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 for monitoring remaining life of an electric machine for a motor vehicle includes sensing a temperature of a component of the electric machine at one or more time intervals. A percentage of life of the component consumed at each time interval is calculated and the percentages of life consumed are summed to determine a total percentage of life consumed. The total percentage of life consumed is compared to a selected threshold. A life monitor system for an electric machine for a vehicle includes a temperature sensor secured to a component of the electric machine. An engine control unit is operably connected to the temperature sensor and is configured to calculate a remaining life of the component of the electric machine compared to a selected threshold, based on temperature data from the temperature sensor.

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: An electric machine system includes an electric motor, an auxiliary device configured to receive filtered electric power, and a filter. The filter is configured to receive electric power and to pass filtered electric power to the auxiliary device at a frequency not used for power conversion to rotational energy by the electric motor. A method for operating the electric machine system is also disclosed.

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: An electric machine system includes an electric motor and an oil pump disposed within a housing. The oil pump is configured to disperse oil in a pattern about a rotational axis within the electric motor. A method for operating the electric machine system is also disclosed.

Abstract: A stator for an electric machine includes a stator winding located at a stator core. The stator winding has one or more phases, each phase including a single unitary conductor having at least two conductor segments arranged in an electrically parallel relationship. A connection portion is formed in the single unitary conductor between a first conductor segment and a second conductor segment of the at least two conductor segments to connect the conductor to an electrical component.

Abstract: A component for an electric machine includes a spool having a main body portion provided with a first end portion that extends substantially uninterrupted to a second end portion through an intermediate portion. A plurality of mounting elements are provided on the first end portion. A star member is operatively connected to the spool. The star member includes a main body, a plurality of flap members that extend from the main body and collectively define a central opening, and a plurality of mounting members that extend into the central opening. The plurality of mounting members engage with corresponding ones of the plurality of mounting elements to detachably mount the star member to the first end portion of the spool.

Abstract: A rotor assembly includes a lamination and a hub. The hub includes an inner portion and an outer portion surrounding the inner portion and separated from it by an expansion gap. The rotor assembly also includes two or more connecting members coupling the inner portion to the outer portion, the connecting members having a first end and a second end.

Abstract: An electrical machine has been developed that opportunistically regulates the voltage supplied to the coil of the electrical machine. The electrical machine includes a stator winding, a rotatable electromagnet, and a voltage regulator. The voltage regulator is configured to control an output voltage of the electrical machine. The regulator is configured to vary the magnitude of the output voltage based at least in part on acceleration of the vehicle.

Abstract: An electric machine including a housing and a stator arranged within the housing. The stator includes a body having a first end that extends to a second end through an intermediate portion. The intermediate portion includes an inner diametric surface and an outer diametric surface. A sleeve member is arranged on the outer diametric surface of the stator. The sleeve member includes body member having an inner diametric region that extends to an outer diametric region through an intermediate region. The sleeve member defines a flux carrying member having a magnetic flux flow path that passes magnetic flux from the stator to the outer diametric region.

Abstract: An electric machine including a housing, and a stator mounted within the housing. The stator includes an outer perimetric surface and an inner perimetric surface. A rotor is mounted, at least in part, within the inner perimetric surface of the stator. The rotor is rotatable relative to the stator. A stator sleeve extends about the stator. The stator sleeve includes a first sleeve portion and a second sleeve portion. The first sleeve portion includes a first diametric edge that extends to a second diametric edge, and the second sleeve portion includes a first diametric edge section that extends to a second diametric edge section. The stator sleeve is configured and disposed to establish a coolant cavity about the outer perimetric surface of the stator.

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: An electric machine includes a stator mounted within the housing, and a transmission member mounted within the housing and surrounded at least in part by the stator. The transmission member includes a gear mechanism operatively coupled to an output shaft. The transmission mechanism is rotatable relative to the stator.

Abstract: An apparatus for loading stator windings into a stator core. The apparatus includes an arbor member including a body having an outer diametric portion including a plurality of slots. The apparatus also includes a first guide track having a first end that is positioned adjacent the outer diametric portion. A second guide track includes a first end is positioned adjacent the outer diametric portion and spaced from the first end of the first guide track. The apparatus further includes a third guide track including a first end is positioned adjacent the outer diametric portion and spaced from the first end of the first guide track and the first end of the second guide track. At least one of the first, second, and third guide tracks and the arbor member is positionable to guide slot segment portions of corresponding first, second, and third stator windings into predetermined ones of the slots.

Abstract: An electric machine includes a rotor. The rotor includes a body having a number of pole members, a central hub, and a plurality of mounting members. The plurality of mounting members are fewer than half the number of pole members. A fan member is mounted to the rotor. The fan member includes a number of fan blades that project outward from a hub portion. A plurality of mounting elements are provided on select ones of the number of fan blades. The plurality of mounting members engage respective ones of the plurality of mounting elements to attach the fan member to the rotor.

Abstract: An apparatus and method for forming at least one end turn and at least one stator slot segment of a conductor for a stator of a dynamoelectric machine comprising at least two forming die sets. The forming die sets are disposed having a space substantially equal to a width of the conductor between adjacent die sets and include a female forming die and a male forming die linearly slideable to the female forming die. The die sets are disposed such that both at least one end turn and at least one stator slot segment are formable between the male forming dies and the female forming dies when the male forming dies are sequentially actuated to the female forming dies.

Abstract: An alternator configured for use in a vehicle comprises a stator having a plurality of stator windings. A rotatable field coil is positioned adjacent to the stator within the alternator. A field driver circuit is configured to deliver an electric current to the field coil. A voltage sensor is configured to detect a battery voltage. A controller in the alternator is configured to execute either a first field current control program or a second field current control program depending at least in part upon the detected battery voltage. The first field current control program is configured to control the electric current delivered to the field coil in a 12 volt vehicle power system. The second field current control program is configured to control the electric current delivered to the field coil in a 24 volt vehicle power system.

Abstract: A method of loading stator windings into a stator core includes guiding a first stator winding including a plurality of slot segment portions along at least one guide track towards an arbor member having a plurality of slots, inserting one of the plurality of slot segment portions of the first stator winding into one of the plurality of slots, and guiding a second stator winding including a plurality of slot segment portions along the at least one guide track towards the arbor member. The method also includes indexing one of the at least one guide track and the arbor member to position another of the plurality of slots adjacent the at least one guide track, inserting one of the plurality of slot segment portions of the second stator winding into another of the plurality of slots, rotating the arbor member, and feeding a plurality of slot segment portions into remaining ones of the plurality of slots.