Delta Electronics, Inc.

Ballard Power Systems Corporation

Magna Powertrain of America, Inc.

Raymond Ong

Roy Inge Davis

Tod R Tesch

Ali Yousefzadi Nobakht

Timothy J Allen

Changhong Liu

In a stator stack an in-slot cooling system that includes: (a) two or more conductors of a hairpin winding provided within each slot in a first group of the slots, each conductor running axially across the stator stack and being at a different predetermined radial distance from an air gap; and (b) adjacent each slot of the first group of slots at the end that is in the vicinity of the air gap, a bridge portion of the laminating material that closes the slot and forms in the stator stack substantially adjacent the conductor having the shortest predetermined distance from the air gap an axial cooling channel that allows a coolant to flow therein without leakage therefrom.

In-slot cooling system for an electric machine with hairpin windings

An electric machine is provided that includes a stator defining a rotor chamber and a plurality of stator slots disposed circumferentially about the stator. The stator includes a plurality of phase groups each including a plurality of circuits. Each circuit includes a plurality of winding sets of a plurality of phase conductors connected in series for carrying an alternating current voltage. A rotor is disposed in the rotor chamber for rotating relative to the stator. The phase conductors are laid in a plurality of layers of the plurality of stator slots. Stator slots that include phase conductors carrying different phases are shared slots and stator slots that include phase conductors carrying the same phase are same slots. The circuits are arranged with balanced quantities of same slots and shared slots for reducing stator losses at high rotational speeds of the rotor relative to the stator.

Electric machine with six layer hairpin winding layout

A rotor assembly for use in an electric motor or generator where the mass of the rotor assembly is reduced with respect to conventional rotor assemblies. In addition, the rotor assembly is configured to be scalable to different sized electric motors. Within the rotor assembly, the rotor hub, the shaft, and the permanent magnets can independently or collectively be modified to have a reduced mass. In one aspect, a portion of the rotor hub adjacent to the shaft is configured with passages and spokes. In another aspect, an intermediate hub with lightening holes is provided between the shaft and the rotor hub. In yet another aspect, a large diameter hollow shaft replaces a portion of the rotor hub. In yet another aspect, the permanent magnets are configured to have an arc-shape, which permits the thickness of the magnets to be reduced without reducing the efficiency of the magnets.

Rotor assembly for a permanent magnet power electric machine

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Novi, MI, United States of America

Raymond Ong