Gm Global Technolgoy Operations, Inc.

Xiaohui Du

Edward L Kaiser

Paul Buchholz

Chandra S Namuduri

Suresh Gopalakrishnan

Thomas W Nehl

Khwaja M Rahman

Shawn Harold Swales

Elizabeth I Wooden

Leonid Basin

Norman Schoenek

Min-Joong Kim

Alexandru Rajala

John Czubay

Robert T Dawsey

An electric machine includes a machine rotor circumscribed by a machine stator, and having a rotor shaft, rotor stack, and end cap which rotate about an axis. The end cap includes lobes equal in number to a number of pole pairs of the machine rotor. A position sensor assembly has a predetermined alignment with the machine rotor and stator. The sensor assembly includes a sensor rotor formed by the lobes and a sensor stator having a printed circuit board with conductive sine and cosine traces. Machine rotor rotation causes the sensor assembly to output an unmodulated sine and cosine signals to a controller, which then calculates a calibrated reference angle. A magnetic axis of an electrical phase of the machine is aligned with and bisects a peak of the sine trace. A direct axis of the machine rotor aligns with an edge of a lobe.

Electric machine with inductive position sensor assembly and method for assembling and aligning the same

A stator assembly includes a plurality of stator slots having multiple respective slot layers and a plurality of hairpins. The plurality of hairpins have a respective first leg positioned in one of the multiple respective slot layers and a respective second leg positioned in another of the multiple respective slot layers. A first set of n adjacent slots of the plurality of stator slots is configured to accommodate the plurality of hairpins carrying a current in a first phase, n being an integer. The plurality of hairpins is configured in respective conductor layers (L, L. . . ) having a plurality of respective turn locations defining n respective turn positions. The plurality of hairpins is configured to occupy the n respective turn positions an equal number of times such that the respective conductor layers (L, L. . . ) are electrically balanced.

Stator assembly with electrically balanced conductor layers

A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.

Distributed connection ring assembly for stator assembly

A connection support assembly for a stator assembly can be used to secure electrical jumper wires of an electric machine. The connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip.

Connection support assembly for stator assembly

A transmission includes a first motor/generator having a first rotor that is selectively rotatable about a first axis and a second motor/generator having a second rotor that is selectively rotatable about a second axis. A first planetary gearset and a second planetary gearset each has a respective first planetary member, a respective second planetary member, and a respective third planetary member. One of the members of the first planetary gearset is operatively connected to the first rotor to receive torque therefrom. One of the members of the second planetary gearset is operatively connected to the second rotor to receive torque therefrom.

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West Bloomfield, MI, United States of America

Xiaohui Du