Ford Global Technolgoies, LLC

Siraj Siddiqui

Hafiz Shafeek Khafagy

Ahmed Awadi

Hussam Makkiya

Eric Michael Rademacher

Cyrille Goldstein

William David Guarino

Michael Coury

Steven Anatole Frait

Mohannad Hakeem

Alexander O'Connor Gibson

Hank Kwong

Casey Taylor Dunn

Andrew Moen

Yuji Fujii

James C Rollinson

Giuseppe Domenico Suffredini

Ben Bulat

Joshua Norwood

Kenneth G Kraft

Jeremy Richard Ikerd

Peter Alexander Szpara

Garrett Tietz

An electric machine includes a stator core, interconnected hairpin windings, and a terminal. The interconnected hairpin windings are arranged between an inner diameter and an outer diameter of the core. The interconnected hairpin windings are arranged to form a plurality of electrical phases. The terminal is configured to connect a first of the plurality of electrical phases of the hairpin windings to a power source. The terminal has a first plate that is connected to a first pair of hairpins that are disposed along the outer diameter of the core. The terminal has a second plate that is connected to a second pair of hairpins that are disposed along the inner diameter of the core. The terminal has a bridge plate that extends between and connects the first plate to the second plate.

Vehicle and corresponding electric machine for a vehicle

A motor for an electric vehicle includes a motor housing for receiving a stator. A plurality of caps each have an outer rim and a washer portion defining a bolt receiving opening. The outer rim of each of the caps is press-fit into the receptacles in the motor housing. The caps are each attached to the stator by one of the bolts. The heads of the bolts clamp the cap to the stator to retain one end of the stator. The outer rim holds the cap in the motor housing while the washer portion flexes axially in response to thermal expansion and contraction of the motor housing. A method is disclosed for assembling the stator into the motor housing.

Stator free end retainer

An e-machine is disclosed that comprises a stator, a terminal block, and a plurality of interface conductors. The stator is disposed inside a housing in a wet portion of the housing that contains transmission fluid. The terminal block is attached to the housing and is electrically connected to an inverter system controller of the e-machine. The terminal block is disposed in a dry portion of the housing that does not contain transmission fluid. The plurality of interface conductors each include a hollow conductive body, a stator lead lug on a first end connected to windings of the stator, and a busbar on a second end connected to the terminal block. A seal is assembled at an intermediate location in a groove on an outer surface of the hollow conductive body. A plug is assembled inside the hollow conductive body.

Phase terminal interface

A terminal block includes a housing having sidewalls defining a cavity. One of the sidewalls defines a hole opening into the cavity. A conductor is supported in the cavity and is configured to electrically connect with an inverter. A terminal lug extends through the hole. The terminal lug includes a body having a first end disposed in the cavity and attached to the conductor and a second end external to the cavity and configured to attach to a terminal lead of an electric machine. The terminal lug further includes a support integrally formed with the body and disposed between the first and second ends to be located within the hole. A sealing member is attached to the support and is in sealing engagement with the hole to prevent fluid from entering the cavity.

Terminal block with sealing terminal lug

Systems and methods for improving operation of a vehicle that includes an engine that may be automatically stopped and started are presented. In one example, vehicle launch control parameters are adjusted responsive to a learned driving style. The approach may provide vehicle launches that are closer to driver expectations than vehicle launches that are based solely on accelerator pedal position.

Methods and systems for improving automatic engine stopping and starting

A vehicle transaxle includes a housing, an electric machine stator, a plurality of mounting plates, and a first set of fasteners. The housing has internal walls that define a cavity and an access opening to the cavity. The electric machine stator is disposed within the cavity between a first of the internal walls and the opening. The plurality of mounting plates secures a first longitudinal end of the stator to the housing proximate the opening. Each fastener of the first set of fasteners extends through one of the mounting plates, through the stator, and engages the first of the internal walls to secure a second longitudinal end of the stator to the first of the internal walls.

Hybrid/electric vehicle transmission

A vehicle transmission includes a housing, an electric machine stator, a support plate, and a plurality of fasteners. The housing has an internal rear wall and a side wall that define a cavity. The electric machine stator is disposed within the cavity. The support plate is disposed within the cavity. The support plate engages the internal side wall such that a press-fit engagement is formed between the support plate and the internal side wall. The electric machine is disposed between the support plate and the internal rear wall. The plurality of fasteners extends through the support plate, through the stator, and engages the rear internal wall to secure the stator to the housing.

A vehicle transmission includes a housing, an electric machine, a bracket, and a plurality of fasteners. The housing has internal rear and internal side walls that define a cavity. The electric machine stator and the bracket are disposed within the cavity. The bracket has a metallic inner ring and an elastomer outer ring. The elastomer outer ring engages the internal side wall. The electric machine stator is disposed between the bracket and the internal rear wall. The plurality of fasteners extends through the metallic inner ring, through the stator, and engages the rear internal wall to secure the stator to the housing.

Methods and systems are provided for enabling engine start/stop function in a vehicle with a detachable door. In one example, a method may include, adjusting an engine start/stop strategy responsive to a driver side door of the vehicle been detected to be absent. The adjustment to the start/stop strategy further may be modified based on a type of transmission system coupled to the vehicle.

Methods and systems for enabling engine start/stop function

Systems and methods for operating an engine that may be automatically stopped and started responsive to vehicle operating conditions are disclosed. In one example, the engine may be automatically started after it has been automatically stopped in response to a driver applying a brake pedal while the vehicle's transmission is engaged in park. The engine may be started to increase transmission pump pressure prior to engaging a gear to reduce vehicle launch time.

Automatic engine stopping and starting for a parked vehicle

A vehicle is provided. The vehicle may include an engine that is configured to auto-stop and auto-start. The system may also include a controller programmed to power an electrical actuator coupled to a steering mechanism to synchronize a drive angle of the vehicle and a steering wheel angle of the vehicle, in response to a parameter indicative of a likelihood of a wheel slip event exceeding a threshold and the steering-wheel angle being greater than a predetermined threshold.

Method and system for active steering for start-stop events

Systems and methods for operating a hybrid powertrain or driveline that includes an engine and an integrated starter/generator are described. In one example, the integrated starter/generator may crank the engine via a pinion gear during a first engine start. The integrated starter/generator may crank the engine via a belt during a second engine start.

Methods and system for starting an engine

A vehicle engine start/stop control method includes shifting an automatic transmission to a park or neutral position and auto-stopping the engine in response the automatic transmission being in the park or neutral position for a predetermined period of time that begins with a shift of the automatic transmission to the park or neutral position.

Vehicle and start/stop method for a vehicle engine

A vehicle start/stop method includes inhibiting auto-stopping an engine responsive to an engine auto-stop command, activating a transmission gear shifter, and a rotational speed of a steering wheel being less than a threshold; auto-stopping the engine responsive to the engine auto-stop command, activating the gear shifter, and the rotational speed being greater than the threshold; auto-starting the engine responsive to activating the gear shifter and the rotational speed being less than the threshold while the engine is auto-stopped; and inhibiting auto-starting the engine responsive to activating the gear shifter and the rotational speed being greater than the threshold while the engine is auto-stopped.

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LaSalle, Canada

Siraj Siddiqui