Abstract: An electric machine includes a core defining a first axial end, a second axial end opposite the first axial end, and a plurality of slots extending between the first axial end and the second axial end. Windings are wound on the core. The windings include in-slot portions positioned in the plurality of slots and end turn portions positioned on the first axial end and the second axial end. A cooling tube is coupled to the end turn portions of the windings. A heat transfer member extends between the cooling tube and the windings and is in contact with the cooling tube and the windings.

Abstract: A method of fabricating an armature for a motor includes providing a laminated assembly having a length, a central axis, and a plurality of open slots each extending the length and each configured to locate one conductor at a first greater radial distance from the central axis and another conductor at a second lesser radial distance from the central axis. A first conductor is inserted into a first one of the slots at the greater radial distance such that the first conductor extends out of the first one of the slots. A free end of the inserted first conductor is bent in each of a first direction and a second direction orthogonal to the first direction. A second conductor is inserted into a second one of the slots at the lesser radial distance such that the second conductor extends out of the second one of the slots. A free end of the inserted second conductor is bent in each of the two orthogonal directions.

Abstract: An interlock system and method are provided for protecting high voltage electrical couplings. The interlock system may control access to the electrical couplings based on the voltage of the electrical couplings. The interlock system may also selectively energize and de-energize the electrical couplings based on the position of a lid.

Abstract: An electro-dynamic machine is provided and includes stator assembly end turns and a coolant chargeable bladder disposable to contact the end turns.

Abstract: An apparatus is provided and includes a hub, including opposing faces, a first sidewall fixed to the opposing faces to define a first interior and a second sidewall fixed to one of the opposing faces to define a second interior within the first interior, a first assembly, disposed within the second interior, to generate current from input mechanical energy, a second assembly, electrically coupled to the first assembly and disposed within the first interior, to generate mechanical energy to be transmitted to external mechanical elements from current associated with the current generated by the first assembly and first and second couplings, the first coupling being disposed to mechanically couple the first and second assemblies and the second coupling being disposed to mechanically couple the second assembly and the external mechanical elements.

Abstract: An electric machine includes a housing, a stator fixedly mounted relative to the housing, and a rotor assembly rotatably mounted relative to the stator. The rotor assembly includes a plurality of rotor laminations forming a rotor body, one or more permanent magnets provided in the rotor body, and a sleeve extending around the one or more permanent magnets. The sleeve provides a thermal interface between the one or more permanent magnets and the rotor body.

Abstract: An electric machine system includes: an electric motor; and an absorption cooling system driven by heat generated by the electric motor and configured to cool a primary cooling fluid that removes the heat from the electric motor to a temperature below an ambient temperature of an ultimate heat sink. A method for operating the electric machine system is also disclosed.

Abstract: A starter motor for an engine includes a housing and a planetary gear assembly. The housing defines an interior space. The planetary gear assembly is at least partially positioned in the interior space and includes (i) a sun gear having a first number of gear teeth equal to a pitch diameter of the sun gear, (ii) a ring gear having a second number of gear teeth equal to a pitch diameter of the ring gear, and (iii) no more than two planet gears each connected to a planetary gear carrier. Each planet gear of the no more than two planet gears has a third number of gear teeth equal to a pitch diameter of the no more than two planet gears.

Abstract: An electrical machine includes a voltage regulator, a rectifier, a first terminal structure, and a second terminal structure. The voltage regulator includes a first electrical lead. The rectifier includes a second electrical lead. The first terminal structure extends from the first electrical lead and defines a receptacle opening. The first terminal structure includes (i) a first prong configured to at least partially occlude the receptacle opening, and (ii) a second prong configured to at least partially occlude the receptacle opening. The second terminal structure extends from the second electrical lead. The second terminal structure extends through the receptacle opening and defines a first connection surface against which the first prong is positioned, and an opposite second connection surface against which the second prong is positioned. The first terminal structure and the second terminal structure mechanically connect and electrically connect the first electrical lead to the second electrical lead.

Abstract: A slot liner is configured for association with a tooth of an electro-dynamic machine core having an annular rim and circumferentially spaced teeth radially extending from the annular rim. The slot liner includes sidewalls configured to line circumferential surfaces of the tooth, first and second tabs formed by bends in the sidewalls, the first tab being configured to line a portion of the annular rim adjacent to the tooth and the second tab being configured to overlap with a tab of an adjacent slot liner and a retainer configured to retain the sidewalls against a radially inward portion of the tooth.

Abstract: A stator includes a stator core having a plurality of slot segments, a plurality of stator winding conductors arranged in select ones of the plurality of slot segments, a jumper conductor interconnecting select ones of the plurality of stator winding conductors to form one or more stator windings, a common conductor connected to at least one of the stator winding conductors, a phase conductor connected to corresponding ones of the one or more stator windings, and a composite sleeve provided on at least one of the jumper conductor, the common conductor, and the phase conductor. The composite sleeve includes a first sleeve, and a second sleeve positioned about the first sleeve. One of the first and second sleeves is formed from a compressed amide synthetic fiber. The first and second sleeves cooperate to provide protection for the conductor from external elements.

Abstract: An electrical device includes a plurality of stacked laminates that form a tubular stator portion, a cooling passage partially defined by orifices formed in the plurality of stacked laminates, a housing including a cavity further defining the cooling passage, the cooling passage defining a fluid flow path parallel to a rotational axis of the stator portion, a sump portion communicative with the cooling passage, the sump portion including a cavity defined by the stator portion and the housing member.

Abstract: An alternator includes a housing having an inner surface and an outer surface, a stationary field coil component fixedly mounted to the inner surface of the housing through one or more mechanical fasteners, and a heat sink component mounted to the outer surface of the housing. The heat sink component includes one or more openings that align with corresponding ones of the one or more mechanical fasteners.

Abstract: A method for controlling a specific electric machine includes receiving with a controller a back electromotive force (BEMF) coefficient for the specific electric machine. The controller is configured to control operation of an inverter coupled to the electric machine where the inverter is configured to provide or receive multi-phase electricity to or from the electric machine in motor mode or generator mode, respectively. The method further includes receiving with the controller an input related to a selected torque to be applied by or a selected power to be removed from the electric machine. The method further includes determining a first electrical parameter the inverter is to apply to in motor mode or a second electrical parameter the inverter is to convert power to in generator mode using the BEMF coefficient, and applying the first electrical parameter to the electric machine or converting the received power to the second electrical parameter.

Abstract: A method of inserting a continuous conductor having a rectangular cross-section into slot segments formed in a stator core includes deforming in a first direction a core member having a first end portion that extends to a second end portion to widen an opening at end portions of the slot segments, inserting one or more continuous conductors having a rectangular cross-section into select ones of the slot segments, and deforming in a second direction the core member to narrow the opening at end portions of the slot segments.

Abstract: A spacer for supporting conductors in a stator assembly of an electric machine includes a plurality of positioning elements cooperating with various conductors in the specials region of the winding arrangement. The spacer illustratively includes an insulating body formed of an electrically non-conductive material and including surfaces facing axially inwardly for contacting short conductors and crossover pockets for receiving crossover conductors which electrically connect an inner winding set and an outer winding set. The spacer further illustratively includes phase lead pockets facing axially outwardly for receiving a terminal phase lead conductor.

Abstract: A permanent magnet rotor assembly for an electric machine includes a rotor core including one or more axially-extending openings and one or more permanent magnets located in the one or more axially-extending openings defining one or more gaps between the one or more permanent magnets and the one or more axially-extending openings. One or more thermally-conductive bars are located in the one or more gaps to transfer thermal energy from an interior of the rotor assembly toward an axial end of the rotor assembly.

Abstract: A method of P-forming a conductor having a rectangular cross-section to create a continuous stator winding. The method includes forming a conductor having a rectangular cross-section into a series of first and second substantially parallel segments that meet at a vertex, deforming the conductor such that each of the first and second segments are non-parallel to form a cross-over feature at the vertex, and deforming a section of each of the first and second segments to include corresponding first and second portions that are generally parallel to create the continuous stator winding.

Abstract: An apparatus is provided and includes a hub, including first and second opposing faces, a first sidewall fixed at opposite ends thereof to the first and second opposing faces to define a first interior between the first and second opposing faces and a second sidewall fixed to one of the first and second opposing faces to define a second interior within the first interior, a first assembly, disposed within the second interior, to generate current from input mechanical energy and a second assembly, electrically coupled to the first assembly and disposed within the first interior, to generate mechanical energy from current associated with the current generated by the first assembly.

Abstract: A starter motor including a frame having a terminal mounting portion, and a field fixedly mounted relative to the frame. An armature is rotatably supported relative to the field. A conductor having a terminal mounting section is electrically connected to one of the field and the armature. A terminal extends through the terminal section of the conductor and the terminal mounting portion of the frame. The terminal includes a plurality of threads. A conductor mounting element threadably engages with the plurality of threads. The conductor mounting element is configured to form a threaded clamped connection that establishes a solid metal compressive stack up connection between the conductor and the terminal.