Gm Global Technolgoy Operations, Inc.

Visteon Global Technolgoies, Inc.

Paul F Turnbull

Alan G Holmes

Daniel J Berry

Edward L Kaiser

Chia-Chou Yeh

Khwaja M Rahman

Shawn Harold Swales

Matthew D Laba

Brian Schulze

Steven E Schulz

Brendan M Conlon

Peter James Savagian

Mohammad N Anwar

John C Morgante

Fredrick R Poskie

Steven Lee Hayslett

Harry J Bauer

Brian J Gallert

Daryl A Wilson

William C Deneszczuk

Shawn Scott Hawkins

Christopher J Twarog

Rolf Blissenbach

Pankaj Mithal

Ryan Van Tiem

Michael C Muir

Mehrdad Teimor

Micah Joel Fuchs

William J Omell

George D Dolan

William Turnbull

An electric machine produces motor torque having continuously variable magnetic and reluctance torque components. The electric machine includes stator and rotor assemblies. Different ends of the rotor hub have different average magnetic field strengths, with the second field strength at one end being weaker than the other. The rotor hub translates along the rotor shaft to vary the magnetic and reluctance torque components at different speed and torque operating points of the electric machine. A vehicle includes the machine, a transmission, a load, and a controller executing a method for controlling the axial position of the rotor hub. The method may include determining the speed and a torque of the electric machine, determining a corresponding desired axial position of a rotor hub, and translating the rotor hub to the desired axial position.

Electric machine having continuously-variable magnetic characteristics and method of controlling the same

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

A number of variations may include a method of assembly of a rotor and a stator having a concentric air gap in an electric motor comprising: providing inflatable gap support tooling in a deflated state in an air gap between a rotor and a stator; filling the inflatable gap support tooling with a fluid so that it uniformly fills at least a portion of the air gap between the stator and the rotor and holds the stator and the rotor together as a single unit; placing the single unit into a motor assembly; seating a plurality of bearings into the motor assembly; locking the stator into place in the motor assembly; removing the fluid from the inflatable gap support tooling; and removing the inflatable gap support tooling from the motor assembly.

Inflatable air gap tooling for assembly of rotor and stator

An electric motor powers a fluidic pump fluidly connected to a hydraulic circuit. Operating the electric motor includes determining a heat transfer coefficient for the electric motor based upon a temperature of hydraulic fluid in the hydraulic circuit. A temperature of the electric motor is determined based upon the heat transfer coefficient. Operation of the electric motor is controlled based upon the temperature of the electric motor.

Method and apparatus for controlling an electric motor employed to power a fluidic pump

An apparatus for providing a coolant to a stator and a rotor of an electric motor in a vehicle having a coolant pump is provided. The apparatus includes a base defining a plurality of first openings through at least one of which the coolant is flowable to the stator. The apparatus also includes at least one wall extending from the base to define a cavity configured to receive the coolant from the coolant pump. The apparatus further includes at least one first raised member within the cavity that extends from the base. The at least one first raised member defines at least one second opening substantially aligned with one of the first openings to form a first passageway through which the coolant is flowable to the rotor. The apparatus may be located above the electric motor such that the coolant is flowable by gravity to the stator and/or the rotor.

Apparatus, system, and method for cooling an electric motor

A method for operating an electric machine of a ground vehicle includes periodically determining an aging parameter based upon a temperature of the electric machine and periodically determining a short-term aging effect based upon the periodically determined aging parameter. A long-term aging effect is determined based upon the short-term aging effect. A short-term temperature adjustment is determined based upon the short-term aging effect and a long-term temperature adjustment is determined based upon the long-term aging effect. A temperature-based derated motor torque is determined based upon the long-term temperature adjustment and the short-term temperature adjustment. Operation of the electric machine is controlled responsive to an operator command for torque based upon the temperature-based derated motor torque.

Method and apparatus for controlling an electric machine

An electric power assembly for a vehicle is disclosed. An electric motor includes a stator and a rotor being rotatable about a pivot axis relative to the stator. An inverter is coupled to the electric motor and includes a power switching device that outputs an electrical signal from the inverter at a first frequency and having interference at a second frequency. The second frequency is a byproduct of the electrical signal creating the first frequency. The stator is electrically connected to the inverter to receive the first frequency such that the stator produces a first magnetic field. A frequency filter is attached to the rotor and directs the portion of the electrical signal having the second frequency to the rotor such that the rotor produces a second magnetic field that interacts with the first magnetic field to rotate the rotor about the pivot axis relative to the stator.

Electric power assembly for a vehicle

A hub assembly for an electric machine includes a rotor hub and a machine rotor. Rotation of the machine rotor generates an electromagnetic (EM) field. The hub assembly includes a resolver rotor that encodes an angular position of the machine rotor as a set of resolver signals. An EM field barrier ring between the resolver rotor and the rotor hub adds a magnetic barrier between the machine rotor and the resolver rotor to reduce noise in the resolver signals. The resolver rotor may be bonded to the EM field barrier ring. The EM field barrier ring may have an L-shaped cross section, and may be press-fitted into a pocket of the rotor hub. A vehicle includes a transmission having an input member and an electric machine having a rotor shaft connected to the input member of the transmission. The electric machine includes the hub assembly noted above.

Rotor hub assembly with non-magnetic resolver shielding ring

An electric vehicle powertrain includes a battery configured to couple with an external power source, a power plant including at least one three-phase electric motor, and a power controller configured to receive electrical energy from the battery and to controllably provide electrical energy to the at least one electric motor. The electric motor includes a stator having a plurality of electrical windings and a rotor having a magnetic field orientation, with the rotor being configured to rotate relative to the stator. The power controller is configured to warm an engine fluid by determining the position of the rotor relative to the stator; determining a DC current for each of the three motor phases such that the electromagnetic field of the stator mirrors the magnetic field orientation of the rotor; and by providing the determined DC currents to the electric motor to resistively heat the fluid.

Electric vehicle fluid preheater

A hybrid transmission having an input member, an output member, and a single motor/generator is characterized by a plurality of fixed-ratio modes of operation and at least one electrically variable mode of operation. In the fixed-ratio modes of operation, the speed ratio between the input member and the output member is independent of the speed of the motor/generator. In the electrically variable mode of operation, the speed ratio between the input member and the output member is dependent upon the speed of the motor/generator.

Electrically variable transmission

Methods, systems, and vehicles are provided pertaining to the determination of a temperature of a vehicle motor having an ignition when the ignition is turned on following a period of time in which the ignition had been turned off. A memory stores a function having a boundary condition that comprises a prior temperature from when the ignition was turned off. A processor is coupled to the memory. The processor is configured to determine an amount of time for which the ignition has been turned on and determine the temperature of the motor using the function if the amount of time for which the ignition has been turned on is less than a predetermined threshold.

Vehicle motor temperature determination

An insulator assembly for a stator assembly of an electric machine includes an annular ring attached to a stator core, and a plurality of coil separators supported by the annular ring and extending from the annular ring axially along a longitudinal axis. One of the coil separators is disposed between each adjacent pair of the coils to prevent contact between adjacent coils having a different electrical phase. The coil separators are slideably inserted between the adjacent pairs of coils, with the annular ring positioning and supporting the coil separators.

Stator assembly having a phase-to-phase insulator, and a method of assembling a stator assembly

A vehicle includes a power source, a motor, and a computing device. The power source provides electrical energy to the motor, and the motor generates rotational motion from the electrical energy received. The computing device is configured to estimate a temperature of the motor in real time based at least in part on a thermal model of the motor. The thermal model includes a plurality of nodes and at least one thermal resistance. Each node represents a region of the motor and each thermal resistance represents a heat transfer path between at least two of the nodes. A method includes solving one or more energy balance equations to determine a temperature change at each node and estimating the temperature of the motor in real time based at least in part on the temperature change at each node and at least one of the thermal resistances in the thermal model.

Motor temperature estimation based on thermal model

An oil-cooled motor/generator for an automotive powertrain located outside of the transmission is provided, such as a BAS motor/generator. The motor/generator may have a stator, a rotor circumscribed by the stator, and a motor shaft on which the rotor is mounted for rotation. A housing assembly may surround the stator and the rotor, with a bearing positioned between the housing assembly and the motor shaft. A flow control member may at least partially circumscribe the rotor axially adjacent the stator. A bearing retainer may be positioned axially adjacent the bearing. A rotor end ring may be axially adjacent the rotor. The housing assembly may have an inlet configured to receive cooling oil. The housing assembly, the flow control member, the bearing retainer and the rotor end ring may be configured to distribute the cooling oil from the inlet to cool the stator, the rotor and the bearing.

Oil cooled motor/generator for an automotive powertrain

A system for controlling a switch reluctance machine is provided. The system includes multiple phases located in the switch reluctance machine, each phase having multiple machine coils. Each machine coil is independently connected to a positive side switch circuit and a negative side switch circuit. Each positive side switch circuit is in electrical parallel connection with the other positive side switch circuits, and configured to control the flow of current through the machine coil to which it is connected. Similarly, the negative side switch circuits are connected in electrical parallel and configured to control the flow of current through the machine coil to which they are connected. The positive side and negative side switch circuits may be provided in a buck boost configuration or two half bridge configurations.

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Canton, MI, United States of America

Paul F Turnbull