Ford Global Technolgoies, LLC

Singar Rathnam

Akash Changarankumarath Pradeepkumar

Michael W Degner

Franco Leonardi

Joel A Hetrick

Man Prakash Gupta

Devan James Anderson

Gary Thomas Martini

Christopher White

Steven White

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

An electric machine includes a stator core having an outer circumferential surface, an inner circumferential surface, and longitudinal slots recessed into the inner circumferential surface. Each of the slots has first and second radial walls, an outboard circumferential wall extending between the radial walls, an entrance portion having opposing first and second angled walls extending divergently away from the inner circumferential surface, a first shoulder connecting the first radial wall to the first angled wall, and a second shoulder connecting the second radial wall to the second angled wall. Windings are disposed in the slots. Slot liners are also disposed in the slots such that the windings are disposed in an interior of the slot liners. At least one of the slot liners has first and second flaps angled towards each other from opposing sidewalls of the slot liner, wherein the first and second flaps cooperate to define an inner varnish dam, and the first flap, the second flap, and the corresponding one of the slots cooperate to define an outer varnish dam.

Electric machine slot liner with enhanced varnish control

A method for applying varnish to a stator of an electric motor includes depositing varnish onto an outer laminate of the stator, accumulating the deposited varnish with a ridge on the outer laminate, and directing the accumulated varnish into a slot of the outer laminate with the ridge.

Laminate with varnish accumulation feature

An electric machine includes a stator core having a plurality of stacked laminations that are arranged in sets that each define a circumferentially extending slot through a thickness of the set. The sets are circumferentially rotated relative to each other in sequence such that each slot only partially overlaps with one or more adjacent slots to form a continuous helical cooling path around the stator core. Windings are supported on the stator core.

Electric machine with helical cooling path

A skewed rotor core assembly having a resin mold disposed in a plurality of longitudinal channels and a resin flow path is provided. The rotor core has a first and second magnet stack each defining a plurality of longitudinal channels. The plurality of longitudinal channels for the first stack are misaligned with the plurality of longitudinal channels for the second stack. Methods of making the same are also provided.

Magnet fixation by transfer resin molding in a skewed rotor stack segment application

A vehicle, electric machine, and method of manufacturing an electric machine include a stator having teeth extending from a yoke portion toward a rotor and defining slots between adjacent teeth with windings positioned within the slots, wherein the slots are coated with an electrically insulating material having an arcuate surface exiting the slots and extending at least partially over the teeth on at least one end face of the stator to form a winding guide for bending/positioning the windings. The winding guide may be formed by a molded epoxy that replaces insulating paper slot liners while providing a template for forming the hairpin bends of end windings.

Electrified vehicle having electric machine stator with embedded wire support overmold

A vehicle includes a battery, an electric machine, a thermistor, and a controller. The electric machine is configured to draw electrical power from the battery to propel the vehicle. The electric machine has a rotor and a stator. The stator has a core, interconnected hairpins, and a neutral bar. The core defines slots. The interconnected hairpin windings are arranged within the slots and are arranged to form a plurality of electrical phases. The neutral bar is connected to each of the electrical phases and defines an orifice. The thermistor is disposed within the orifice and is configured to sense a temperature of the electric machine. The controller is programmed to control a power output of the electric machine based on the temperature of the electric machine.

Electric machine for hybrid/electric vehicle

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

A vehicle includes a battery, an electric machine, a thermistor, and a controller. The electric machine is configured to draw electrical power from the battery to propel the vehicle. The electric machine has a rotor and a stator. The stator has a core defining a plurality of slots and windings arranged within the slots. The thermistor is disposed within a first of the slots between first and second axial ends of the core and is configured to measure a temperature of the electric machine. The controller is programmed to control a power output of the electric machine based on the temperature of the electric machine.

Growing community of inventors

Farmington Hills, MI, United States of America

Singar Rathnam