Abstract: An electric cycle with a frame that may include a tube and an opening. The tube may extend from a first end to a second end and may define a tube interior volume in fluid communication with the opening. An electric power unit may be mounted to the frame proximal the second end of the tube and may have a cooling air inlet and an exhaust port. A cooling path may be defined through the tube interior volume and at least a portion of the electric power unit. The cooling path may be in fluid communication with the opening so that air may flow into the opening, through the tube, into the cooling air inlet and out of the exhaust port of the electric power unit.

Abstract: An electric cycle with a frame that may include a tube and an opening. The tube may extend from a first end to a second end and may define a tube interior volume in fluid communication with the opening. An electric power unit may be mounted to the frame proximal the second end of the tube and may have a cooling air inlet and an exhaust port. A cooling path may be defined through the tube interior volume and at least a portion of the electric power unit. The cooling path may be in fluid communication with the opening so that air may flow into the opening, through the tube, into the cooling air inlet and out of the exhaust port of the electric power unit.

Abstract: A transmission-mounted electric machine includes an integrated rotational position sensor. The rotational position sensor includes a rotor element and a stator element. The stator element is attached to a stator element of the transmission at a plurality of mounting points and includes an alignment adjustment mechanism. The rotor element of the sensor is slip-fit against a shoulder of a rotor hub and held in place using a wave spring.

Abstract: An electric motor includes a rotor and a stator. The stator surrounds the rotor, has a top half, a bottom half, and wire windings, and is fixed with respect to the drive-unit housing. The stator is cooled by gravity feed via a fluid supplied by an external source and flowing onto and past the top half. The motor also includes a fluid dam fixed relative to the stator. The fluid dam is configured to guide the fluid around the stator and shield the rotor from the fluid flowing past the stator thereby limiting an amount of the fluid between the rotor and the stator such that spin losses in the electric motor are controlled. An electro-mechanical drive-unit employing the above described electric motor is also disclosed.

Abstract: An electric motor assembly includes a motor shaft rotatable about a longitudinal axis, an angular position sensor rotor, and a deformable pin. The motor shaft has an axial keyway formed therein, and the axial keyway has a nominal keyway dimension. The angular position sensor rotor is coupled to the motor shaft to rotate with the motor shaft. The angular position sensor rotor has an axial key to fit within the axial keyway of the motor shaft, and the axial key has a nominal key dimension that is less than the nominal keyway dimension. The deformable pin is located in the axial keyway under compression between the axial key and the motor shaft to inhibit rotational shifting of the angular position sensor rotor relative to the motor shaft.

Abstract: An electric motor includes a rotor and a stator. The stator surrounds the rotor, has a top half, a bottom half, and wire windings, and is fixed with respect to the drive-unit housing. The stator is cooled by gravity feed via a fluid supplied by an external source and flowing onto and past the top half. The motor also includes a fluid dam fixed relative to the stator. The fluid dam is configured to guide the fluid around the stator and shield the rotor from the fluid flowing past the stator thereby limiting an amount of the fluid between the rotor and the stator such that spin losses in the electric motor are controlled. An electro-mechanical drive-unit employing the above described electric motor is also disclosed.

Abstract: A rotor assembly with a cooling mechanism having first and second channels is provided. The rotor assembly includes a shaft having a hollow portion and a rotor core having at least one rotor stack positioned at least partially around the shaft. The rotor core has a first end and a second end. The rotor stack forms an interior cavity which is only partially filled with a permanent magnet so as to define a gap in the rotor stack. The first channel is configured to direct fluid flow in a generally radial direction from the hollow portion of the shaft. The second channel is at least partially defined by the gap in the interior cavity of the rotor stack and is configured to direct the fluid flow from the first channel to at least one of the first and second ends of the rotor core.

Abstract: A bar-wound stator, which is connectable to a plurality of fixed terminal points, includes a plurality of stator teeth and a plurality of magnet wires. Each of the plurality of magnet wires has a winding portion wound about at least one of the plurality of stator teeth and a junction portion extending away therefrom. A plurality of flexible leads each have a first portion ultrasonically welded directly to a respective one of the junction portions of the plurality of magnet wires. A second portion of each of the plurality of flexible leads extends flexibly away from the first portion and is configured for attachment to a respective one of the fixed terminal points.

Abstract: A rotor assembly is provided. The assembly includes a hub and a rotor core having a first rotor lamination positioned at least partially around the hub. The first rotor lamination is at least partially defined by a first segment and a second segment that are configured to connect or interlock. The first segment includes a projection extending from a first body. The projection is configured to engage with a corresponding notch in the second segment in order to connect the first segment to the second segment. At least one first mounting tab extends from the first body and is configured to engage with a corresponding first groove on an outer periphery of the hub in order to connect the first segment to the hub.

Abstract: A stator core includes a first lamination and a second lamination. The first lamination is formed from a plurality of first segments and has a plurality of first mounting ears. The second lamination is formed from a plurality of second segments and has a plurality of second mounting ears. The first lamination and the second lamination are aligned with a common axis and are rotated about the common axis such that the first lamination is not aligned with the second lamination.

Abstract: A rotor core configured to rotate about an axis includes a first end lamination, a second end lamination, and a middle lamination, which is disposed axially between the first end lamination and the second end lamination. The middle lamination has a plurality of first apertures, and the first end lamination and the second end lamination do not have the first apertures.

Abstract: A housing surrounding a stator or a rotor includes an annular cooling chamber, which is formed within the housing and defines a circumferential fluid path around the stator or rotor. A fluid inlet and a fluid outlet are communication with the annular cooling chamber. A primary divider separates the fluid inlet from the fluid outlet.

Abstract: A bearing lock is provided that improves upon existing methods of stabilizing a bearing in an electric motor. The bearing is fit between a rotatable shaft and a nonrotating annular support. The bearing has an inner race surrounding the rotatable shaft and has an outer race surrounded by the annular support. The bearing lock has an annular body with a midportion, an inner wall, and an outer wall. Both the inner wall and the outer wall extend generally in a first direction from the midportion and are spaced from one another to define an annular cavity therebetween. The outer wall has circumferentially-spaced integral tabs that extend at least partially toward the inner wall to provide a biasing force to lock the body to the annular support when the annular support is placed in the annular cavity.

Abstract: An electric motor assembly includes a motor shaft rotatable about a longitudinal axis, an angular position sensor, and a deformable pin. The motor shaft has an axial keyway formed therein, and the axial keyway has a nominal keyway dimension. The angular position is coupled to the motor shaft to rotate with the motor shaft. The angular position sensor has an axial key to fit within the axial keyway of the motor shaft, and the axial key has a nominal key dimension that is less than the nominal keyway dimension. The deformable pin is located in the axial keyway under compression between the axial key and the motor shaft to inhibit rotational shifting of the angular position sensor relative to the motor shaft.

Abstract: An electric machine having a stator body and a machine housing is provided. The stator body includes a stator ring of generally annular shape and a plurality of stator teeth projecting radially inward. A first bolt hole is defined in either the stator ring or machine housing, and a first receptacle is defined in the other and is coaxial with the first bolt hole. A second bolt hole is defined in either the stator ring or machine housing, and a second receptacle is defined in the other and is coaxial with the second bolt hole. A first counter bore is coaxial with the first receptacle. A first hollow dowel is mated to the first counter bore and the first bolt hole, and defines a first dowel hole, which is coaxial with the first counter bore and the first bolt hole.

Abstract: A stator core includes a first lamination and a second lamination. The first lamination is formed from a plurality of first segments and has a plurality of first mounting ears. The second lamination is formed from a plurality of second segments and has a plurality of second mounting ears. The first lamination and the second lamination are aligned with a common axis and are rotated about the common axis such that the first lamination is not aligned with the second lamination.

Abstract: A pump-motor assembly includes a motor housing, a motor disposed substantially within the motor housing, and a pumping element driven by the motor. A pressurized region is filled with a fluid pressurized by the pumping element, and a fluid passage is in fluid communication with the pressurized region and the motor housing. Fluid flows from the pressurized region to the motor housing and at least partially submerges the motor.

Abstract: The present invention comprehends a gerotor or gear pump driven by a permanent magnet motor which exhibits cogging torque, i.e., resistance to rotation when de-energized caused by interaction between permanent magnets in the rotor and teeth on the stator. Such interaction causes the rotor to come to rest in one of many defined rotational positions and resist rotation when electrical power to the motor has been terminated. The permanent magnet motor is coupled, preferably directly, to a gerotor pump having meshing rotors or a gear pump having meshing gears. When the motor is de-energized, the pump rotors or gears come to rest and their rotation is resisted by the cogging torque of the motor. The invention finds particular application in automotive transmissions and systems with parallel pumps.

Abstract: A rotor assembly with a cooling mechanism having first and second channels is provided. The rotor assembly includes a shaft having a hollow portion and a rotor core having at least one rotor stack positioned at least partially around the shaft. The rotor core has a first end and a second end. The rotor stack forms an interior cavity which is only partially filled with a permanent magnet so as to define a gap in the rotor stack. The first channel is configured to direct fluid flow in a generally radial direction from the hollow portion of the shaft. The second channel is at least partially defined by the gap in the interior cavity of the rotor stack and is configured to direct the fluid flow from the first channel to at least one of the first and second ends of the rotor core.

Abstract: A bearing lock is provided that improves upon existing methods of stabilizing a bearing in an electric motor. The bearing is fit between a rotatable shaft and a nonrotating annular support. The bearing has an inner race surrounding the rotatable shaft and has an outer race surrounded by the annular support. The bearing lock has an annular body with a midportion, an inner wall, and an outer wall. Both the inner wall and the outer wall extend generally in a first direction from the midportion and are spaced from one another to define an annular cavity therebetween. The outer wall has circumferentially-spaced integral tabs that extend at least partially toward the inner wall to provide a biasing force to lock the body to the annular support when the annular support is placed in the annular cavity.