Abstract: A heat-sink base provided with heat-sink fin portions, a manufacturing method and a motor provided with the heat-sink base. The base is produced by pouring cast metal into a mold cavity to replace a pattern having a predetermined sublimation temperature. The base includes a preformed heat-sink member comprising a plurality of heat-sink fin portions and at least one anchor portion embedded at least partially in the pattern, and a base body comprising an enclosed base portion and a holder portion for receiving and holding the at least one anchor portion. By virtue of the invented method, the heat-sink member having an extremely thin thickness can be mounted on the base body and the overall surface area of the heat-sink base is increased considerably.

Abstract: An induction motor controller is provided. The induction motor controller includes a first module that derives a commanded stator voltage vector, in a rotor flux reference frame, via a rotor flux regulator loop and a torque regulator loop, which process at least partially in the rotor flux reference frame. The induction motor controller includes a second module that processes the commanded stator voltage vector to produce AC (alternating current) power for an induction motor.

Abstract: A powertrain backlash control system is provided for use with an electric vehicle (EV), where the EV uses at least one powertrain to provide forward vehicle motion and at least one additional powertrain to provide rearward vehicle motion. The control system eliminates backlash by maintaining a positive motor torque within each powertrain when the vehicle is in-gear, thus applying a minimum forward torque demand to the powertrain dedicated to forward motion and applying a minimum reverse torque demand to the powertrain dedicated to rearward motion.

Abstract: A gear assembly is provided that simplifies the integration of a differential assembly into the hollow rotor of an electric motor. The gear assembly utilizes a hollow cross member that includes a central portion and a plurality of hollow extension members onto which the gears are mounted. Within each of the hollow extension members is a pin. When the pins are withdrawn, the assembly fits unimpeded within the hollow rotor. When the pins are partially extended out of the corresponding extension members, the ends of the pins fit within apertures in the rotor. A plug fits within a centrally located thru-hole in the central portion of the hollow cross member, thereby locking the pins in the extended position and locking the gear assembly in place.

Abstract: A seat comprises: a seat cushion including a first mesh; a seat extension configured to move into a closed position and an extended position relative to the seat cushion, the seat extension including a second mesh; a first conduit forming a first air channel between the first and second meshes in the closed and extended positions; and a fan configured to draw air from the first and second meshes using the first conduit.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. The coolant manifold includes a middle member that allows coolant to enter the axial coolant channels via transition laminations, where the transition laminations include coolant distribution channels that direct the flow of coolant entering into the manifold into the stator-integrated axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to improve end winding cooling uniformity, two or more end laminations are included on either end of the stator assembly which restrict and direct the flow of coolant exiting the axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to increase the velocity of the coolant exiting the axial coolant channels, thereby improving end winding cooling uniformity, end laminations are integrated into the stator which restrict the flow of coolant from the axial coolant channels.