Abstract: A machine includes a high voltage element and an enclosure surrounding the high voltage element. The enclosure includes a first insulating insert disposed at least partially within a first wall and being electrically non-conductive and surrounding a first conductive insert and an enclosure cover formed at least partially of an electrically non-conducting substrate and having a first opening formed therein sized to allow a first fastener or an extension of the first conductive insert to pass through it. Removal of the enclosure cover causes the high high-voltage element to cease operating.

Abstract: An electric machine including a stator having a body provided with at least one alignment member, and a resolver positioned relative to the stator. The resolver includes at least one alignment element. An alignment adaptor is configured to receive each of the stator and the resolver. The alignment adaptor includes an alignment system that positions the alignment member and the alignment element to establish a desired alignment between the stator and the resolver.

Abstract: A method of operating an electric machine includes flowing a coolant into an interior portion of a housing of the electric machine, and sensing a level of coolant in a coolant collection area within the interior portion with a coolant level sensor arranged at the housing.

Abstract: A permanent magnet electric machine includes a housing, a stator mounted within the housing, and a rotor assembly rotatably mounted within the housing relative to the stator. The rotor assembly includes a rotor body having a plurality of rotor laminations. A plurality of permanent magnets having axial end portions is mounted to the rotor body. An amount of thermal interface material (TIM) is arranged between the axial end portions of adjacent ones of the plurality of permanent magnets.

Abstract: An electric machine includes a housing having an outer surface and an inner surface that defines an interior portion. The housing also includes a connection zone having a first end portion that extends from the outer surface to a second end portion that is exposed to the interior portion. The connection zone includes a connection passage. A terminal block extends through the connection passage. The terminal block includes a non-electrically conductive member that is sealed against the connection passage, and an electrically conductive member covered by the non-electrically conductive member. The electrically conductive member includes a first end section that extends to a second end section through an intermediate section. The first end section has a first connection zone and the second end section has a second connection zone. The second connection zone is at an angle relative to the first connection zone.

Abstract: An adapter assembly is provided and includes a body having a first periphery, a second periphery opposite the first periphery and a central region interposed between the first and second peripheries. The first periphery is attachable to a first housing at a first aperture thereof, the first housing defining an interior in which a first motor is disposable. The second periphery is attachable to a second housing at a second aperture thereof, the second housing defining an interior in which a second motor is disposable. The central region is configured to encase a coupling for operably coupling the first and second motors via the first and second apertures, respectively, for output to a shaft.

Abstract: A drive train component includes a housing having a plurality inner surfaces that collectively define an interior portion. A gear set is arranged within the interior portion. The gear set includes a first side and a second side. A gear shock control member is positioned between one of the first and second sides of the gear set and an adjacent component. The gear shock control member includes a plurality of pre-loaded biasing members that direct an axial force onto the gear set.

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: A stator includes a body portion having an outer portion and an inner portion that defines an interior region, a plurality of stator teeth members extending from the inner portion into the interior region, and at least one continuous conductor wound around select ones of the plurality of stator teeth members to form at least one pole. Each of the plurality of stator teeth members including a number of wraps of the at least one continuous conductor. The at least one continuous conductor including a number of twists that is fewer than the number of wraps.

Abstract: An asynchronous boost assist system for a motor vehicle includes a first electric motor, a second electric motor positioned opposite the first electric motor and a differential gear system operatively connected to the first and second electric motors. The differential gear system includes a first differential gear set and a second differential gear set. The first differential gear set is operatively connected to the first and second electric motors and the second differential gear set is configured and disposed to operatively connect to first and second vehicle wheels. A controller is operatively connected to each of the first and second electric motors. The controller selectively independently controls an operational speed of each of the first and second electric motors to selectively provide an acceleration boost through the second differential gear set.

Abstract: An electric machine includes a rotor lamination assembly having a lamination member formed from a material having a first yield strength. The lamination member includes a first bridge portion having a first width, and a first bridge zone having a first thickness. The rotor lamination assembly also includes at least one lamination section having a second bridge zone having a second thickness. The second thickness is greater than the first thickness. The rotor lamination assembly further includes at least one lamination element formed from a second material having a second yield strength that is higher than the first yield strength, and at least one lamination component. The at least one lamination component includes a second bridge portion having a second width. The second width is greater than the first width.

Abstract: An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a vibration sensor arranged within the housing. The vibration sensor includes a sensing member configured and disposed to detect vibrations of the electric machine.

Abstract: A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure.

Abstract: An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a coolant system fluidly connected to the housing. The coolant system delivers a flow of coolant through the housing. A coolant temperature sensor is arranged within the housing and exposed to the flow of coolant. The coolant temperature sensor configured and disposed to detect a temperature of the coolant in the housing.

Abstract: An electric machine system including an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing, and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes a switch module having a switch member. The switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A cooling system that includes an expandable coolant manifold is arranged in the switch portion of the machine housing. The expandable coolant manifold is fluidly connected to the switch module.

Abstract: A method of joining a plurality of electrical conductors in an electric machine comprises the steps of providing a core with a plurality of circumferentially spaced openings, and positioning a plurality of conductors within the openings of the core in a plurality of concentric layers. Each conductor includes an end that extends from the core. The ends of the conductors have a first shape. The method also includes the step of shaping the ends of the conductors with a set of forming dies to form a second shape. Additionally, the method includes the step of joining a pair of adjacent ends with a joining tool to form a joint with a third shape after shaping the ends to form the second shape. The method further includes the step of removing the set of forming dies and the joining tool from the joint after the joining step.

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: An electric machine includes: a stator having stator windings; a rotor configured to interact electromagnetically with the stator; and a housing configured to house the stator and the rotor. A material matrix is disposed within the housing and in contact with the stator windings. The material matrix defines a plurality of passages configured for the cooling fluid to flow within to remove heat from the stator windings.

Abstract: Disclosed is a rotor for a fluid cooled electric machine including a rotor shaft rotably located at a central axis and a plurality of rotating coolant passages extending outwardly from the rotor shaft to direct a flow of coolant to a desired impingement location on the electric machine thereby removing thermal energy from the impingement location. Further disclosed is a fluid cooled electric machine including a plurality of coolant passages each including at least one coolant passage inlet and at least one coolant passage outlet, the plurality of coolant passages configured to rotate about the central axis and direct a flow of coolant therethrough to a desired impingement location thereby removing thermal energy from the impingement location.

Abstract: A method of insulating a conductor wire comprises the steps of providing an electrically conductive core having a longitudinal axis and applying an electrical insulation material to an outer surface of the core. The method further comprises the steps of elevating the temperature of the electrical insulation material and applying external pressure to the electrical insulation material to facilitate adhesion with the core.