Borgwarner Inc.

Ecomotors, Inc.

Ecomotors International

Tyler R Garrard

Christopher Meszaros

Will Robert Nielsen Hippen

Franz J Laimboeck

Peter Hofbauer

Frederick Michael Huscher

Diana D Brehob

Jeffrey Carter

Erwin Perry Ellwood, Iii

Christopher Joel Maurus

John P Kresse

Patrick James McCleer

Robert Merrion

Adrian Tusinean

Roger Budde

Will Robert Hippen

Will R Hippen

A rotating machine includes a machine housing defining a housing interior, a shaft disposed in the housing interior, with the shaft having a length and an axis extending along the length. The shaft is rotatable about the axis. The rotating machine also includes an impeller wheel disposed in the housing interior and coupled to and rotatable by the shaft, with the impeller wheel having an angular position with respect to the axis. The rotating machine further includes a backplate coupled to the machine housing and having a first side facing the impeller wheel, at least one target element coupled to and rotatable with the impeller wheel, a circuit board coupled to the first side of the backplate and facing the impeller wheel, and at least one sensor disposed on the circuit board for detecting the at least one target element to determine the angular position of the impeller wheel.

Rotating machine including an impeller wheel, and at least one target element and at least one sensor to determine angular position of the impeller wheel

An electric machine includes a rotor extending along an axis and a stator lamination stack radially spaced from the rotor. The stator lamination stack has circumferentially spaced teeth defining gaps therebetween. The electric machine also includes a coil winding disposed in the gaps between the circumferentially spaced teeth and a guard plate disposed at one of the first and second stator ends. The guard plate extends radially away from the axis and includes a plurality of teeth guards extending radially, with each of the teeth guards aligned with one of the teeth of the stator lamination stack to electrically insulate the coil winding from the teeth of the stator lamination stack. The plurality of teeth of the stator lamination stack extend radially inward toward the axis and the teeth guards of the guard plate extend radially inward toward the axis.

Electric machine

A rotating machine includes a shaft, a first impeller wheel, and a second impeller wheel. The rotating machine also includes a first seal assembly including a first carbon ring disposed about the shaft, with the first carbon ring having a first carbon surface. The first seal assembly also includes a first mating ring disposed about the shaft, with the first mating ring having a first mating surface facing and configured to contact the first carbon surface. The rotating machine additionally includes a second seal assembly including a second carbon ring disposed about the shaft, with the second carbon ring having a second carbon surface. The second seal assembly also includes a second mating ring disposed about the shaft, with the second mating ring having a second mating ring surface facing and configured to contact the second carbon surface.

Rotating machine and mating ring included therein

An electrically-assisted turbocharger includes a shaft extending along an axis, a compressor wheel, a turbine wheel, a housing, and an electric machine. The electric machine includes a rotor rotatably coupled to the shaft and a stator lamination stack radially spaced from the rotor. The stator lamination stack has circumferentially spaced teeth defining gaps therebetween. The electric machine also includes a coil winding disposed in the gaps between the circumferentially spaced teeth and a guard plate disposed at one of the first and second stator ends. The guard plate extends radially away from the axis and includes a plurality of teeth guards extending radially, with each of the teeth guards aligned with one of the teeth of the stator lamination stack to electrically insulate the coil winding from the teeth of the stator lamination stack.

Electric machine and electrically-assisted turbocharger including the same

A turbocharger includes a bearing housing containing a motor within an interior portion of the bearing housing. A liquid-cooled power module is secured to an exterior portion of a bearing housing. The power module contains electrical components that power and control speed of the motor, and has an enclosure that includes sealed first and second volumes separated by a common wall. The first volume is a liquid-cooled compartment for removing heat generated from the electrical components, and the second volume is a liquid-free compartment containing the electrical power components. The electrical power components are fixed to the common wall, which is formed of a heat conductive material, and which may include fins extending into the first volume to optimize heat transfer from the common wall into the liquid-cooled compartment. Finally, the liquid-cooled power module communicates with the motor directly through the bearing housing.

Liquid-cooled enclosure for turbocharger power module

A system and method is provided for controlling an electric machine rotatably coupled to a rotatable shaft of an electronically-controlled one of a turbocharger and an exhaust-driven turbo supercharger fluidly coupled to an exhaust duct of an internal combustion engine. An operating temperature of a component of the engine is determined or estimated an operating temperature of a component of the engine or coupled to the engine, which is compared to a threshold temperature. The electric machine is controlled to operate as a motor in response to the determined or estimated temperature of the component being below a threshold temperature.

System and method for controlling an electronically-controlled turbocharger

By relieving the shaft of an electronically-controlled turbocharger (ECT) in a central region of where a rotor of an electric machine couples with the shaft eases assembly of the electric machine onto the shaft. On either side of the relieved section, the fit between the shaft and the rotor may be a slip fit or an interference fit. Alternatively, the rotor is relieved in a central section. In some embodiments, the shaft is welded to the rotor. In yet other embodiments, the outside of the shaft and the inside of the rotor are threaded with a nut or a pin to secure the shaft to the rotor or the rotor itself has threads to engage with threads on the shaft. Such arrangements ease assembly and allow adjustment of dynamic characteristics of the rotor system.

Electric rotor fit onto a turbomachine shaft

An internal-combustion engine has an electronically-controlled one of a turbocharger and an exhaust-driven turbo supercharger coupled to an exhaust duct of the engine, and the engine is controlled during a shift event of a transmission coupled to an output shaft of the engine by determining a target engine speed at the end of the shift event, and controlling electrical energy supplied to an electric machine, rotatably coupled to a rotatable shaft that is rotatably coupled to the electronically-controlled turbocharger or exhaust-driven turbo supercharger, to control rotation of the rotatable shaft coupled to the turbocharger or exhaust-driven turbo supercharger to attain the target engine speed.

System and method for controlling an electronically-controlled turbocharger during a transmission autoshift event

A number of variations may include a product comprising: a rotor core comprising a body, wherein the body includes an inner surface and an outer surface, a first end cap which extends radially from a first end of the body and a second end cap which extends radially from a second end of the body, wherein the first end cap, the second end cap, and the outer surface define an annular cavity; at least one sleeve adjacent at least one of the first end cap or the second end cap; at least one magnet contained within the annular cavity; and at least one bearing operatively attached to the at least one sleeve.

Electric motor rotor with extended shoulders for bearings

It is common in electric machines to use the housing as a heat sink to remove energy from the electric machine. In some applications, however, the housing receives energy from a hot element. For example, in an electronically controlled turbocharger, the very hot turbine housing radiates and conducts energy to the electric machine housing exacerbating the heating within the electric machine. To reduce the heat transfer into the electric machine, a gap is provided between the stator and the housing outside the stator. In one alternative, the gap is filled with an insulating material. In another embodiment, the gap is an air gap with the stator located within the housing by circumferential rings or axial rods in corresponding grooves. In yet another embodiment, coolant is provided to the gap at the top and drained away at the bottom under the action of gravity.

Insulation in an electric machine

Performance of an electric motor can be improved if coolant is provided to the coils of the stator. An electric motor is disclosed that has a shaft onto which the rotor is secured. The motor has a stator that is mounted on bearings that are mounted on the shaft. The stator has a plurality of coils. A coolant guide is provided that fills voids between the groups of windings. The coolant guide has a plurality of fingers with the fingers arranged between adjacent pairs of coils. The coolant guide has internal passages to accept pressurized coolant and outlet holes to spray coolant onto the coils. In other embodiments, the fingers guide coolant to reach all coils under the force of gravity.

Cooling stator coils of an electric motor

A rotor of an electric machine is disclosed that resists expansion of the rotor components even at high rotational speed. The rotor includes first and second pluralities of laminations having slots to accept rotor bars. A support disk, also having slots, is placed between the laminations. The support disk, into which the rotor bars are slid, restrains the rotor bars from bending outwardly at high rotational speeds of the rotor. The rotor bars are further restrained at the ends by end rings, which have apertures into which ends of the rotor bars are placed. In some embodiments, containment rings are placed over axial extension of the end rings to prevent outward bowing at high speeds. In some embodiments, the rotor includes a stiffener sleeve to provide additional resistance to expansion during high rotational speeds.

Electric motor rotor

An electronically-controlled turbocharger (ECT) includes a rotor (of an electric motor) on the shaft of the turbomachine. There are a variety of embodiments for securing the rotor onto the shaft including, but not limited to: having a taper on both the shaft on the rotor and using a nut engaging with threads in the shaft to put the two tapers together; a press fit; splines and grooves also using a nut; and a shoulder on the shaft that the rotor abuts when a nut is engaged with threads on the shaft. To accommodate these retaining features, the diameter of the shaft is greater near the turbine end of the shaft. A first bearing installed on the shaft near the turbine end of the shaft has a larger inside diameter than a second bearing installed on the other side of the rotor.

Bearings for a turbomachine having an electric motor

Master and slave pullrods are disclosed in which a master pullrod is coupled to a journal of a crankshaft. The slave pullrod indirectly couples to the crankshaft by coupling to the master pullrod. Such a configuration allows two connecting rods to be coupled to the journal of the crankshaft inline with each other.

Growing community of inventors

Buellton, CA, United States of America

Tyler R Garrard