Abstract: Methods and apparatus for fabricating an armature for a motor. In some embodiments, the conductors of an armature are bent according to a non-linear profile that results in better management of conductor stresses, and better final alignment of the position of the conductor free end.

Abstract: An electric machine includes an electric machine housing having a first end, a second end, and an interior. A stator is fixedly mounted relative to the electric machine housing. A pump housing is provided at one of the first and second ends. A rotor is rotatably supported relative to the stator. The rotor includes a shaft having a first end that extends to a second end through an uninterrupted intermediate portion having an outer surface. One of the first and second ends extends into the pump housing. At least one vane element projects from the outer surface and is arranged in the pump housing.

Abstract: A slot liner is configured for association with a tooth of an electro-dynamic machine core having an annular rim and circumferentially spaced teeth radially extending from the annular rim. The slot liner includes sidewalls configured to line circumferential surfaces of the tooth, first and second tabs formed by bends in the sidewalls, the first tab being configured to line a portion of the annular rim adjacent to the tooth and the second tab being configured to overlap with a tab of an adjacent slot liner and a retainer configured to retain the sidewalls against a radially inward portion of the tooth.

Abstract: A machine includes a high voltage element and an enclosure surrounding the high voltage element. The enclosure includes a first insulating insert disposed at least partially within a first wall and being electrically non-conductive and surrounding a first conductive insert and an enclosure cover formed at least partially of an electrically non-conducting substrate and having a first opening formed therein sized to allow a first fastener or an extension of the first conductive insert to pass through it. Removal of the enclosure cover causes the high high-voltage element to cease operating.

Abstract: A lamination assembly having a lamination stack including a plurality of lamination members, and at least one inter-lamination thermal transfer member coupled to at least one of the plurality of lamination members. The at least one inter-lamination thermal transfer member establishes a heat dissipation path from the lamination stack.

Abstract: A rotor assembly for a permanent magnet electric machine includes a plurality of rotor laminations joined to form a rotor body. Each of the plurality of rotor laminations includes a plurality of slots. One or more permanent magnets are mounted within respective ones of the plurality of slots. Each of the one or more permanent magnets includes a thermal enhancement bonding coating. A method of forming a rotor assembly is also disclosed.

Abstract: An electric machine includes a housing, a stator fixedly mounted relative to the housing, and a rotor assembly rotatably mounted relative to the stator. The rotor assembly includes a plurality of rotor laminations forming a rotor body, one or more permanent magnets provided in the rotor body, and a sleeve extending around the one or more permanent magnets. The sleeve provides a thermal interface between the one or more permanent magnets and the rotor body.

Abstract: An electro-dynamic machine is provided and includes stator assembly end turns and a coolant chargeable bladder disposable to contact the end turns.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A stator core includes a plurality of slot segments, a plurality of stator winding conductors arranged in select ones of the plurality of slot segments, and a ceramic covering provided on one or more of the plurality of stator winding conductors. The ceramic covering includes an adhesive bonded to the one of the plurality of stator winding conductors to provide insulation for the one or more stator winding conductors.

Abstract: A drive train component includes a housing having a plurality inner surfaces that collectively define an interior portion. A gear set is arranged within the interior portion. The gear set includes a first side and a second side. A gear shock control member is positioned between one of the first and second sides of the gear set and an adjacent component. The gear shock control member includes a plurality of pre-loaded biasing members that direct an axial force onto the gear set.

Abstract: An adapter assembly is provided and includes a body having a first periphery, a second periphery opposite the first periphery and a central region interposed between the first and second peripheries. The first periphery is attachable to a first housing at a first aperture thereof, the first housing defining an interior in which a first motor is disposable. The second periphery is attachable to a second housing at a second aperture thereof, the second housing defining an interior in which a second motor is disposable. The central region is configured to encase a coupling for operably coupling the first and second motors via the first and second apertures, respectively, for output to a shaft.

Abstract: An electric machine including a housing having a body including an inner surface that defines an interior, a first end defining an opening exposing the interior, and a second end. A stator is fixedly mounted to the inner surface of the housing. A rotor is supported within the interior. The rotor defines an axis of rotation. An end cover extends across the opening adjacent one of the first end and the second end of the stator. A cooling system is carried by the end cover. The cooling system includes a body having a cooling fluid plenum, a plurality of stator nozzles and a plurality of rotor nozzles. The stator nozzles are configured and disposed to direct multiple jets of a coolant toward the stator and the plurality of rotor nozzles are configured and disposed to guide multiple jets of the coolant toward the rotor.

Abstract: An interlock system and method are provided for protecting high voltage electrical couplings. The interlock system may control access to the electrical couplings based on the voltage of the electrical couplings. The interlock system may also selectively energize and de-energize the electrical couplings based on the position of a lid.

Abstract: 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.

Abstract: A machine housing includes a conductor seal system including an outer seal member and an inner seal member. The outer seal member has an outer seal body formed from a first material. The outer seal body includes an outer surface portion and an inner surface portion defining a central opening. The outer surface portion includes a housing gripping portion and the inner surface portion includes at least one retention feature arranged within the central opening. The inner seal member includes an inner seal body formed from a second material. The inner seal body includes an outer surface having at least one retaining element configured and disposed to engage with the at least one retention feature to join the inner seal member to the outer seal member to establish a water proof and dust proof seal at the opening extending through the housing body.

Abstract: An electric machine includes a housing having an interior portion, a stationary member including a stationary field is fixedly mounted to the housing and a movable member including a rotating field is rotatably mounted relative to the stationary member. A positive pressure introduction system is fluidically coupled to the housing. The positive pressure introduction system is configured and disposed to raise an internal pressure of the interior portion of the housing.