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 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: A variable flux electric starter motor includes a frame, an armature rotatably mounted within the frame, and a primary field mounted to the frame. The primary field includes a plurality of primary windings electrically connected one to another. A relay is electrically coupled to at least one of the plurality of poles. A supplemental field is mounted to the frame. The supplemental field includes a supplemental winding electrically connected in parallel to the plurality of primary windings.

Abstract: A method of operating a variable flux electric machine includes passing an electrical current through a plurality of wound poles of a wound field to generate a first flux, rotating an armature at a first crank point having a first speed in response to the first flux, shorting at least one of the plurality of wound poles, generating a second flux through a permanent magnet (PM) field having a plurality of PM poles, and rotating the armature at a second crank point having a second speed in response to the second flux, the second speed being greater than the first speed.

Abstract: A variable flux electric machine including a frame, an armature rotatably mounted within the frame, a first field having a plurality of windings that defines at least one wound pole fixedly mounted relative to the frame, a second field having at least one permanent magnet (PM) that defines at least one PM pole fixedly mounted relative to the frame, and a relay electrically coupled to the plurality of windings of the first field.

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: A terminal block for an apparatus includes at least one terminal conductor having a first end that extends to a second end. The first end includes a first connection portion and the second end includes a second connection portion. A non-electrically conductive member covers the at least one terminal conductor. The non-electrically conductive member includes a body having a first end section arranged at the first end extending through an intermediate section to a second end section arranged at the second end. The first end section includes a first opening exposing the first connection portion, and the second end portion includes a second opening exposing the second connection portion. The body further includes a conductor routing system having at least one conductor routing member configured and disposed to restrain and guide a conductor member across the at least one terminal conductor.

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 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: 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: A stator assembly includes a first conductor having a first leg portion, and second leg portion. Each of the first and second leg portions includes corresponding first and second free end portions. The first free end portion includes first and second surface portions and the second free end portion includes first and second surface segments. A second conductor includes a first leg section, and a second leg section including corresponding first and second free end sections. The first free end section includes first and second surface zones and the second free end section including first and second surface sectors. The second free end portion and the first free end section are twisted creating a cross-over region causing the first surface portion to abut the second surface zone. The second free end portion is joined to the first free end section through a bond that exists at the cross-over region.

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: An electric machine is provided including a housing, a stator assembly positioned within the housing, and a machine lead electrically coupled to the stator assembly. A terminal block assembly is overmolded onto an external lead to provide a covered environment for electrically coupling the external lead to the machine lead.

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.

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: 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: A composite sleeve for a conductor including a conductor having an outer surface, a first sleeve positioned about the outer surface of the conductor, 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 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.