Abstract: A powertrain includes an engine that has a crankshaft. A first motor-generator is drivingly connected to the crankshaft via an endless rotatable device. The powertrain includes a transmission that has a transmission input member driven by the crankshaft and a transmission output member. A front differential is operatively connected with front half shafts. A transfer case is configured to distribute torque of the transmission output member to the front differential and to a driveshaft. A rear differential is configured to transfer torque from the driveshaft to rear half shafts. A second motor-generator is drivingly connected to the rear differential. A gearing arrangement is configured to multiply torque from the second motor-generator to the rear half shafts. A controller controls the second motor-generator to function as a motor that provides torque to the rear wheels through the rear differential. A modular rear drive unit operatively connects to the vehicle body.

Abstract: A powertrain includes an engine that has a crankshaft. A first motor-generator is drivingly connected to the crankshaft via an endless rotatable device. The powertrain includes a transmission that has a transmission input member driven by the crankshaft and a transmission output member. A front differential is operatively connected with front half shafts. A transfer case has a gearing arrangement configured to distribute torque of the transmission output member to the front differential and to a driveshaft. A rear differential is operatively connectable with the driveshaft, and is configured to transfer torque from the driveshaft to rear half shafts. A second motor-generator is drivingly connected to the rear differential. A controller is operatively connected to the second motor-generator, and controls the second motor-generator to function as a motor that provides torque to the rear wheels through the rear differential. A modular rear drive unit operatively connects to the vehicle body.

Abstract: An interior permanent magnet machine includes a stator including a plurality of electrical conductors. The interior permanent magnet machine further includes a rotor concentrically disposed in relation to the stator. The rotor is configured to rotate relative to the stator about a rotational axis and includes a plurality of polar pieces arranged annularly about the rotational axis. At least one of the polar pieces includes a magnetic layer configured to magnetically interact with the electrical conductors. The magnetic layer has a substantially conic section shape.

Abstract: An electric motor assembly includes a stator having a first set of electrical windings. The motor assembly includes a rotor assembly rotatable about an axis of rotation and that has a rotor with first and second rotor segments. Each of the rotor segments has a respective set of magnets spaced therearound. The motor assembly has a phaser that includes a phaser actuator and a phaser gear mechanism. The phaser gear mechanism has a plurality of members. The phaser actuator and the first and second rotor segments are each operatively connected to a different respective one of the members. The phaser actuator is activatable to change an angular position of the member to which the phaser actuator is operatively connected, moving one of the rotor segments about the axis of rotation relative to the other of the rotor segments to reduce back electromotive force in the first set of stator windings.

Abstract: An integrated rotary transformer and resolver and a motor including an integrated rotary transformer and resolver is provided. The integrated rotary transformer and resolver may include, but is not limited to, a stator having an outer surface and a plurality of slots disposed along the outer surface, a plurality of sensing coils, the plurality of sensing coils disposed in at least some of the plurality of slots, a rotor having a surface varying from a first predetermined thickness to a second predetermined thickness, and a controller electrically coupled to the plurality of sensing coils and configured to determine a position of the rotor based upon a voltage induced in each of the coils due to a relative thickness of the rotor opposed to the respective sensing coil.

Abstract: A hybrid powertrain for propelling a vehicle includes an engine and an energy storage system operatively connected to the engine. Both the engine and the energy storage system are operable for providing power to propel the vehicle. A control system is operatively connected to the engine and the energy storage system and is configured to execute a stored algorithm that determines required energy reserve, remaining energy, and power capability of the energy storage system. The control system commands operation in one of a first operating mode, a second operating mode, and a third operating mode based on the required energy reserve, the remaining energy, and the power capability of the energy storage system.

Abstract: Controlling a synchronous electric machine includes determining a rotor field current of a wound rotor of the synchronous electric machine and determining a time-rate change in field flux linkage. A rotor field voltage is determined based upon the time-rate change in the field flux linkage, and a rotor field resistance is determined based upon the rotor field voltage and the rotor field current. A rotor temperature is determined based upon the rotor field resistance. Operation of the synchronous electric machine is controlled responsive to a torque command and the rotor temperature.

Abstract: A powertrain includes a first electric motor, a second electric motor and a transmission. The first electric motor includes an interchangeable winding set to provide the required power for the specific propulsion configuration utilized to propel the vehicle, i.e., a hybrid propulsion configuration or a full electric propulsion configuration. The transmission is operable in different powerflows to support operation of the powertrain in either of the hybrid propulsion configuration or the full electric propulsion configuration. The same powertrain may be used for either the hybrid propulsion configuration or the full electric propulsion configuration by switching the specific winding set installed into the first electric motor.

Abstract: An interior permanent magnet machine includes a rotor having a plurality of slots. First and second slots are disposed in a first pole and the third and fourth slots are disposed in a second pole. A first angle is defined between respective centerlines of the first and second slots. A second angle is defined between respective centerlines of the third and fourth slots. The first angle is configured to be sufficiently different from the second angle so that torque ripple is reduced. Thus the rotor is configured such that the angular configuration of slots in a first pole is different from the angular configuration of slots in a second pole of the rotor.

Abstract: A stator assembly includes a plurality of stator slots defining multiple slot layers. The assembly includes a plurality of hairpins each having a respective first leg positioned in one of the multiple slot layers and a respective second leg positioned in another of the multiple slot layers. Each hairpin is configured to allow a current to flow from the respective first leg to the respective second leg. The plurality of hairpins is divided into multiple hairpin layers. The hairpins form multiple winding sets, such as first, second, third and fourth winding sets. Each of the winding sets at least partially includes the hairpins from at least two of the multiple hairpin layers. The multiple slot layers may include six slot layers. The multiple hairpin layers may include six hairpin layers. Thus, at least one of the hairpin layers may be “shared” by two winding sets.

Abstract: Controlling a synchronous electric machine includes determining a rotor field current of a wound rotor of the synchronous electric machine and determining a time-rate change in field flux linkage. A rotor field voltage is determined based upon the time-rate change in the field flux linkage, and a rotor field resistance is determined based upon the rotor field voltage and the rotor field current. A rotor temperature is determined based upon the rotor field resistance. Operation of the synchronous electric machine is controlled responsive to a torque command and the rotor temperature.

Abstract: An interior permanent magnet machine includes a rotor having a plurality of slots. First and second slots are disposed in a first pole and the third and fourth slots are disposed in a second pole. A first barrier is defined by the first, second, third and fourth slots. The slots are configured to be symmetric relative to their respective pole axes. A first angle is defined between the first and second slots. A second angle is defined between the third and fourth slots. The first angle is configured to be sufficiently different from the second angle so that torque ripple is minimized. Thus the rotor is configured such that the angular configuration of slots in a first pole is different from the angular configuration of slots in a second pole of the rotor.

Abstract: A method and assembly for forming a rotor include forming a rotor core having a plurality of voids and placing the formed rotor core into a die cavity. The method includes moving a plurality of support shoes to define an outer diameter of the die cavity, and injecting at least one of the plurality of voids with a magnetic slurry. At least one permanent magnet is formed from the magnetic slurry by applying pressure to the rotor core and the magnetic slurry within the die cavity and by applying a magnetic field to align the magnetic slurry. After forming the at least one permanent magnet within the rotor core, the plurality of support shoes are retracted and the rotor core removed with the at least one permanent magnet formed therein.

Abstract: A powertrain includes an engine that has a crankshaft. A first motor-generator is drivingly connected to the crankshaft via an endless rotatable device. The powertrain includes a transmission that has a transmission input member driven by the crankshaft and a transmission output member. A front differential is operatively connected with front half shafts. A transfer case has a gearing arrangement configured to distribute torque of the transmission output member to the front differential and to a driveshaft. A rear differential is operatively connectable with the driveshaft, and is configured to transfer torque from the driveshaft to rear half shafts. A second motor-generator is drivingly connected to the rear differential. A controller is operatively connected to the second motor-generator, and controls the second motor-generator to function as a motor that provides torque to the rear wheels through the rear differential. A modular rear drive unit operatively connects to the vehicle body.

Abstract: A stator assembly includes a plurality of stator slots defining a plurality of slot layers. The assembly includes a plurality of hairpins each having respective first and second legs positioned in respective ones of the slot layers. Each of the hairpins is one of a short-pitched coil, a long-pitched coil and a full-pitched coil. The short-pitched, long-pitched and full-pitched coils are configured to extend over a first, second and third number of the stator slots, respectively. The hairpins may be divided into first, second, third, fourth, fifth and sixth hairpin layers. One of the hairpin layers includes at least one short-pitched coil, and another of the hairpin layers includes at least one long-pitched coil. The first, third and fifth hairpin layers each may include at least two short-pitched coils while the second, fourth and sixth hairpin layers each may include at least two long-pitched coils.

Abstract: A conductor is provided for an electric machine having an axis, a radial direction extending outward from the axis, and a tangential direction perpendicular to the radial direction. The conductor includes a solid core, having radial faces substantially perpendicular to the radial direction of the electric machine and tangential faces substantially perpendicular to the tangential direction of the electric machine. At least one tangential depression is formed on at least one of the tangential faces. The tangential depression creates a tangential void within a rectangular envelope defined by the solid core. Therefore, the surface area of the solid core is greater than the surface area of the rectangular envelope.

Abstract: A hybrid powertrain system has a high-voltage electric circuit including a high-voltage battery and a DC link coupled to first and second inverters electrically connected to first and second torque machines. A method for operating the hybrid powertrain system includes receiving a motor torque command for the second torque machine, determining a preferred DC link voltage for achieving the motor torque commanded from the second torque machine, selectively interrupting electric power flow between the high-voltage battery and the DC link to achieve the preferred DC link voltage.

Abstract: A method of manufacturing a stator core is disclosed. The method includes advancing a blank at each of a plurality of press cycles to form a segment at each of the press cycles and shaping the segments. Shaping the segments further includes activating a tooth punch, activating a mounting-ear punch, and activating an joint punch. The method also includes separating the segments from the blank.

Abstract: An interior permanent magnet machine includes a stator including a plurality of electrical conductors. The interior permanent magnet machine further includes a rotor concentrically disposed in relation to the stator. The rotor is configured to rotate relative to the stator about a rotational axis and includes a plurality of polar pieces arranged annularly about the rotational axis. At least one of the polar pieces includes a magnetic layer configured to magnetically interact with the electrical conductors. The magnetic layer has a substantially conic section shape.

Abstract: A vehicle includes a motor, an alternating current (AC) power bus, a power inverter module (PIM), and a controller. The PIM includes a semiconductor die assembly with semiconductor power switches arranged in electrical parallel for delivering AC power to the motor via the bus. The controller determines an operating mode of the vehicle, selects and activates a designated one of the switches during a threshold low-current state of the PIM, and selects and activates all of the switches during a high-current state of the PIM. A PIM assembly for the vehicle includes the die assembly and controller. A method for optimizing energy efficiency of the vehicle includes providing the die assembly noted above, automatically determining the operating mode, and selecting and activating one of the switches when the operating mode corresponds to the threshold low-current state, and all of the electrical switches during the threshold high-current state of the PIM.