Abstract: Systems and methods of controlling a length of an air gap in an electric machine using an air gap controller may include: determining an air gap length value for an electric machine at least in part using an air gap controller, comparing the determined air gap length value to an air gap target value using the air gap controller, and outputting a control command from the air gap controller to a controllable device associated with an air gap control system when the determined air gap length value differs from the air gap target value by a predefined threshold. A control command may be configured to impart a change to an operating parameter associated with the air gap control system to adjust a length of an air gap between an outer surface of a rotor core and an inner surface of a stator core of the electric machine.

Abstract: A magnetic-core assembling tool may include first and second compression plate alignment guides configured to be respectively fitted to first and second compression plates of a magnetic-core assembly, a plurality of semiannular tension bars, and a clamping plate. The semiannular tension bars may be attached at a first end to the first compression plate alignment guide and at a second end to the clamping plate. The clamping plate may include a plurality of compression shoes configured to apply a variable amount of compression to the magnetic-core assembly. A method of assembling a magnetic-core assembly includes assembling a plurality of lamination stacks, staging the plurality of lamination stacks to provide a magnetic-core assembly, assembling a magnetic-core assembling-tool around the magnetic-core assembly, and injecting magnet retention adhesive into a plurality of magnet retention slots in the magnetic-core assembly housed in the magnetic-core assembling tool.

Abstract: Methods for processing an iron cobalt alloy, along with components formed therefrom, are provided. The method may include: pre-annealing a sheet of an iron cobalt alloy at a pre-anneal temperature (e.g., about 770° C. to about 805° C.); thereafter, cutting a component from the sheet; thereafter, heat-treat annealing the component at a treatment temperature (e.g., about 845° C. to about 870° C.) for a treatment period (e.g., about 1 minute to about 10 minutes); and thereafter, exposing the component to oxygen at an oxidizing temperature to form an insulation layer on a surface of the component.

Abstract: An electric machine having an electrically insulative manifold is disclosed. In one example aspect, an electric machine includes a non-electrically conductive manifold. The manifold defines a chamber operable to receive a cooling fluid. The electric machine includes a prime winding in fluid communication with the chamber and one or more secondary windings in electrical communication with the prime winding and in fluid communication with the chamber. Further, the electric machine includes an electric machine terminal extending through the non-electrically conductive manifold and coupled with the prime winding. The electric machine terminal can provide or collect cooling fluid from the chamber of the manifold and can act as the electrical connection point for directing electrical power to or from the windings of the electric machine.

Abstract: An electric machine having a hybrid insulative-conductive manifold is disclosed. In one aspect, an electric machine includes a manifold that includes an insulative plate and a conductive backplate positioned adjacent to the insulative plate. The insulative plate and the backplate define a first channel and a second channel therebetween. The electric machine also includes a prime winding and a secondary winding electrically isolated from the prime winding. The prime winding and the secondary winding are both in fluid communication with the first channel and the second channel. A terminal conductor extends through the backplate and insulative plate and is electrically coupled with the prime winding. The terminal conductor is electrically isolated from the backplate and provides cooling fluid to the prime winding and the first channel so that cooling fluid flows between the terminal conductor and the prime winding and between the terminal conductor and the first channel.

Abstract: Systems and methods of controlling a length of an air gap in an electric machine using an air gap controller may include: determining an air gap length value for an electric machine at least in part using an air gap controller, comparing the determined air gap length value to an air gap target value using the air gap controller, and outputting a control command from the air gap controller to a controllable device associated with an air gap control system when the determined air gap length value differs from the air gap target value by a predefined threshold. A control command may be configured to impart a change to an operating parameter associated with the air gap control system to adjust a length of an air gap between an outer surface of a rotor core and an inner surface of a stator core of the electric machine.

Abstract: Systems and methods of controlling a length of an air gap in an electric machine using an air gap controller may include: determining an air gap length value for an electric machine at least in part using an air gap controller, comparing the determined air gap length value to an air gap target value using the air gap controller, and outputting a control command from the air gap controller to a controllable device associated with an air gap control system when the determined air gap length value differs from the air gap target value by a predefined threshold. A control command may be configured to impart a change to an operating parameter associated with the air gap control system to adjust a length of an air gap between an outer surface of a rotor core and an inner surface of a stator core of the electric machine.

Abstract: A magnetic-core assembling tool may include first and second compression plate alignment guides configured to be respectively fitted to first and second compression plates of a magnetic-core assembly, a plurality of semiannular tension bars, and a clamping plate. The semiannular tension bars may be attached at a first end to the first compression plate alignment guide and at a second end to the clamping plate. The clamping plate may include a plurality of compression shoes configured to apply a variable amount of compression to the magnetic-core assembly. A method of assembling a magnetic-core assembly includes assembling a plurality of lamination stacks, staging the plurality of lamination stacks to provide a magnetic-core assembly, assembling a magnetic-core assembling-tool around the magnetic-core assembly, and injecting magnet retention adhesive into a plurality of magnet retention slots in the magnetic-core assembly housed in the magnetic-core assembling tool.

Abstract: Methods for processing an iron cobalt alloy, along with components formed therefrom, are provided. The method may include: pre-annealing a sheet of an iron cobalt alloy at a pre-anneal temperature (e.g., about 770° C. to about 805° C.); thereafter, cutting a component from the sheet; thereafter, heat-treat annealing the component at a treatment temperature (e.g., about 845° C. to about 870° C.) for a treatment period (e.g., about 1 minute to about 10 minutes); and thereafter, exposing the component to oxygen at an oxidizing temperature to form an insulation layer on a surface of the component.

Abstract: An electric machine having an electrically insulative manifold is disclosed. In one example aspect, an electric machine includes a non-electrically conductive manifold. The manifold defines a chamber operable to receive a cooling fluid. The electric machine includes a prime winding in fluid communication with the chamber and one or more secondary windings in electrical communication with the prime winding and in fluid communication with the chamber. Further, the electric machine includes an electric machine terminal extending through the non-electrically conductive manifold and coupled with the prime winding. The electric machine terminal can provide or collect cooling fluid from the chamber of the manifold and can act as the electrical connection point for directing electrical power to or from the windings of the electric machine.

Abstract: An electric machine may include a rotor shaft that has a hollow region configured to receive a coolant. The hollow region is defined by an inner surface which has a slope that increases from a first inner diameter at a first end to a second inner diameter at a second end. Centrifugal force generated when rotating the rotor shaft causes the coolant to flow across the inner surface of the rotor shaft from the first end to the second end at a velocity depending at least in part on the slope of the inner surface of the rotor shaft. A method of cooling an electric machine includes injecting a coolant into a first end of the hollow region of the rotor shaft, rotating the rotor shaft at an operational rate of rotation, with the rotation generating centrifugal force that causes the coolant to flow from the first end to the second end, transferring heat from the rotor shaft to the coolant.

Abstract: A method for operating a permanent magnet electric machine of an engine includes determining a fault condition of the permanent magnet electric machine; and reducing a magnetism of one or more permanent magnets of the permanent magnet electric machine by increasing a temperature of the one or more permanent magnets in response to determining the fault condition of the permanent magnet electric machine.

Abstract: Systems and methods of controlling a length of an air gap in an electric machine using an air gap controller may include: determining an air gap length value for an electric machine at least in part using an air gap controller, comparing the determined air gap length value to an air gap target value using the air gap controller, and outputting a control command from the air gap controller to a controllable device associated with an air gap control system when the determined air gap length value differs from the air gap target value by a predefined threshold. A control command may be configured to impart a change to an operating parameter associated with the air gap control system to adjust a length of an air gap between an outer surface of a rotor core and an inner surface of a stator core of the electric machine.

Abstract: An electric machine may include a rotor shaft that has a hollow region configured to receive a coolant. The hollow region is defined by an inner surface which has a slope that increases from a first inner diameter at a first end to a second inner diameter at a second end. Centrifugal force generated when rotating the rotor shaft causes the coolant to flow across the inner surface of the rotor shaft from the first end to the second end at a velocity depending at least in part on the slope of the inner surface of the rotor shaft. A method of cooling an electric machine includes injecting a coolant into a first end of the hollow region of the rotor shaft, rotating the rotor shaft at an operational rate of rotation, with the rotation generating centrifugal force that causes the coolant to flow from the first end to the second end, transferring heat from the rotor shaft to the coolant.

Abstract: A method for operating a permanent magnet electric machine of an engine includes determining a fault condition of the permanent magnet electric machine; and reducing a magnetism of one or more permanent magnets of the permanent magnet electric machine by increasing a temperature of the one or more permanent magnets in response to determining the fault condition of the permanent magnet electric machine.