Enhanced permanent magnet claw pole segment geometry

A claw pole member for an electric machine including a plurality of claw pole segments. Each of the plurality of claw pole segments includes a radial projecting member, an axial outer surface extending to a cantilevered end portion, and an axial inner surface extending axially outwardly of the radial projecting member to a cantilevered end section. A first side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section, and a second side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section. The first and second side surfaces define a taper of the claw pole segment. Each of the first and second side surfaces includes a recessed portion that extends into the claw pole segment.

Claw pole having shaped claw pole segments

A number of variations may include a solenoid assembly comprising: a shaft; a pinion-plunger operatively attached to the shaft and having a first end comprising a plurality of teeth; a plurality of iron cores surrounding at least a portion of the pinion-plunger and the shaft; at least one solenoid coil winding and at least one spool surrounding each of the plurality of iron cores; a stop adjacent a first end of the plurality of iron cores; a guide adjacent a second end of the plurality of iron cores opposite of the stop; a biasing member in operative communication with the first end the pinion-plunger; and wherein the solenoid assembly is constructed and arranged so that when the solenoid assembly is activated the pinion-plunger is magnetically drawn toward the stop.

Starter

An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a cooling tower having first and second axial ends. The cooling tower includes a metallic wall defining radially inner and outer wall surfaces and extending about the package central axis. The radially inner wall surface defines an axially extending air passage through the cooling tower with an inlet proximate the first axial end. Spaced metallic ribs are in conductive thermal communication with the radially inner wall surface traverse and the air passage. Power electronics devices are attached in conductive thermal communication to the radially outer wall surface. The cooling tower provides a heat sink for the power electronics devices with a primary cooling path for each of the power electronics device extending radially inwardly to the cooling tower. An electric machine including such an electronic package is also disclosed.

Axially extending electric machine electronics cooling tower

An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.

Pedestal surface for MOSFET module

An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a support structure having opposite first and second axial ends spaced along a package central axis. A plurality of power electronics devices connected to the support structure and electronic control circuitry is carried by the support structure. The electronic control circuitry is substantially surrounded by and operatively connected to the power electronics devices. The control circuitry includes circuit board material having opposing substantially parallel sides, wherein the control circuitry comprises first and second control circuit portions respectively disposed on separate first and second circuit board material portions wherein the first and second circuit board material portions substantially coextend with distinct first and second imaginary planes, respectively. An electric machine employing such an electronic package is also disclosed.

Circuit layout for electric machine control electronics

Embodiments of the invention provide a starter that includes a motor with an armature that is coupled to a pinion. In some embodiments, the starter can include a main field coil that can be configured and arranged to produce a main magnetic field flux. Some embodiments include at least one auxiliary flux assembly arranged in close proximity with the main field coil and electrically disconnected from it. In some embodiments, a control system can operatively power the main field coil to produce a magnetic field flux. In some embodiments, the at least one auxiliary flux assembly can provide a supplementary field flux adding to the main magnetic field flux that interacts with the armature.

Growing community of inventors

Anderson, IN, United States of America

Michael D Bradfield