Patents by Inventor David Crecelius
David Crecelius has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20240087997Abstract: An electric drive unit having a stator body, a plurality of sets of field windings mounted to the stator body, a rotor received in the stator body and rotatable relative to the stator body, a plurality of phase terminals, and a current sensor assembly. Each of the phase terminals is coupled to an associated one of the sets of field windings. The current sensor assembly has a plurality of current sensor laminations, and a sensor. The current sensor laminations are generally C-shaped and are abutted against one another to form a sensor lamination stack. The sensor lamination stack defines a gap. The current sensor laminations are disposed about a corresponding one of the phase terminals. The sensor is disposed in the gap.Type: ApplicationFiled: November 20, 2023Publication date: March 14, 2024Inventors: James P. DOWNS, David CRECELIUS, Jeffrey J. RONNING, Paul J. VALENTE, John C. MORGANTE
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Publication number: 20240063672Abstract: A motor drive system has a rotor assembly that is rotatable about an axis and includes a hollow shaft, a tube, and one or more fin sets. The tube is received in the shaft and defines a first passage. The fin sets are disposed about the tube and are engaged to the shaft. Each fin set defines a plurality of circumferentially spaced apart fins that are coupled to the shaft and the tube. The first passage is configured to discharge fluid communicated therethrough into a return chamber that is formed in the rotor assembly. A plurality of second passages are formed between the shaft and fins and are in fluid communication with the return chamber.Type: ApplicationFiled: November 3, 2023Publication date: February 22, 2024Inventors: Jeffrey J. RONNING, James P. DOWNS, John C. MORGANTE, Peter D. FISCHER, David CRECELIUS, Zugang HUANG, Paul J. VALENTE
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Patent number: 11888356Abstract: A motor drive system with a rotor assembly having an insert, which is received into a blind hollow rotor space in a rotor shaft. The insert is unitarily and integrally formed and defines a central hole, which is disposed along a rotational axis of the rotor assembly, and a plurality of slots that extend through an outer circumferential surface of the insert. The insert is disposed in the rotor shaft such that the outer circumferential surface of the insert is engaged to the inside circumferential surface of the rotor shaft. The central hole forms a first fluid passage through the insert, while the slots form a plurality of second fluid passages through the insert.Type: GrantFiled: March 1, 2023Date of Patent: January 30, 2024Assignee: American Axle & Manufacturing, Inc.Inventors: Jeffrey J. Ronning, James P. Downs, John Morgante, Peter D. Fischer, David Crecelius, Zugang Huang, Paul J. Valente
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Patent number: 11862543Abstract: An electric drive unit having a stator, a rotor received in the stator and rotatable about a central longitudinal axis, and an inverter assembly that includes a plurality of power semiconductors, a plurality of heat sinks and an end plate. The power semiconductors are thermally coupled to the heat sinks. Each of the heat sinks has a plurality of fins that extend into a flow channel that is coaxial with the plurality of sets of field windings. The end plate is coupled to the power semiconductors and has a projection, which is sealingly coupled to the stator and which and partly defines an annular cavity, and a coolant port that is coupled in fluid communication with the annular cavity. The flow channel is in fluid communication with and disposed in a flow path between the annular cavity and the cooling channels in the stator body.Type: GrantFiled: June 13, 2022Date of Patent: January 2, 2024Assignee: American Axle & Manufacturing, Inc.Inventors: James P. Downs, David Crecelius, Jeffrey J. Ronning, Paul J. Valente, John C. Morgante
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Patent number: 11863046Abstract: An electric drive unit having a multi-phase electric motor and an inverter with a plurality of power semiconductors, an inverter mount, and a plurality of busbars. The power semiconductors are mounted to the base of the inverter mount in an annular arrangement and with the terminals of the power semiconductors extending through the base. Each of the busbars has a first busbar portion, which includes a first body and a set of first fingers that are fixedly coupled to the first body, and a second busbar portion that includes a second body and a set of second fingers that are fixedly coupled to the second body. Associated fingers in the first and second sets of fingers of each bus bar are mechanically and electrically coupled to opposite sides of a corresponding one of the terminals.Type: GrantFiled: August 4, 2022Date of Patent: January 2, 2024Assignee: American Axle & Manufacturing, Inc.Inventors: James P. Downs, Paul J. Valente, Jeffrey J. Ronning, John C. Morgante, David Crecelius, Zugang Huang
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Publication number: 20230208228Abstract: A motor drive system with a rotor assembly having an insert, which is received into a blind hollow rotor space in a rotor shaft. The insert is unitarily and integrally formed and defines a central hole, which is disposed along a rotational axis of the rotor assembly, and a plurality of slots that extend through an outer circumferential surface of the insert. The insert is disposed in the rotor shaft such that the outer circumferential surface of the insert is engaged to the inside circumferential surface of the rotor shaft. The central hole forms a first fluid passage through the insert, while the slots form a plurality of second fluid passages through the insert.Type: ApplicationFiled: March 1, 2023Publication date: June 29, 2023Inventors: Jeffrey J. RONNING, James P. DOWNS, John MORGANTE, Peter D. FISCHER, David CRECELIUS, Zugang HUANG, Paul J. VALENTE
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Publication number: 20230134328Abstract: An electric motor can include a stator body defining fluid channels extending axially for fluid communication between axial ends of the stator body. Conductive windings can form first loops extending axially outward from the first end of the stator body and second loops extending axially outward from the second end of the stator body. A first cap can be coupled to the first end of the stator body and can include a first wall. The first wall can be between the first loops and the channels. Pins can extend from a side of the first wall that is opposite the first loops. The second cap can be coupled to the second end of the stator body and include a second wall. The second wall can be between the second loops and the channels. Pins can extend from a side of the second wall that is opposite the second loops.Type: ApplicationFiled: December 31, 2022Publication date: May 4, 2023Inventors: John MORGANTE, James P. DOWNS, David CRECELIUS, Peter FISCHER, Jeffrey J. RONNING
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Patent number: 11626765Abstract: A motor drive assembly having an electric motor with a rotor that includes a rotor shaft and a heat exchanger received in the rotor shaft. The heat exchanger has an insert body with an outer insert surface that is engaged to an inside surface of the rotor shaft. The insert body includes a plurality of segments. Each of the segments defines a first through-hole, and a plurality of second through-holes. Each of the segments is fixedly coupled to one another. A first flow passage extends through the first through-holes in the plurality of segments. Each of the second through-holes defines a portion of a corresponding second flow passage. The second flow passages are disposed concentrically about the first flow passage.Type: GrantFiled: August 8, 2018Date of Patent: April 11, 2023Assignee: American Axle & Manufacturing, Inc.Inventors: Jeffrey J. Ronning, James P. Downs, John Morgante, Peter D. Fischer, David Crecelius, Zugang Huang, Paul J. Valente
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Patent number: 11569698Abstract: An electric motor can include a stator body defining fluid channels extending axially for fluid communication between axial ends of the stator body. Conductive windings can form first loops extending axially outward from the first end of the stator body and second loops extending axially outward from the second end of the stator body. A first cap can be coupled to the first end of the stator body and can include a first wall. The first wall can be between the first loops and the channels. Pins can extend from a side of the first wall that is opposite the first loops. The second cap can be coupled to the second end of the stator body and include a second wall. The second wall can be between the second loops and the channels. Pins can extend from a side of the second wall that is opposite the second loops.Type: GrantFiled: December 21, 2020Date of Patent: January 31, 2023Assignee: American Axle & Manufacturing, Inc.Inventors: John Morgante, James P. Downs, David Crecelius, Peter Fischer, Jeffrey J. Ronning
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Publication number: 20220385146Abstract: An electric drive unit having a multi-phase electric motor and an inverter with a plurality of power semiconductors, an inverter mount, and a plurality of busbars. The power semiconductors are mounted to the base of the inverter mount in an annular arrangement and with the terminals of the power semiconductors extending through the base. Each of the busbars has a first busbar portion, which includes a first body and a set of first fingers that are fixedly coupled to the first body, and a second busbar portion that includes a second body and a set of second fingers that are fixedly coupled to the second body. Associated fingers in the first and second sets of fingers of each bus bar are mechanically and electrically coupled to opposite sides of a corresponding one of the terminals.Type: ApplicationFiled: August 4, 2022Publication date: December 1, 2022Inventors: James P. DOWNS, Paul J. VALENTE, Jeffrey J. RONNING, John C. MORGANTE, David CRECELIUS, Zugang HUANG
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Publication number: 20220310493Abstract: An electric drive unit having a stator, a rotor received in the stator and rotatable about a central longitudinal axis, and an inverter assembly that includes a plurality of power semiconductors, a plurality of heat sinks and an end plate. The power semiconductors are thermally coupled to the heat sinks. Each of the heat sinks has a plurality of fins that extend into a flow channel that is coaxial with the plurality of sets of field windings. The end plate is coupled to the power semiconductors and has a projection, which is sealingly coupled to the stator and which and partly defines an annular cavity, and a coolant port that is coupled in fluid communication with the annular cavity. The flow channel is in fluid communication with and disposed in a flow path between the annular cavity and the cooling channels in the stator body.Type: ApplicationFiled: June 13, 2022Publication date: September 29, 2022Inventors: James P. DOWNS, David CRECELIUS, Jeffrey J. RONNING, Paul J. VALENTE, John C. MORGANTE
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Patent number: 11456239Abstract: An electric drive module having a motor and an inverter that are disposed in a housing The motor includes a stator, which has a plurality of sets of windings. The inverter has a plurality of power semiconductors, which are mounted into a retaining member, an end plate, which is sealingly coupled to the retaining member, and an inlet port that extends through the end plate. Sets of the semiconductor devices are electrically coupled to corresponding sets of the windings. Power terminals on the semiconductor devices are coupled to a heat sink. Fins on the heat sinks extend into an annular region that is adjacent to axial ends of the windings. At least one of the retaining member and the end plate is sealingly coupled to the housing assembly. The inlet port, the annular region and cooling passages in the stator are coupled in fluid communication.Type: GrantFiled: March 10, 2022Date of Patent: September 27, 2022Assignee: American Axle & Manufacturing, Inc.Inventors: James P. Downs, David Crecelius, Jeffrey J. Ronning, Paul J. Valente, John C. Morgante
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Publication number: 20220199501Abstract: An electric drive module having a motor and an inverter that are disposed in a housing The motor includes a stator, which has a plurality of sets of windings. The inverter has a plurality of power semiconductors, which are mounted into a retaining member, an end plate, which is sealingly coupled to the retaining member, and an inlet port that extends through the end plate. Sets of the semiconductor devices are electrically coupled to corresponding sets of the windings. Power terminals on the semiconductor devices are coupled to a heat sink. Fins on the heat sinks extend into an annular region that is adjacent to axial ends of the windings. At least one of the retaining member and the end plate is sealingly coupled to the housing assembly. The inlet port, the annular region and cooling passages in the stator are coupled in fluid communication.Type: ApplicationFiled: March 10, 2022Publication date: June 23, 2022Inventors: James P. DOWNS, David CRECELIUS, Jeffrey J. RONNING, Paul J. VALENTE, John C. MORGANTE
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Patent number: 11303183Abstract: An electric drive module having a motor and an inverter that are disposed in a housing The motor includes a stator, which has a plurality of sets of windings. The inverter has a plurality of power semiconductors, which are mounted into a retaining member, an end plate, which is sealingly coupled to the retaining member, and an inlet port that extends through the end plate. Sets of the semiconductor devices are electrically coupled to corresponding sets of the windings. Power terminals on the semiconductor devices are coupled to a heat sink. Fins on the heat sinks extend into an annular region that is adjacent to axial ends of the windings. At least one of the retaining member and the end plate is sealingly coupled to the housing assembly. The inlet port, the annular region and cooling passages in the stator are coupled in fluid communication.Type: GrantFiled: October 14, 2021Date of Patent: April 12, 2022Assignee: American Axle & Manufacturing, Inc.Inventors: James P. Downs, David Crecelius, Jeffrey J. Ronning, Paul J. Valente, John C. Morgante
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Publication number: 20220037954Abstract: An electric drive module having a motor and an inverter that are disposed in a housing The motor includes a stator, which has a plurality of sets of windings. The inverter has a plurality of power semiconductors, which are mounted into a retaining member, an end plate, which is sealingly coupled to the retaining member, and an inlet port that extends through the end plate. Sets of the semiconductor devices are electrically coupled to corresponding sets of the windings. Power terminals on the semiconductor devices are coupled to a heat sink. Fins on the heat sinks extend into an annular region that is adjacent to axial ends of the windings. At least one of the retaining member and the end plate is sealingly coupled to the housing assembly. The inlet port, the annular region and cooling passages in the stator are coupled in fluid communication.Type: ApplicationFiled: October 14, 2021Publication date: February 3, 2022Inventors: James P. DOWNS, David CRECELIUS, Jeffrey J. RONNING, Paul J. VALENTE, John C. MORGANTE
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Patent number: 11218063Abstract: The present disclosure relates to a transmission system having a transmission subsystem, a transmission housing for housing the transmission subsystem, and a rotor operably associated with the transmission subsystem. The rotor has a weight and dimension to act as a flywheel. At least one stator pole segment is housed within the transmission housing and has at least one stator winding thereon positioned in proximity to a surface of the rotor. An inverter communicates with the stator winding and electrically energizes the winding to cause rotation of the rotor.Type: GrantFiled: November 26, 2019Date of Patent: January 4, 2022Assignee: American Axle & Manufacturing, Inc.Inventors: David Crecelius, James P. Downs
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Publication number: 20210184517Abstract: An electric motor can include a stator body defining fluid channels extending axially for fluid communication between axial ends of the stator body. Conductive windings can form first loops extending axially outward from the first end of the stator body and second loops extending axially outward from the second end of the stator body. A first cap can be coupled to the first end of the stator body and can include a first wall. The first wall can be between the first loops and the channels. Pins can extend from a side of the first wall that is opposite the first loops. The second cap can be coupled to the second end of the stator body and include a second wall. The second wall can be between the second loops and the channels. Pins can extend from a side of the second wall that is opposite the second loops.Type: ApplicationFiled: December 21, 2020Publication date: June 17, 2021Inventors: John Morgante, James P. Downs, David Crecelius, Peter Fischer, Jeffrey J. Ronning
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Patent number: 10879749Abstract: An electric motor can include a stator body defining fluid channels extending axially for fluid communication between axial ends of the stator body. Conductive windings can form first loops extending axially outward from the first end of the stator body and second loops extending axially outward from the second end of the stator body. A first cap can be coupled to the first end of the stator body and can include a first wall. The first wall can be between the first loops and the channels. Pins can extend from a side of the first wall that is opposite the first loops. The second cap can be coupled to the second end of the stator body and include a second wall. The second wall can be between the second loops and the channels. Pins can extend from a side of the second wall that is opposite the second loops.Type: GrantFiled: November 22, 2017Date of Patent: December 29, 2020Assignee: American Axle & Manufacturing, Inc.Inventors: John Morgante, James P. Downs, David Crecelius, Peter Fischer, Jeffrey J. Ronning
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Publication number: 20200227964Abstract: A motor drive system with a rotor assembly having an insert, which is received into a blind hollow rotor space in a shaft, a coolant inlet and a coolant outlet. The insert has an insert body, a first flow passage and a plurality of second flow passages. The insert body has an outer insert surface that is engaged to an inside surface of a shaft wall of the shaft. The first flow passage extends longitudinally through the insert body. The second flow passages extend longitudinally through the insert body radially between the outer insert surface and the first flow passage. The coolant inlet is fluidly coupled to one of the first and second flow passages, while the coolant outlet is fluidly coupled to the other one of the first and second flow passages.Type: ApplicationFiled: August 8, 2018Publication date: July 16, 2020Inventors: Jeffrey J. RONNING, James P. DOWNS, John MORGANTE, Peter D. FISCHER, David CRECELIUS, Zugang HUANG, Paul J. VALENTE
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Publication number: 20200099282Abstract: The present disclosure relates to a transmission system having a transmission subsystem, a transmission housing for housing the transmission subsystem, and a rotor operably associated with the transmission subsystem. The rotor has a weight and dimension to act as a flywheel. At least one stator pole segment is housed within the transmission housing and has at least one stator winding thereon positioned in proximity to a surface of the rotor. An inverter communicates with the stator winding and electrically energizes the winding to cause rotation of the rotor.Type: ApplicationFiled: November 26, 2019Publication date: March 26, 2020Inventors: David CRECELIUS, James P. DOWNS