Abstract: A method and system of cooling an enclosure or motor is disclosed. An exemplary permanent magnet electric motor is formed with an external stator and an internal rotor. The motor controller is in thermal proximity to the motor but is thermally isolated from the motor by an air chamber. In one exemplary embodiment, one or more heat sinks are provided to create efficient heat removal paths. In another exemplary embodiment, one of more heat pipes are located in the system.

Abstract: Thermal management of an electric machine is implemented by selecting a stator core configuration in accordance with an intended machine application and determining the minimum heat dissipation necessary to maintain the temperature of the core segment configuration at peak excitation within acceptable limits is determined. A core model is used to ascertain thermal distribution at peak excitation. In accordance therewith, a pattern in the selected core segment configuration is established for placement of at least one heat pipe for removing heat from the core. Preferably, heat pipes are located at high thermal points in the core segment and oriented in alignment with mapped lines of flux. By placing the heat pipe either at the center of the core or at a recessed boundary layer between the core and winding, the heat pipe can capture and conduct excess heat away from the heat generating areas of the core, thus maintaining the core and the excitation windings at desired temperature.

Abstract: A portable range extender can be used to supply electrical power to an electric vehicle operable by an electric traction motor. The portable range extender includes an engine, a dynamoelectric machine coupled to the engine by a shaft, an autonomous range extender controller for controlling operations of the range extender independently of a controller for the vehicle, and circuitry associated with the engine and machine. The range extender and its controlling circuitry are self contained within an enclosure. The enclosure is partitioned to form two sections, a first section housing the dynamoelectric machine and the second section housing the engine. Windows in the enclosure provide a path for air cooling of the range extender components.

Abstract: A portable range extender can be used to supply electrical power to an electric vehicle operable by an electric traction motor. The portable range extender includes an engine, a dynamoelectric machine coupled to the engine by a shaft, an autonomous range extender controller for controlling operations of the range extender independently of a controller for the vehicle, and circuitry associated with the engine and machine. To start operation, electrical energization is applied from the vehicle battery to the dynamoelectric machine for operation as a motor to drive the shaft. As the shaft accelerates, the rotational speed of the shaft and the temperature of the engine are sensed. When the speed and temperature obtain predetermined thresholds, fuel is supplied to the engine and ignition is activated. The engine then operates as a prime mover to drive the shaft in lieu of the machine.