Abstract: A rotor for an electric machine includes a magnetic core configured for arrangement on a shaft. An end ring is arranged on opposite axial ends of the magnetic core. A composite sleeve includes an annular body including an inner surface and an outer surface, and a polymer matrix encapsulating circumferentially oriented fibers. The composite sleeve includes a first tapered portion on the inner surface arranged adjacent to an axial end thereof and configured to facilitate press-fitting of the composite sleeve onto the rotor.

Abstract: Presented are electric motors and apparatuses thereof for discharging an electric charge buildup on the rotor. In an embodiment, an electric motor apparatus includes a case, a stator arranged within the case, a rotor, a motor shaft extending longitudinally through the rotor to include an axial end, a grounding brush having an outer surface and an elliptical surface, and a spring including one portion maintaining slidable contact with the case and another portion coupled to an outer surface of the brush, the elliptical surface attached to the axial end of the motor shaft for causing a current flow via the brush through the case, which can act as system ground, for discharging an electric charge buildup on the stator due to a parasitic capacitance between the stator and rotor.

Abstract: A rotor grounding system for an electric machine includes a rotor including a shaft assembly configured to rotate about an axis. A housing supports the shaft assembly for rotation of the rotor. A bearing assembly has an outer circumference disposed against the shaft assembly. A discharge bar extends through at least a part of the bearing assembly. The bearing assembly has an inner circumference disposed against the discharge bar. A discharge circuit is defined between the rotor and the housing, where the discharge circuit extends through the bearing assembly and the discharge bar.

Abstract: A current sensing apparatus may include a common mode core surrounding two or more current conductors and a current sensing element proximate the common mode core.

Abstract: A bi-material permanent magnet for an electric machine includes a core including a first magnetic material and a shell portion located on the core and made of a second magnetic material. The first magnetic material comprises a magnet material with an energy less than 20 Mega Gauss Oersteds (MGOe). The second magnetic material comprises a magnet material with an energy greater than 30 MGOe.

Abstract: Bearing impedance in a rotary electric machine may be estimated by isolating bearings from a frame with a dielectric pad, determining a pad capacitance, supporting the rotor by an inner race of the bearing, operating the rotary electric machine, measuring bearing inner race and outer race voltages, measuring current bypassing the dielectric pad, and estimating bearing capacitance and resistance based upon the pad capacitance, the measured and the measured current.

Abstract: A method of controlling an electric motor of a vehicle includes monitoring torque command signals from a vehicle system to the electric motor, each torque command signal configured to cause the electric motor to output a commanded torque, and monitoring a speed of the vehicle and an output torque of the electric motor, the output torque responsive to a drive signal generated based on the torque command signals. The method also includes, based on the output torque and the vehicle speed indicating a low motor efficiency condition, modulating the drive signal between a first torque value and a second torque value that is less than the first torque value, the first torque value greater than the commanded torque and selected to increase an efficiency of the electric motor.

Abstract: An enclosure for a rotary electric machine may include a housing supporting a stator of the electric machine and first and second end plates attached to the housing and rotatably supporting a rotor at opposite ends with respective first and second bearings isolated from the end plates.

Abstract: An electric machine includes a housing, a rotor rotatably mounted to the housing, and a stator mounted to the housing about the rotor. The stator includes a stator body formed from a plurality of laminations. The plurality of laminations include an outer annular surface defining a radius, an inner annular surface spaced from the rotor, and a plurality of radially inwardly extending stator teeth spaced one from another by plurality of gaps. Each of the plurality of gaps extend along the radius and include an opening exposed at the inner annular surface. The opening has a first side portion and a second side portion each extending at an angle relative to the radius.

Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Abstract: An electric machine grounding system with low impedance includes a rotor that has a shaft assembly and that is configured to rotate about an axis. The shaft assembly has a surface. A housing supports the shaft assembly for rotation of the rotor. A holder extends from the housing. A ground assembly is held between the holder and the shaft assembly and includes a plurality of strands that extend to the surface to ground the shaft assembly to the housing.

Abstract: An electric machine may have a stator and a rotor including stacked plurality of electrical steel laminations forming a slot including a first end and opposing sides, the first end defined by a bridge extending between electrical steel on opposing sides of the slot, the bridge being located between the first end of the slot and an outer diameter surface of the rotor and beneath the outer diameter surface of the rotor, the bridge forming a base of a channel open at an outer diameter surface of the rotor.

Abstract: Induced currents in a multi-phase AC motor may be attenuated by operating the multi-phase AC motor with an AC choke surrounding an AC bus providing multi-phase AC voltage to multi-phase AC stator windings in a stator, wherein the AC choke may include an effective bandwidth at least covering resonant frequencies of a capacitance between the multi-phase AC stator windings and the stator or a frame of the AC motor.

Abstract: A method of controlling an electric motor of a vehicle includes monitoring torque command signals from a vehicle system to the electric motor, each torque command signal configured to cause the electric motor to output a commanded torque, and monitoring a speed of the vehicle and an output torque of the electric motor, the output torque responsive to a drive signal generated based on the torque command signals. The method also includes, based on the output torque and the vehicle speed indicating a low motor efficiency condition, modulating the drive signal between a first torque value and a second torque value that is less than the first torque value, the first torque value greater than the commanded torque and selected to increase an efficiency of the electric motor.

Abstract: A power control system for an electric vehicle includes a power inverter comprising a switch module including a plurality of power switches, a controller board, and a gate driver board in communication with the controller board and configured to drive gates of the plurality of switches. A first housing is made of polymer composite, encloses the power inverter, defines a first cooling cavity in thermal communication with a first surface of the switch module, and encapsulates a portion of at least one of the switch module, the controller board and the gate driver board.

Abstract: A vehicle, suspension system of the vehicle and method of operating the suspension system is disclosed. The suspension system includes a rotary motor, a rectifier circuit and a logic circuit. The rotary motor is configured to generate a current based on a direction of rotation of the rotary motor. The rectifier circuit is configured to applying a damping force against the rotation at the rotary motor based on an impedance. The logic circuit changes the impedance of the rectifier circuit based on the direction of rotation of the rotary motor.

Abstract: A vehicle, suspension system and method of dampening a force on the suspension system is disclosed. The suspension system includes a damper having a first damping element and a second damping element configured to rotate relative to each other in response to a force received at the suspension system. The second damping element induces an eddy current in the first damping element during relative rotation. A feature of one at least one of the first damping element and the second damping element provides a first electrical resistance to the eddy current during relative rotation in a first direction and a second electrical resistance to the eddy current during relative rotation in a second direction. The first electrical resistance generates a first damping force and the second electrical resistance generates a second damping force.

Abstract: An electric propulsion system includes a rotary electric machine having an output member, a rechargeable energy storage system (“RESS”) connected to the electric machine, a user interface device, and a controller. The RESS includes multiple battery modules and a switching circuit, the latter being configured, in response to electronic switching control signals, to connect the battery modules in a parallel-connected configuration or a series-connected configuration, as a selected battery configuration. The user interface device receives an operator-requested drive mode request as an electrical signal indicative of a desired drive mode of the electric propulsion system.

Abstract: A rotor for an electric machine includes a rotor body formed from a plurality of rotor laminations defining a first axial end and a second axial end. Each of the plurality of rotor laminations includes a plurality of openings that are aligned so as to define a plurality of passages through the rotor body. A plurality of reinforcement elements extend through the plurality of laminations. Each of the plurality of reinforcement elements is arranged in a corresponding one of the plurality of passages and includes a first end portion and a second end portion. The first end portion and the second end portion of select ones of the plurality of reinforcement elements extend outwardly of the first axial end and the second axial end. An end ring is positioned at the first axial end. The end ring is integrally formed with the select ones of the plurality of reinforcement elements.

Abstract: A stator assembly for an axial flux motor includes a heat exchanger jacket configured to circulate a heat transfer liquid. A stator also includes a plurality of stator cores each having a conductive winding, an electrically insulating material disposed over at least a portion of the conductive wire winding, and a molded soft magnetic composite (SMC) material. The heat exchanger jacket is disposed circumferentially around at least a portion of a perimeter of the stator. Each stator core defines a peripheral surface configured to contact the heat exchanger jacket and at least a portion of the peripheral surface is defined by the molded soft magnetic composite (SMC) material. Methods of making a molded soft magnetic composite (SMC) material stator core are also provided.