Patent application number | Description | Published |
20100133945 | SEGMENTED STATOR CORE WINDING APPARATUS AND METHOD OF WINDING A SEGMENTED STATOR CORE - A winding apparatus for a segmented core having a plurality of stator teeth includes a mounting fixture configured to support select ones of the plurality of stator teeth. The mounting fixture is configured to rotate about an axis defined by each of the plurality of stator teeth. The winding apparatus also includes a plurality of stator tooth holding elements operatively connected to the mounting fixture. Each of the plurality of stator tooth holding elements are configured to retain a select one of the plurality of a stator teeth relative to the mounting fixture. The mounting fixture is selectively rotated about the axis of at least one of the plurality of teeth to apply wraps of wire to the one of the plurality of stator teeth while at the same time rotating others of the plurality of stator teeth that have already been wrapped with wire. | 06-03-2010 |
20100139896 | LIQUID COOLED STATOR TERMINAL BLOCK FOR AN ELECTRIC MACHINE - An electric machine including a housing having an outer surface and an inner surface that defines an interior portion. The housing includes a connection zone. A fluid circuit passes, at least in part, through the housing. The fluid circuit includes an inlet portion and an outlet portion. A stator assembly is arranged within the interior portion of the housing. The stator assembly includes at least one connector lead, and a terminal block extending through the housing. The terminal block includes a non-electrically conductive member that is sealed against the housing. The non-electrically conductive member includes a fluid cavity. At least one electrically conductive member is covered, at least in part, by the non-electrically conductive member. The fluid cavity guides a fluid along a portion of the at least one electrically conductive member to absorb heat. | 06-10-2010 |
20100253164 | STATOR ASSEMBLY INCLUDING A TERMINAL BLOCK FOR AN ELECTRIC MACHINE - An electric machine includes a housing having an outer surface and an inner surface that defines an interior portion. The housing also includes a connection zone having a first end portion that extends from the outer surface to a second end portion that is exposed to the interior portion. The connection zone includes a connection passage. A terminal block extends through the connection passage. The terminal block includes a non-electrically conductive member that is sealed against the connection passage, and an electrically conductive member covered by the non-electrically conductive member. The electrically conductive member includes a first end section that extends to a second end section through an intermediate section. The first end section has a first connection zone and the second end section has a second connection zone. The second connection zone is at an angle relative to the first connection zone. | 10-07-2010 |
20110072652 | METHOD OF WINDING A PLURALITY OF STATOR TEETH OF A SEGMENTED STATOR CORE - A winding apparatus includes a mounting fixture configured to support a plurality of stator teeth. The mounting fixture is configured to rotate about an axis defined by each of the plurality of stator teeth. A plurality of stator tooth holding elements are connected to the mounting fixture. The plurality of stator tooth holding elements retain a select one of the plurality of stator teeth relative to the mounting fixture. The mounting fixture is selectively rotated about the central axis of at least one of the plurality of teeth to apply wraps of wire to the one of the plurality of stator teeth while at the same time rotating others of the plurality of stator teeth. A wire guiding member is supported by the mounting fixture. The wire guiding member is configured and disposed to establish a desired length of wire between adjacent ones of the plurality of stator teeth. | 03-31-2011 |
20110114399 | TRACTION MOTOR AND PLANETARY GEAR ASSEMBLY - A vehicle includes a chassis, a traction member associated with the chassis, and a drive system associated with the chassis and the traction member comprising an electric traction motor, a planetary gear assembly coupled to the electric traction motor, the planetary gear assembly comprising an output member coupled to the traction member, wherein rotation of the output member provides a drive torque for the traction member. | 05-19-2011 |
20110115320 | REVERSIBLE PLANETARY GEAR ASSEMBLY - A planetary gear assembly includes a ring gear configured for connection to a rotor of an electric motor when in a first position and configured for connection to a housing of the electric motor when in a second position, a sun gear configured for connection to the housing when the ring gear is in the first position and configured for connection to the rotor when the ring gear is in the second position, and a plurality of planet gears configured to mesh with the ring gear and the sun gear. | 05-19-2011 |
20110115321 | ELECTRIC MOTOR AND PLANETARY GEAR ASSEMBLY - An electric motor assembly includes a stator defining a first interior space, a rotor positioned within the first interior space and configured for rotation relative to the stator, the rotor defining a second interior space, and a planetary gear assembly associated with the rotor and at least partially positioned within the second interior space. | 05-19-2011 |
20110148243 | STATOR CORE FOR AN ELECTRIC MACHINE - A stator includes a body portion having an outer portion and an inner portion that defines an interior region, a plurality of stator teeth members extending from the inner portion into the interior region, and at least one continuous conductor wound around select ones of the plurality of stator teeth members to form at least one pole. Each of the plurality of stator teeth members including a number of wraps of the at least one continuous conductor. The at least one continuous conductor including a number of twists that is fewer than the number of wraps. | 06-23-2011 |
20110273039 | Electric Machine Cooling System and Method - Embodiments of the invention provide an electric machine module including a module housing, which can at least partially define a machine cavity. In some embodiments, an electric machine can include a stator assembly and a rotor assembly and can be positioned in the machine cavity. In some embodiments, the module housing can include a coolant transport network, which can include at least one passage in fluid communication with at least one first annulus and at least one second annulus. In some embodiments, the first annulus can be substantially axially adjacent to an axial end of the stator assembly and the second annulus can be substantially axially adjacent to an axial end of the rotor assembly. In some embodiments, the annuli can include a plurality of annulus apertures. | 11-10-2011 |
20110273040 | Electric Machine Cooling System and Method - Some embodiments of the invention provide an electric machine including a rotor assembly. In some embodiments, the rotor assembly can include a plurality of rotor laminations including at least one first aperture positioned through a portion of the rotor laminations. In some embodiments, the first apertures can form at least one magnet channel when the rotor assembly is substantially assembled. At least one permanent magnet can be positioned in each of the magnet channels. In some embodiments, at least one second aperture can be positioned through a portion of some of the laminations, along a Q-axis, and adjacent to the at magnet channel. Also, the second apertures can be configured and arranged to form at least one first coolant channel when the rotor assembly is substantially assembled. | 11-10-2011 |
20110273047 | ROTOR LAMINATION ASSEMBLY - An electric machine includes a stator, and a rotor lamination assembly configured to rotate relative to the stator. The rotor assembly includes at least one lamination member that includes a body having an inner diametric edge that extends to an outer diametric edge, and at least one magnet receiving member. The at least one magnet receiving member is formed in the body and includes a first end that extends to a second end. The second end is spaced from the outer diametric edge to form a bridge portion. The at least one lamination member includes at least one stress concentration element positioned between the inner diametric edge and the outer diametric edge. The at least one stress concentration element is configured and disposed to reduce stress in the bridge portion. | 11-10-2011 |
20110273049 | ROTOR LAMINATION ASSEMBLY - An electric machine includes a stator, and a rotor lamination assembly configured and disposed to rotate relative to the stator. The rotor lamination assembly includes at least one lamination member including a body member having an outer diametric edge, and at least one magnet receiving member. The at least one magnet receiving member includes a first end that extends to a second end. The second end establishes an interruption zone in the outer diametric edge. | 11-10-2011 |
20110273121 | Electric Machine Component Temperature Monitoring - Embodiments of the invention provide an electric machine module including a module housing. In some embodiments, the module housing can at least partially define a machine cavity into which an electric machine can be positioned. The electric machine can include a rotor assembly comprising a plurality of laminations and a least one magnet positioned substantially within the rotor assembly. In some embodiments, at least one temperature sensor can be operatively coupled to, and in thermal communication with, a portion of the rotor assembly. The temperature sensor can be configured to sense a temperature of the rotor assembly. In some embodiments, at least one transmitter can be in communication with the temperature sensor and can transmit a signal from the temperature sensor to a receiver. In some embodiments, the receiver can be coupled to the module housing and in communication with a controller. | 11-10-2011 |
20110285222 | Sleeve Member for an Electric Machine - Embodiments of the invention provide an electric machine module including a module housing. The module housing can include a sleeve member coupled to at least one end cover and can define a machine cavity. In some embodiments, the sleeve member can include an inner perimeter and can be coupled to a stator assembly of an electric machine. In some embodiments, the electric machine can be positioned within the machine and at least partially enclosed by the module housing. In some embodiments, a coolant jacket can be defined by at least a portion of the sleeve member and at least a portion of the stator assembly. | 11-24-2011 |
20110285241 | ROTOR LAMINATION ASSEMBLY - An electric machine includes a rotor lamination assembly having a lamination member formed from a material having a first yield strength. The lamination member includes a first bridge portion having a first width, and a first bridge zone having a first thickness. The rotor lamination assembly also includes at least one lamination section having a second bridge zone having a second thickness. The second thickness is greater than the first thickness. The rotor lamination assembly further includes at least one lamination element formed from a second material having a second yield strength that is higher than the first yield strength, and at least one lamination component. The at least one lamination component includes a second bridge portion having a second width. The second width is greater than the first width. | 11-24-2011 |
20110298319 | Electric Machine Cooling System and Method - Embodiments of the invention provide an electric machine module including a housing defining a machine cavity. In some embodiments, an electric machine can be positioned within the machine cavity and include a rotor hub coupled to rotor laminations. The rotor hub can include first and second axial ends and the rotor laminations can include a recess. In some embodiments, the recesses can be aligned to define a portion of a plurality of coolant channels that can be in fluid communication with the machine cavity. In some embodiments, the rotor hub can include first and second rotor hub inlets in fluid communication with at least a portion of the coolant channels. The first and the second rotor hub inlets can be adjacent to the axial ends of the rotor hub. In some embodiments, the coolant channels are in fluid communication with the rotor hub inlets are not the same coolant channels. | 12-08-2011 |
20120013207 | STATOR SLEEVE FOR AN ELECTRIC MACHINE AND METHOD OF ESTABLISHING A COOLANT CAVITY ABOUT A STATOR FOR AN ELECTRIC MACHINE - An electric machine including a housing, and a stator mounted within the housing. The stator includes an outer perimetric surface and an inner perimetric surface. A rotor is mounted, at least in part, within the inner perimetric surface of the stator. The rotor is rotatable relative to the stator. A stator sleeve extends about the stator. The stator sleeve includes a first sleeve portion and a second sleeve portion. The first sleeve portion includes a first diametric edge that extends to a second diametric edge, and the second sleeve portion includes a first diametric edge section that extends to a second diametric edge section. The stator sleeve is configured and disposed to establish a coolant cavity about the outer perimetric surface of the stator. | 01-19-2012 |
20120013211 | ELECTRIC MOTOR HAVING A SELECTIVELY ADJUSTABLE BASE SPEED - An electric machine includes a stator mounted within the housing, and a transmission member mounted within the housing and surrounded at least in part by the stator. The transmission member includes a gear mechanism operatively coupled to an output shaft. The transmission mechanism is rotatable relative to the stator. | 01-19-2012 |
20120013225 | ELECTRIC MACHINE ALIGNMENT ADAPTER - An electric machine including a stator having a body provided with at least one alignment member, and a resolver positioned relative to the stator. The resolver includes at least one alignment element. An alignment adaptor is configured to receive each of the stator and the resolver. The alignment adaptor includes an alignment system that positions the alignment member and the alignment element to establish a desired alignment between the stator and the resolver. | 01-19-2012 |
20120032540 | Phase Lead Connection for Parallel Path Electric Machine - A stator for an electric machine includes a stator winding located at a stator core. The stator winding has one or more phases, each phase including a single unitary conductor having at least two conductor segments arranged in an electrically parallel relationship. A connection portion is formed in the single unitary conductor between a first conductor segment and a second conductor segment of the at least two conductor segments to connect the conductor to an electrical component. | 02-09-2012 |
20120068657 | ELECTRIC MACHINE SYSTEM INCLUDING AN ELECTRIC MACHINE HAVING SWITCHED STATOR WINDINGS - An electric machine system includes an electric motor. The electric motor includes a stator having a plurality of windings that define a number of phases. A plurality of switch members are operatively coupled to the plurality of windings. The plurality of switch members are no more than one less than three times the number of phases. A controller is operatively coupled to the plurality of switch members. The controller selectively changes a state of the plurality of switch members to establish one of a first electrical connection configuration of the plurality of windings and a second electrical connection configuration of the plurality of windings. | 03-22-2012 |
20120112568 | COOLING SYSTEM FOR AN ELECTRIC MACHINE SYSTEM INCLUDING AN ALTERNATING CURRENT (AC) ELECTRIC MACHINE HAVING AN INTEGRATED SWITCH ASSEMBLY - An electric machine system includes an alternating current (AC) electric machine. The AC machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. A direct current (DC) power source is electrically connected to the stator through the switch assembly. A cooling system is fluidly connected to the AC electric machine. The cooling system directs a flow of coolant onto the switch assembly in the switch portion of the machine housing, and onto at least one of the stator and the rotor in the machine portion of the machine housing. | 05-10-2012 |
20120112573 | ELECTRIC MACHINE SYSTEM INCLUDING AN ALTERNATING CURRENT (AC) ELECTRIC MACHINE HAVING AN EXPANDABLE COOLANT MANIFOLD - An electric machine system including an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing, and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes a switch module having a switch member. The switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A cooling system that includes an expandable coolant manifold is arranged in the switch portion of the machine housing. The expandable coolant manifold is fluidly connected to the switch module. | 05-10-2012 |
20120112576 | INVERTER FOR AN ELECTRIC MACHINE - An electric machine system including an alternating current (AC) electric machine having a machine housing, and a plurality of switch members arranged within a switch housing. The plurality of switch members are electrically connected to the AC electric machine. A direct current (DC) power source is electrically connected to the plurality of switch members. The DC power source generates a DC current. A controller is arranged within a control housing that is remote from the switch housing. The controller is electrically connected to the plurality of switch members and is configured and disposed to selectively activate select ones of the plurality of switch members in order to convert the DC current between the DC power source and an alternating current (AC) to operate the AC electric machine. | 05-10-2012 |
20120112608 | ELECTRIC MACHINE HAVING AN INTEGRATED INVERTER - An electric machine system includes an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion, a rotor rotatably mounted relative to the stator, and a plurality of switch members are arranged within the switch portion. The plurality of switch members are electrically connected to the stator. A direct current power source is electrically connected to the plurality of switch members. A controller is arranged within a controller housing and electrically connected to the plurality of switch members. The controller housing is distinct from and remotely mounted relative to the AC electric machine. The controller is configured and disposed to activate select ones of the plurality of switch member to convert DC current between the DC power source and an AC current to operate the AC electric machine. | 05-10-2012 |
20120112680 | ELECTRIC MACHINE SYSTEM INCLUDING AN ALTERNATING ELECTRIC CURRENT (AC) ELECTRIC MACHINE HAVING A SWITCH MODULE - An electric machine system includes an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing and a rotor is rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes at least one switch module having at least one switch member. The at least one switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A direct current (DC) power source is electrically connected to the stator through the switch assembly. A controller is operatively connected to the switch assembly. | 05-10-2012 |
20120126660 | ROTOR LAMINATION COMPRESSION SLEEVE FOR AN ELECTRIC MACHINE - An electric machine including a stator, and a rotor lamination assembly configured and disposed to rotate relative to the stator. The rotor lamination assembly includes a plurality of laminations that define an outer diametric surface. A rotor lamination compression sleeve extends about the outer diametric surface of the rotor lamination assembly. The rotor lamination compression sleeve exerts a compressive radial force on the rotor lamination assembly. The rotor lamination compression sleeve is configured and disposed to expand when subjected to a centrifugal force while still maintaining a compressive radial force. | 05-24-2012 |
20120181882 | ELECTRIC MACHINE HAVING AN INTEGRATED ROTOR TEMPERATURE SENSOR - An electric machine includes a housing, a stator mounted within the housing, and a rotor rotatably mounted within the housing relative to the stator. The rotor includes a rotor lamination assembly having a plurality of laminations. A temperature sensor is arranged within the housing. The temperature sensor includes a sensing surface configured and disposed to detect a temperature of the rotor. | 07-19-2012 |
20120181883 | ELECTRIC MACHINE WITH INTEGRATED COOLANT TEMPERATURE SENSOR - An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a coolant system fluidly connected to the housing. The coolant system delivers a flow of coolant through the housing. A coolant temperature sensor is arranged within the housing and exposed to the flow of coolant. The coolant temperature sensor configured and disposed to detect a temperature of the coolant in the housing. | 07-19-2012 |
20120181884 | ELECTRIC MACHINE HAVING AN INTEGRATED COOLANT LEVEL SENSOR - An electric machine includes a housing having a coolant collection area, a stator mounted within the housing, a rotor assembly rotatably mounted within the housing relative to the stator, and a coolant level sensor arranged at the coolant collection area. The coolant level sensor includes a sensing surface configured and disposed to detect a level of coolant collected in the coolant collection area. | 07-19-2012 |
20120181965 | ELECTRIC MACHINE HAVING AN INTEGRATED VIBRATION SENSOR - An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a vibration sensor arranged within the housing. The vibration sensor includes a sensing member configured and disposed to detect vibrations of the electric machine. | 07-19-2012 |
20120181967 | PERMANENT MAGNET ELECTRIC MACHINE HAVING AN INTEGRATED MAGNETIC FLUX SENSOR - A permanent magnet electric machine that includes a housing, a stator mounted within the housing, a rotor assembly, a plurality of permanent magnets mounted within the rotor assembly, and a magnetic flux sensor arranged within the housing. The magnetic flux sensor includes a sensing surface configured and disposed to detect magnetic flux leaking from the rotor assembly. | 07-19-2012 |
20120183247 | ELECTRIC MACHINE WITH INTEGRATED BEARING TEMPERATURE SENSOR - An electric machine includes a housing and a shaft arranged within the housing. The shaft includes a first end portion and a second end portion. At least one bearing is mounted at one of the first end portion of the shaft and the second end portion of the shaft. A stator is mounted within the housing and a rotor is mounted relative to the shaft and rotatable relative to the stator. A temperature sensor is integrated into the housing at the at least one bearing. The temperature sensor includes a sensing element that detects a temperature of the at least one bearing. | 07-19-2012 |
20120186869 | METHOD OF BLOCKING ELECTRO-MAGNETIC INTERFERENCE (EMI) IN AN ELECTRIC MACHINE AND APPARATUS - A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure. | 07-26-2012 |
20120194012 | Electric Machine Cooling System and Method - Some embodiments of the invention provide an electric machine module comprising an electric machine including a rotor assembly and a rotor hub. In some embodiments, the module can include a output shaft substantially circumscribed by the rotor hub and including at least one channel and at least one coolant outlet. A cavity can be formed by at least the output shaft and the rotor hub. Some embodiments can include a sleeve substantially circumscribing a portion of the output shaft with at least a portion of the sleeve positioned substantially within the cavity between the output shaft and the rotor hub. The sleeve can include at least one groove. | 08-02-2012 |
20120235534 | CONDUCTOR INSULATION ARRANGEMENT FOR ELECTRIC MACHINE WINDING - An electric machine includes a core with a plurality of slots. A plurality of conductors are positioned in each of the plurality slots, with each slot including an equal number of conductors. At least one slot liner is also positioned in each of the plurality of slots. Each slot liner provides at least one slot liner channel in the associated slot, and each of the plurality of conductors extend through one of the slot liner channels. Differing numbers of slot liner channels are provided in the plurality of slots. Accordingly, all slots have the same number of conductors positioned therein, but all slots do not have the same number of slot liner channels. | 09-20-2012 |
20120238142 | Electric Machine with Fully Enclosed In-Slot Conductors - An electric machine includes a core with a plurality of slots. A plurality of electric conductors are positioned in the slots. Each of the plurality of electric conductors includes a U-turn portion extending between two in-slot portions and connection ends extending from the in-slot portions. The connection ends are positioned on an opposite end of the core from the U-turn portions. A plurality of insulation tubes are positioned in the plurality of slots. The in-slot portions of the electric conductors extend through the insulation tubes. | 09-20-2012 |
20120262013 | Electric Machine Module Cooling System and Method - Embodiments of the invention provide an electric machine module. The module can include a module housing, which can comprise a sleeve member. In some embodiments, the sleeve member can include an inner wall and an outer wall, and the module housing can at least partially define a machine cavity. In some embodiments, a coolant jacket can be positioned substantially between a portion of the inner wall and a portion of the outer wall. Also, in some embodiments, at least one boss can be positioned in the sleeve member so that the at least one boss can be substantially integral with both the inner wall and the outer wall, and can extend through a portion of the coolant jacket. | 10-18-2012 |
20120274156 | ELECTRIC MACHINE MODULE INSULATION SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots, a weld end, and an insertion end. In some embodiments, conductors can be positioned in the slots so that portions of the conductors extend from the weld end and the insertion end. An insulation member including recesses can be coupled to at least a portion of the conductors that extend from the weld end of the stator assembly. | 11-01-2012 |
20120286596 | Cooling Combinations for Electric Machines - Some embodiments of the invention provide an electric machine module comprising a housing including a sleeve member and at least one end cap. In some embodiments, the sleeve member can include a first coolant jacket and a second coolant jacket. Also, in some embodiments, the end cap can include an end cap coolant jacket. Also, some embodiments provide an electric machine including stator end turns, housing at least partially enclosing the electric machine, and an end cap coolant jacket positioned substantially axially outward relative to at least one of the stator end turns. | 11-15-2012 |
20120305226 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module. The module can include a housing that can define a machine cavity. The housing can include a coolant jacket that contains a first coolant. A coolant sump can be in fluid communication with the machine cavity and can contain a second coolant that is different than the first coolant. The coolant sump can be in thermal communication with the coolant jacket. An electric machine can be positioned within the machine cavity. The electric machine can include a stator assembly, a rotor assembly, and a shaft. The module can also include at least one coolant channel, at least one shaft channel, and at least one rotor channel. | 12-06-2012 |
20130015728 | Electric Machine Module Cooling System and MethodAANM Chamberlin; Bradley D.AACI PendletonAAST INAACO USAAGP Chamberlin; Bradley D. Pendleton IN USAANM Ramey; James J.AACI FortvilleAAST INAACO USAAGP Ramey; James J. Fortville IN USAANM Creviston; Alex S.AACI MuncieAAST INAACO USAAGP Creviston; Alex S. Muncie IN US - Embodiments of the invention provide an electric machine module comprising a module housing. In some embodiments, the module housing can include a sleeve member and at least one end cap. Also, an inner wall of the module housing can at least partially define a machine cavity. In some embodiments a coolant jacket can be positioned within a portion of the sleeve member. Further, in some embodiments, at least one partition can be positioned substantially within the coolant jacket. The partition can be dimensioned to at least partially seal a first region of the coolant jacket from a second region of the cooling jacket. | 01-17-2013 |
20130015740 | Rotor Assembly for an Electric MachineAANM Chamberlin; Bradley D.AACI PendletonAAST INAACO USAAGP Chamberlin; Bradley D. Pendleton IN USAANM Ramey; James J.AACI FortvilleAAST INAACO USAAGP Ramey; James J. Fortville IN US - Some embodiments of the invention include a rotor assembly for an electric machine, including a rotor hub module. In some embodiments, the rotor hub module can include a body comprising a first and second group of apertures, an output shaft through a generally radially central portion of the body, and a support region along a generally radially outward portion of the body. In some embodiments a plurality of ribs can radially extend from a region of the body adjacent to the output shaft aperture to a region of the body adjacent to the support region. In some embodiments a plurality of rotor laminations can be operatively coupled to a portion of an outer diameter of the support region. | 01-17-2013 |
20130038150 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. The housing can include a first axial end, a coolant jacket, and a plurality of coolant passages. In some embodiments, the coolant passages fluidly connect to the coolant jacket via at least one coolant aperture disposed through the housing. The housing can include a first guide positioned adjacent to the first axial end and extending into the machine cavity. The first guide is positioned so that a portion of the first guide is substantially adjacent to a portion of the rotor assembly. In some embodiments, the first guide is configured and arranged to guide a coolant toward the rotor assembly. | 02-14-2013 |
20130049496 | Electric Machine Module Cooling System and Method - Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, an electric machine can be positioned within the machine cavity. In some embodiments, the electric machine can include a stator assembly including potted stator end turns. An end turn member can be positioned within the machine cavity and can include a radially inward flange and a radially outward flange axially extending from a central region. The end turn member is configured and arranged so that the flanges are substantially adjacent the stator end turns. The end turn member can include at least one second member aperture disposed through a portion of the central region. | 02-28-2013 |
20130061457 | METHOD OF FORMING A ROTOR LAMINATION ASSEMBLY - A method of forming a rotor lamination assembly for an electric machine includes aligning a plurality of laminations to form a rotor lamination assembly. The rotor lamination assembly includes an outer diametric surface. The method also includes mounting a rotor lamination compression sleeve to the outer diametric surface of the rotor lamination assembly. The rotor lamination compression sleeve radially compresses the plurality of laminations. | 03-14-2013 |
20130062974 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, a coolant jacket can be at least partially positioned within the housing. In some embodiments, a plurality of coolant apertures can be disposed through at least a portion of the housing to fluidly connect the coolant jacket and the machine cavity. The coolant apertures can comprise a first group configured and arranged to direct a first volume from the coolant jacket. The coolant apertures can comprise a second group configured and arranged to direct a second volume from the coolant jacket. In some embodiments, the first volume can be greater than the second volume. | 03-14-2013 |
20130069455 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, a stator assembly can be positioned within the machine cavity. In some embodiments a transfer member can substantially contact at least a portion of the stator end turns. The transfer member can be in thermal communication with some of the stator end turns and a portion of the housing. In some embodiments, the transfer member can include a substantially non-liquid first element and a substantially liquid second element. | 03-21-2013 |
20130076166 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module. The module can include a housing that can define a machine cavity. The sleeve member can include a first and a second axial end. The sleeve member can further include a first coolant jacket and a first seal element coupled to the sleeve member substantially adjacent to the first axial end to substantially seal at least a portion of the first coolant jacket. The sleeve member can include a second coolant jacket and a second seal element coupled to the sleeve member substantially adjacent to the second axial end to substantially seal at least a portion of the second coolant jacket. The module can include a stator assembly positioned within the machine cavity so that portions of the first and second coolant jackets substantially circumscribe portions of the stator assembly. | 03-28-2013 |
20130099617 | ELECTRIC MACHINE WITH MAGNET HOLDER - An electric machine having a rotor with an axially extending magnet slot. A magnetic material is mounted in a magnet holder to form a magnet holder assembly which is installed in the magnet slot of the rotor. In some embodiments, the magnet holder assembly substantially fills the entire slot volume. In other embodiments, the magnet holder assembly defines a greater thickness of dielectric material between the magnetic material and the major side of the slot nearest the stator than between the magnetic material and the opposite side of the slot. In still other embodiments, a plurality of axially abutting magnet holder assemblies are installed in the magnet slot. In yet other embodiments, the magnet holder comprises two materials with different durometer values wherein one of the materials is resiliently, compressibly engaged with the slot to secure the magnet holder assembly therein. A method of manufacture is also disclosed. | 04-25-2013 |
20130127269 | METHOD OF OPERATING AN ELECTRIC MACHINE HAVING AN INTEGRATED COOLANT LEVEL SENSOR - A method of operating an electric machine includes flowing a coolant into an interior portion of a housing of the electric machine, and sensing a level of coolant in a coolant collection area within the interior portion with a coolant level sensor arranged at the housing. | 05-23-2013 |
20130127288 | ELECTRIC MACHINE WITH INSULATOR SPACER - A stator assembly for an electric machine including a stator core supporting a plurality of electrical conductors. A plurality of elongated insulator spacers is interwoven between the conductors proximate connection ends thereof in axially spaced relation to the stator core. | 05-23-2013 |
20130162071 | ELECTRIC MACHINE WITH ENCAPSULATED END TURNS - An electric machine having a rotor and a stator. The stator includes an electrically conductive wire forming a stator winding. The stator winding forms a first plurality of end turns projecting axially beyond an axial end of the stator core. Each of the wire segments forming the first plurality of end turns has a discrete electrically insulative outer layer. A heat transmissive material having a thermal conductivity of at least about 50 W•m | 06-27-2013 |
20130169098 | MULTI-GRADE MAGNET FOR AN ELECTRIC MACHINE - Apparatus and methods for improved performance of electric machines, including internal permanent magnet electric machines. In some embodiments there are multiple pairs of permanent magnets. Each magnet is fabricated from a pair of materials, one of the materials being selected to have improved high temperature magnetic characteristics, and the second material, in some embodiments, being selected for having improved magnet characteristics at lower temperatures even if with lesser magnetic characteristics at the higher temperatures than the other material. | 07-04-2013 |
20130175853 | HOUSING ASSEMBLY WITH REED SWITCH AND MAGNET - An electric machine and vehicular subsystem, apparatus includes a connection disposed within a housing and connecting a high voltage line with the electric machine. A controller controls the coupling of a power source to the high voltage line. A reed switch is positioned within the housing proximate the high voltage line connection. A member is removably mounted on the housing and structured so that removal of the member is necessary to gain access to the high voltage line connection, the member having a magnet. At least one low voltage communication line extends from the reed switch to the controller. Removal of the member from the housing opens the reed switch. Mounting of the member to the housing closes the reed switch. The controller terminates the providing of electric power to the high voltage line when the member is removed from the housing. | 07-11-2013 |
20130175854 | SAFETY COVER WITH INTEGRATED MAGNET FOR REED SWITCH - An electric power source supplies electrical power to an electric machine of a vehicle via a plurality of high voltage lines. A plurality of connections are disposed within a housing for connecting the high voltage lines. A cover member encloses a hidden magnet and is removably secured to the housing so that removal is necessary to obtain access to the high voltage lines. A reed switch is mounted proximate the cover member, when secured, within a magnetic field of the magnet, whereby the reed switch is closed when the cover member is secured and is open when the cover member is removed. A controller is controllably coupled to the power source via a control connector and circuit of the electric machine. Such circuit extends from the reed switch to the controller, where the controller causes the electric power source to stop supplying electrical power when the cover member is removed. | 07-11-2013 |
20130193811 | INDUCTION ROTOR END RING SUPPORT DEVICE - An induction rotor includes a rotor core having an axial end surface, an end ring proximate the axial end surface that provides electrical communication between respective ends of conductor bars extending through the rotor core, and an end ring support structure that includes a ring member at least partially embedded in the end ring. An end ring support structure may have at least one axially extending member coupled with the ring member, such axially extending member projecting axially inwardly of the axial end surface and engaging the rotor core. An end ring support structure may include a ring member having an axially extending portion embedded in the end ring between radially inner and outer surfaces of the end ring whereby the end ring includes an outer portion, radially outwardly of the axially extending portion, and an inner portion disposed radially inwardly of the axially extending portion of the ring member. | 08-01-2013 |
20130207492 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots. In some embodiments, conductors can be positioned in the slots. The conductors include a turn portion extending between leg portions. The leg portions include an angled portion and a connection portion. The conductors are disposed within the plurality of slots so that the angled and connection portions extend from the stator core at a first axial side. At least one insulation member can be disposed over at least some of the leg portions so that the connection portions are at least partially uncovered. | 08-15-2013 |
20130221773 | ELECTRIC MACHINE MODULE - Embodiments of the invention provide an electric machine module including a stator assembly. The stator assembly includes a stator core comprising a plurality of slots. Conductors can be at least partially disposed within the slots. The conductors can include leg portions and can be positioned so that at least some of the slots include a first leg portion, a second leg portion, a third leg portion, and a fourth leg portion. The stator assembly can include first clearance apertures defined by between circumferentially adjacent first leg portions, second clearance apertures that can be defined between circumferentially adjacent second leg portions, third clearance apertures that can be defined between circumferentially adjacent third leg portions, and fourth clearance apertures that can be defined between circumferentially adjacent fourth leg portions. In some embodiments, the second and third clearance apertures can comprise a greater circumferential size relative to the first and fourth clearance apertures. | 08-29-2013 |
20130237361 | REVERSIBLE PLANETARY GEAR ASSEMBLY - A planetary gear assembly includes a ring gear configured for connection to a rotor of an electric motor when in a first position and configured for connection to a housing of the electric motor when in a second position, a sun gear configured for connection to the housing when the ring gear is in the first position and configured for connection to the rotor when the ring gear is in the second position, and a plurality of planet gears configured to mesh with the ring gear and the sun gear. | 09-12-2013 |
20130257190 | IPM MACHINE WITH THERMALLY CONDUCTIVE COMPOUND - A synchronous electric machine includes a rotor having a substantially cylindrical core with axially extending slots, a plurality of permanent magnets configured as sets defining alternating poles in a circumferential direction, the permanent magnets being located in respective ones of the slots, and a thermally conductive material contiguous with the permanent magnets and the core for transferring heat of the permanent magnets, the material having a thermal conductivity of greater than 0.3 watts per (meter * Kelvin). | 10-03-2013 |
20130264034 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Some embodiments of the invention provide an electric machine module including a housing that defines a machine cavity. A coolant jacket can be at least partially defined by the housing. In some embodiments, a plurality of coolant apertures can be disposed through portions of the housing to fluidly connect the coolant jacket and the machine cavity. One or more solenoid assemblies can be at least partially supported by the housing and positioned substantially adjacent to at least some of the coolant apertures. The solenoid assemblies can be configured to regulate passage of a coolant into the machine cavity from the coolant jacket. | 10-10-2013 |
20130293040 | ELECTRIC MACHINE MODULE COOLING SYSTEM AND METHOD - Embodiments of the invention provide an electric machine module. The module can include a housing that can define a machine cavity. The housing can include a sleeve member that can include a first axial sleeve member comprising a first flange, a second flange, and first recess at least partially defined between the first flange and the second flange. The sleeve member can also include a second axial sleeve member comprising a third flange, a fourth flange, and a second recess at least partially defined between the first flange and the second flange. The first axial sleeve member can be coupled to the second axial sleeve member to form the sleeve member and so that the first recess and the second recess form a coolant jacket. An electric machine can be positioned within the machine cavity so that it is substantially circumscribed by a portion of the coolant jacket. | 11-07-2013 |
20130307362 | CONDUCTOR SPACER CLIP - An assembly of an electric machine includes a plurality of conductor segments each having a turn portion, and a plurality of clips each having a channel member and a bend member, the channel members being attached to respective ones of the conductor segments and thereby holding the respective bend members against the respective turn portions. The attached clips electrically insulate and space adjacent ones of the conductor segments. The bend members prevent adjacent ones of the conductor segments from contacting one another. | 11-21-2013 |
20140014390 | BUSS BAR ASSEMBLY HAVING AXIALLY STACKED BUSS BAR PLATES - A buss bar assembly for a multiphase electrical machine, including a substantially annular dielectric housing having a central axis, a plurality of dielectric phase bar mounting members located within the housing, and a plurality of electrically conductive phase bars. The phase bars are disposed in the housing and substantially surround the central axis. Each phase bar has opposing, substantially planar axial sides and is in engagement with at least one phase bar mounting member. An axial side of each phase bar is in superposition with an axial side of another phase bar whereby the plurality of phase bars are axially stacked along the central axis. The phase bars have mutually spaced positions relative to each other in directions along the central axis, these positions defined by the phase bar mounting members whereby the phase bars are electrically isolated from each other within the housing. | 01-16-2014 |
20140015349 | INTERLOCKING COIL ISOLATORS FOR RESIN RETENTION IN A SEGMENTED STATOR ASSEMBLY - A stator assembly of an electric machine includes a segmented lamination stack formed of an interconnected series of lamination segment stacks, and a plurality of coil isolators each having a conductor wound thereon, each having a radially outward interlock at each circumferential end thereof, and each having a radially inward interlock at each circumferential end thereof, the coil isolators being serially connected by the interlocks to form a cavity closed down the axial length of the stator assembly, the coil isolators electrically insulating the lamination segments from the conductors. | 01-16-2014 |
20140015356 | SEGMENTED ELECTRIC MACHINE CORE SECURED WITH BELT AND METHOD OF MANUFACTURE - An electric machine having a segmented core wherein the core includes a plurality of core segments. The segments are secured together with a belt member that substantially encircles the core segments but does not extend the full axial length of the segments. In some embodiments, the individual segments include a recess on their outer radial surface in which the belt member is positioned. A method of assembling an electric machine having a segmented core is also disclosed. Coils are wound about the poles of a plurality of segments. After forming the coils on the segments, the segments are joined together with a belt member wherein the belt member does not extend the full axial length of the core segments and is positioned between the two axial ends of the core assembly. | 01-16-2014 |
20140015358 | INTEGRATED PHASE CONNECTION ISOLATOR WITH INDIVIDUAL PHASE ISOLATOR - A stator assembly includes a coil isolator having a first flange, a phase separator, and a living hinge connecting the first flange and the phase separator, the coil isolator structured for enclosing a stator lamination stack and for winding a coil thereon in electrical isolation from the stack, the phase separator being radially closeable for enclosing a portion of the coil within the coil isolator. A method of forming a stator includes placing an isolator onto a lamination stack segment, winding a coil onto the isolator, folding a phase separator of the isolator to enclose a portion of the coil, and placing a plurality of bus bars onto the phase separator in physical partition from one another. A method of insulating a phase bus from a stator coil includes forming a coil insulator having a bobbin, a phase separator, and a living hinge coupling the bobbin to the phase separator. | 01-16-2014 |
20140015359 | BUSS BAR ASSEMBLY HAVING PRINTED BUSS BAR PLATES - A buss bar assembly for a multiphase electric machine. The buss bar assembly includes a substantially annular dielectric housing having a central axis. A plurality of dielectric mounting members is located within the housing. A buss bar plate assembly is disposed in the housing, and in engagement with the mounting members. The buss bar plate assembly includes a substantially planar dielectric substrate that has opposing, substantially planar axial sides, and substantially surrounds the central axis. The buss bar plate assembly also includes a plurality of electrically conductive phase bars applied to at least one of the opposing substrate sides. Each phase bar is for electrical connection to a different one of multiple electrical phases and substantially surrounds the central axis, with the phase bars being electrically isolated from each other within the housing. | 01-16-2014 |
20140021811 | PERMANENT MAGNET (PM) ELECTRIC MACHINE INCLUDING PERMANENT MAGNETS PROVIDED WITH A SACRIFICAL COATING HAVING A THERMAL INTERFACE MATERIAL (TIM) - A permanent magnet electric machine including a housing, a stator mounted within the housing, and a rotor assembly rotatably mounted within the housing relative to the stator. The rotor assembly includes a plurality of laminations. Each of the plurality of laminations includes a plurality of slots and one or more permanent magnets mounted within respective ones of the plurality of slots. Each of the plurality of permanent magnets includes a sacrificial coating formed from a thermal interface material (TIM). | 01-23-2014 |
20140028139 | PERMANENT MAGNET ROTOR WITH RESIN-COVERED MAGNET AND LAMINATION FOR THERMAL CONTROL - A method of forming a rotor includes placing a plurality of laminations into a stack having a plurality of longitudinally extending magnet slots, placing a plurality of permanent magnets into ones of the magnet slots, and injecting a low viscosity epoxy resin into the lamination stack, thereby substantially filling the magnet slots with a portion of the epoxy resin having a thermal conductivity greater than 0.3 Watts/(meter*degree Kelvin) and substantially filling axial spaces between adjacent ones of the laminations with a portion of the epoxy resin having a thermal conductivity less than that of the epoxy resin in the magnet spaces. | 01-30-2014 |
20140033514 | ELECTRIC MACHINE WITH SINGLE OR DUAL-SHAPE WINDING CONFIGURATION AND METHOD - A method of making a first stator winding and a second stator winding comprises forming an open winding arrangement on a first stator core, the open winding arrangement including conductor segments positioned in stator slots with at least four layers of conductor segments in each slot, the open winding arrangement further comprising a plurality of leads to a plurality of the conductor segments. The method further comprises forming the open winding arrangement on a second stator core. In addition, the method comprises closing the open winding arrangement on the first stator core by connecting the plurality of leads with first additional conductors to form a three phase winding in a single-shape configuration. Furthermore, the method comprises closing the open winding arrangement on the second stator core by connecting the plurality of leads with second additional conductors to form a three phase winding in a multi-shape configuration. | 02-06-2014 |
20140042840 | PERMANENT MAGNET (PM) ELECTRIC MACHINE INCLUDING PERMANENT MAGNETS PROVIDED WITH A THERMAL INTERFACE MATERIAL (TIM) BETWEEN ADJACENT PERMANENT MAGNETS - A permanent magnet electric machine includes a housing, a stator mounted within the housing, and a rotor assembly rotatably mounted within the housing relative to the stator. The rotor assembly includes a rotor body having a plurality of rotor laminations. A plurality of permanent magnets having axial end portions is mounted to the rotor body. An amount of thermal interface material (TIM) is arranged between the axial end portions of adjacent ones of the plurality of permanent magnets. | 02-13-2014 |
20140054999 | METHOD OF MANUFACTURING AN ELECTRIC MACHINE WITH SEGMENTED PERMANENT MAGNETS - A method for manufacturing a magnet stack for placement in a core member of a permanent magnet electric machine includes providing a plurality of magnet segments, each of the plurality of magnet segments including opposing axial faces having a first surface finish. The method further includes assembling the plurality of first magnet segments into a magnet stack, the magnet stack including a first end with a first axial face of a first magnet segment and an opposing second end with a second axial face of a second magnet segment. Additionally, the method includes finishing the opposing ends of the magnet stack such that the first axial face and the second axial face have a second surface finish that different than the first surface finish. | 02-27-2014 |
20140070636 | ELECTRO-DYNAMIC MACHINE - An electro-dynamic machine is provided and includes stator assembly end turns and a coolant chargeable bladder disposable to contact the end turns. | 03-13-2014 |
20140111050 | IPM ROTOR MAGNET SLOT GEOMETRY FOR IMPROVED HEAT TRANSFER - A rotor includes a stack of metal laminations each having a plurality of magnet slots, corresponding magnet slots of the laminations being substantially aligned with one another and thereby forming longitudinal channels in the rotor, selected ones of the magnet slots having at least one feature protruding from at least one long side thereof. The rotor also includes a plurality of magnets each having a pair of long sides in cross-section, each magnet being disposed in a respective one of the longitudinal channels, and includes a thermal conductor connecting at least one of the long sides of one of the magnets with an adjacent long side of a magnet slot having the at least one feature. The feature abuts a long side of a respective one of the magnets at a distance away from the long side of the respective magnet slot. | 04-24-2014 |
20140111055 | CONDUCTOR WITH DIVOT FOR IMPROVED FORM FACTOR - A conductive element is provided and includes an electrically conductive material and a coating surrounding the electrically conductive material to form a coated member. The coated member is formed with a crown defined by bends in first and second transverse dimensions. The electrically conductive material is formed to define at least one divot proximate to the crown. The at least one divot is discernible through the coating. | 04-24-2014 |
20140113472 | BUSS BAR ASSEMBLY - A buss bar assembly for electrically interconnecting phase leads of first, second, and third phase coil winding assemblies arranged about a stator central axis. A substantially annular dielectric body defines a buss bar central axis, and has an inner face. Substantially annular first, second, and third phase bars at least partially disposed within the body have first, second, and third pluralities, respectively, of phase bar contacts angularly spaced from each other at locations about the buss bar central axis and electrically engagable from outside of the body. The buss bar assembly is adapted for installation such that the stator central axis is substantially surrounded by the body, the coil winding assemblies and inner face interface, and phase leads of the first, second, and third phase coil winding assemblies are electrically engaged with the first, second, and third pluralities of phase bar contacts, respectively. | 04-24-2014 |
20140132094 | THERMAL MANAGEMENT OF AN IPM MOTOR WITH NON-MAGNETIC BARS - A rotor of an electric machine includes a lamination stack having a plurality of longitudinally extending magnet channels each having a magnet space and longitudinally extending gaps on each lateral end of the magnet space. A plurality of permanent magnets are respectively disposed in ones of the magnet channels, substantially non-magnetic bars are disposed in each longitudinally extending gap, and a thermally conductive filler material secures the magnets and the bars within the channels. A method of thermal management of an internal permanent magnet (IPM) rotor includes installing, into at least one longitudinally extending magnet channel of a lamination stack, a pair of substantially non-magnetic bars adjacent opposite lateral ends of a longitudinally extending permanent magnet, and transferring heat from the magnet through the bars into the lamination stack. | 05-15-2014 |
20140175916 | ROTOR ASSEMBLY HAVING LIQUID COOLING - A liquid-cooled rotor assembly for a rotary electric machine, including a shaft provided with a fluid passageway receivable of a liquid coolant, and a substantially cylindrical rotor core rotatable in unison with the shaft. The rotor core is provided with a plurality of passages each terminating at a void in a rotor core axial end. Permanent magnets are disposed in rotor core passages, a gap is defined between each magnet and its respective rotor core passage. The shaft fluid passageway is in fluid communication with the rotor core end voids through the gaps, whereby the rotor core and the magnets are convectively cooled by liquid coolant receivable by the shaft fluid passageway and delivered to a rotor core end through the rotor core passages. Also, a method for liquid cooling a rotor assembly. | 06-26-2014 |
20140197701 | ELECTRIC MOTOR STATOR HOUSING INTERFERENCE GAP REDUCING METHOD AND APPARATUS - A cooling system of an electric machine includes a stator core, a housing, and a thermal interfacial material interposed between complementary mating surfaces of the stator core and the housing for substantially eliminating air gaps therebetween. A method of cooling an electric machine having a housing and a stator includes placing a thermal interfacial material onto a heat transfer interface between the stator and the housing, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method of cooling a stator of an electric machine includes heating a housing having a radially inner surface, coating a radially outer surface of the stator and/or the radially inner surface of the housing with a thermal interfacial material, and inserting the stator into the heated housing, whereby the thermal interfacial material is interposed between the inner surface of the housing and the outer surface of the stator. | 07-17-2014 |
20140197702 | ELECTRIC MOTOR ROTOR THERMAL INTERFACE WITH AXIAL HEAT SINKS - A cooling system of an electric machine first and second heat sinks respectively mounted to axial ends of a rotor core, and a thermal interfacial material interposed between respective complementary surfaces of the heat sinks and the rotor core for substantially eliminating air gaps therebetween. A method of cooling includes placing thermal interfacial material onto a heat transfer interface between the rotor core and the heat sink, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method of cooling includes coating an axially outer surface of the rotor core and/or an axially inner surface of an annular heat sink with thermal interfacial material, and attaching the heat sink to the rotor, whereby thermal interfacial material is interposed between the inner surface of the heat sink and the outer surface of the rotor core. | 07-17-2014 |
20140197703 | ELECTRIC MOTOR ROTOR THERMAL INTERFACE FOR HUB/SHAFT - A cooling system of an electric machine includes a hub, a rotor core, and a thermal interfacial material interposed between respective complementary mating surfaces of the hub and the rotor core for substantially eliminating air gaps therebetween. A method of cooling an electric machine having a rotor core and a hub includes placing a thermal interfacial material onto a heat transfer interface between the rotor core and the hub, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method includes providing a rotor core having a radially inner surface, coating at least one of a radially outer surface of a hub and the radially inner surface of the rotor core with a thermal interfacial material, and inserting the hub into the rotor core, whereby the thermal interfacial material is interposed between the inner surface of the rotor core and the outer surface of the hub. | 07-17-2014 |
20140246177 | LIQUID-COOLED ROTARY ELECTRIC MACHINE HAVING COOLING JACKET WITH BI-DIRECTIONAL FLOW - A liquid-cooled rotary electric machine including a jacket defining a heat transfer surface and a sleeve defining a coolant containment surface. A fluid channel having an entry and an exit is located between the heat transfer and coolant containment surfaces, and traverses the heat transfer surface. The fluid channel defines a flow path for liquid coolant through the machine extending substantially circumferentially about an axis and progressing in a direction parallel with the axis, with the flow path progressing in opposite directions parallel to the axis. Also, a method of liquid-cooling a rotary electric machine that includes traversing a generally cylindrical heat transfer surface with a liquid coolant flow along a flow path extending substantially circumferentially about an axis and progressing in opposite directions parallel to the axis, between a fluid channel entry and a fluid channel exit. | 09-04-2014 |
20140246931 | LIQUID-COOLED ROTARY ELECTRIC MACHINE HAVING FLUID CHANNEL WITH AUXILIARY COOLANT GROOVE - A liquid-cooled rotary electric machine including a heat transfer surface traversed by a fluid channel defining a flow path for liquid coolant through the machine. A first fluid channel portion extends about and progresses in a direction parallel to the central axis, and is interconnected with a second fluid channel portion at spaced locations along the first fluid channel portion. The heat transfer surface includes a zone which the first fluid channel portion does not traverse, and is located between a jacket axial end and the first fluid channel portion. The second fluid channel portion extends into the zone between the interconnections, whereby the zone is traversed by the second fluid channel portion and heat is convectively transferable from the zone to liquid coolant along the flow path. Also, a method for liquid-cooling a rotary electric machine. | 09-04-2014 |
20140246932 | LIQUID-COOLED ROTARY ELECTRIC MACHINE HAVING AXIAL END COOLING - A liquid-cooled rotary electric machine including jacket defining a heat transfer surface in conductive thermal communication with a stator and having an axial end portion partially enclosing an interior volume. A heat source is in conductive thermal communication with a wall of the jacket axial end portion. A fluid channel traverses the heat transfer surface between opposite axial ends of the jacket, and a fluid passage in fluid communication with the fluid channel is defined by jacket axial end portion walls. A flow path of liquid coolant through the machine is defined by the fluid channel and the fluid passage between a machine coolant inlet and outlet, whereby at least a portion of heat transferable between the heat source and the fluid passage is convectively transferable between the jacket axial end portion walls and liquid coolant along the flow path. Also a method for liquid-cooling a rotary electric machine. | 09-04-2014 |
20140246933 | LIQUID-COOLED ROTARY ELECTRIC MACHINE HAVING HEAT SOURCE-SURROUNDING FLUID PASSAGE - A liquid-cooled rotary electric machine including jacket defining a heat transfer surface in conductive thermal communication with a stator and having an axial end portion partially enclosing an interior volume. A heat source is in conductive thermal communication with a wall of the jacket axial end portion. A fluid channel traverses the heat transfer surface between opposite axial ends of the jacket. A fluid passage in fluid communication with the fluid channel is defined by jacket axial end portion walls and substantially surrounds the heat source in an imaginary plane perpendicular to the stator axis. At least a portion of heat transferable between the heat source and the fluid passage is convectively transferable between jacket axial end portion walls and liquid coolant along a flow path of liquid coolant through the machine. Also a method for liquid-cooling a rotary electric machine. | 09-04-2014 |
20140265659 | L-SHAPED SHEET METAL COOLING JACKET WITH STAMPED BEARING SUPPORT - An embodiment of an electric machine includes inner and outer housing sections attached to one another to form, at an axial end of the electric machine, a cooling channel therebetween. Such electric machine also includes a bearing carrier coupled to the housing sections and radially registered to the inside diameter of the inner housing section. An embodiment of an electric machine includes annular, L-shaped inner and outer sheet metal housing sections enclosing a cooling channel at an axial end of the electric machine and otherwise being substantially parallel and contiguous, and includes a first bearing assembly coupled to the inner housing section. | 09-18-2014 |
20140265661 | SHEET METAL COOLING JACKET WITH BAFFLES - An electric machine includes a stator and a housing having at least two sheet metal sections, at least one cooling channel being formed at an axial end of the electric machine between the two sections. A method of cooling an electric machine includes forming two sheet metal housing sections to each include a radially inward extending portion at an axial end of the electric machine and an axially extending portion, and attaching the housing sections to one another at contiguous portions thereof, whereby at least one cooling channel is formed between the respective radially inward extending portions of the sections. A method of cooling an electric machine includes circulating coolant in a plurality of cavities formed between two sheet metal housing sections, the cavities including a cooling channel at an axial end of the electric machine. | 09-18-2014 |
20140265663 | POWER ELECTRONICS ATTACHMENT COVER - An electric machine includes a housing having inner and outer sheet metal members attached to one another to form a coolant channel therebetween, a plurality of power electronic components mounted to an axial end of the electric machine adjacent the coolant channel, and a cover secured to the axial end for enclosing the electronic components. A method of cooling an electric machine includes forming a coolant channel at an axial end of the machine, between inner and outer sheet metal members, attaching a power electronics component to the outer sheet metal member proximate the coolant channel, thereby cooling the electronics component by conduction with the coolant channel, and securing a cover to the axial end for enclosing the power electronics component. | 09-18-2014 |
20140265670 | L-SHAPED SHEET METAL COOLING JACKET WITH BAFFLES AND INTEGRATED POWER ELECTRONICS - An electric machine includes a pair of substantially aligned sheet metal housing sections each including a substantially “L” shaped portion, at least one cooling channel being formed at an axial end between the two sections, and a plurality of power electronics components engaged with at least one of the housing sections adjacent the axial end cooling channel. An embodiment includes a stator, a pair of housing sections enclosing the stator, power electronics components positioned at an axial end of the electric machine for controlling operation of the electric machine, and a coolant flow path that includes a power electronics cooling channel formed at the axial end between the housing sections. A method includes forming an axial end cooling channel between two sheet metal housing sections, and positioning power electronics components at the axial end along the cooling channel, whereby heat from the electronics components is transferred to the cooling channel. | 09-18-2014 |
20140265743 | POWER ELECTRONICS SPRING LOADED BETWEEN COVER AND HOUSING - An electric machine includes a housing having a cooling jacket at an axial end thereof, a plurality of power electronic components mounted to the axial end of the housing proximate the cooling jacket, a cover for enclosing the electronic components, and a biasing member that axially urges the electronic components against the housing. An electric machine includes a cooling jacket in an axial end of a housing, power electronic components, and a spring member for urging the power electronic components against the cooling jacket. A method of cooling an electric machine includes providing a cooling jacket in an axial end of a housing and biasing power electronic components against the cooling jacket. | 09-18-2014 |
20140354089 | ELECTRIC MACHINE WITH LIQUID COOLED HOUSING - An electric machine having a stator, a rotor and a housing assembly with two end caps and inner and outer axially extending members. The outer housing member is disposed about the inner member. Ribs extend from one housing member and engage the other housing member in an interstitial space. The other housing member may be a tubular sleeve. The ribs define axially extending fluid path segments within the interstitial space and the end caps close the opposite axial ends of the interstitial space and define an inlet and an outlet for a liquid coolant. The liquid coolant path may be serpentine. The housing member with ribs may include a sleeve portion with at least some ribs having a width greater than the radial thickness of the sleeve portion. Threaded fasteners can attach the end caps to the enlarged width ribs. The inner and outer housings are advantageously extrudable. | 12-04-2014 |
20140354090 | ELECTRIC MACHINE WITH LIQUID COOLED HOUSING AND END CAP - An electric machine that includes a stator operably coupled with a rotor. At least one axially extending housing member is thermally coupled with the stator core and defines a plurality of axially extending fluid passages. An end cap defines a plurality of end turn fluid passages interconnecting the axially extending fluid passages. The end turn fluid passages are arranged circumferentially about and proximate a first axial end of the stator whereby the axially extending fluid passages and end turn passages define a serpentine path. An electronic component thermally coupled with the end cap is disposed radially inward and axially proximate the plurality of end turn fluid passages. The electronic component may be at least partially axially positioned between the distal limit of the stator windings and the axial limit of the serpentine path. In alternative embodiments, the end cap supports a bearing assembly for the rotor shaft. | 12-04-2014 |
20150055317 | SYSTEMS AND METHODS FOR COVERING ACCESS PORTS - An access port cover system, including a housing for an item, the housing defining interior and exterior regions and including an access port through which access to the item from the exterior region is provided, a cover inhibiting access through the access port from the exterior region to the interior region, and a fastener connectable to the housing and the cover. The fastener has an actuation portion for disconnecting the housing and the cover to permit access through the access port from the exterior region to the interior region, the actuation portion being inaccessible from the exterior region when the fastener is connected to the housing and the cover. | 02-26-2015 |