Abstract: A motor assembly includes a motor, a controller controlling at least one aspect of operation of the motor, and a control housing defining a control chamber. The controller is in part received within the control chamber. The controller includes a main electronics board and a modular connector assembly. The modular connector assembly includes a secondary electronics board and a connector at least in part supporting the secondary electronics board. The connector includes an inner connector portion and an outer connector portion. The connector extends through the control housing such that the inner connector portion is disposed inside the control chamber and the outer connector portion is disposed outside the control chamber. The outer connector portion defines a first access portal facilitating access to a first component of the secondary electronics board.

Abstract: A ducted fan device integrated with a permanent magnet synchronous disc flat wire motor for a flying copter car, including a rotor system, a stator system, an air intake/exhaust control system, a detection system, a driving system and a power supply system. The stator system includes a motor shell, and flat wire coils respectively arranged on an upper end face and a lower end face of an inner wall of the motor shell are connected in series. The rotor system is arranged inside the stator system, including axial flow and radial flow composite integrated blades and permanent magnets. A part of centrifugal blades are replaced by the permanent magnets which are located on an outer side.

Abstract: An electric machine includes a casing, a cap covering the casing to define an enclosure, a heat sink, a circuit board in the enclosure having a first conductive layer as a top face, a second conductive layer as a bottom face, and vias passing through the circuit board between the top and bottom faces. An electronic component is soldered to the circuit board on the first conductive layer and disposed on top of a first part of the vias. A conductive mass is soldered to the circuit board proximal to the electronic component and disposed on top of a second part of the vias. The conductive mass forms part of the circuit through which a power supply of the electric machine flows and is in electric and heat exchange relationship with the electronic component, while the bottom face is in heat exchange relationship with the heat sink.

Abstract: Embodiments of this application disclose a stator, a stator manufacturing method, a motor, and an electric vehicle. The stator includes: a stator tooth part, where a plurality of stator tooth parts are arranged at intervals along a circumferential direction; and a stator yoke part, where the stator yoke part is disposed along a circumferential direction of the stator tooth part, and the circumferential direction is a circumferential direction around a central axis of the stator; where the stator tooth part and the stator yoke part are integrally formed by an oriented silicon steel sheet, and a grain direction of the formed oriented silicon steel sheet points to the central axis of the stator along a radial direction. Therefore, the stator tooth part and the stator yoke part are formed by using one material, and there is no need to splice two materials, thereby reducing process costs.

Abstract: A method of manufacturing of the bus bar assembly includes preparing a mold, positioning a bus bar and a shield in the mold, and molding a bus bar holder. The positioning includes inserting first positioning pins into bus bar through holes to cause the first positioning pins to hold the bus bar, providing the shield in the mold in a state where a lower surface of the shield and a distal end of the first positioning pin are in contact with each other, bringing a second positioning pin into contact with an upper surface of the shield and positioning the shield in a vertical direction, and bringing a third positioning pin extending downward from a lower surface of an upper mold into contact with an upper surface of the bus bar to position the bus bar in the vertical direction.

Abstract: A fixture for holding a stator including a stator core having a plurality of stator windings during assembly. The fixture includes a first fixture portion including a base defining a first stator receiving portion that is receptive of a first end of the stator, a second fixture portion including second stator receiving portion that is receptive of a second end of the stator, and at least one alignment feature provided on one of the first fixture portion and the second fixture portion. The at least one alignment feature is configurated to establish a selected alignment between a terminal end of each of the plurality of stator windings and busbar.

Abstract: A stator assembly for an axial flux motor includes a heat exchanger jacket configured to circulate a heat transfer liquid. A stator also includes a plurality of stator cores each having a conductive winding, an electrically insulating material disposed over at least a portion of the conductive wire winding, and a molded soft magnetic composite (SMC) material. The heat exchanger jacket is disposed circumferentially around at least a portion of a perimeter of the stator. Each stator core defines a peripheral surface configured to contact the heat exchanger jacket and at least a portion of the peripheral surface is defined by the molded soft magnetic composite (SMC) material. Methods of making a molded soft magnetic composite (SMC) material stator core are also provided.

Abstract: A conductive coil for an electric application having a cooling channel for a coolant liquid or gas. The coil includes a wire winding of a plurality of wire turns. The wire winding is compressed about a cooling channel which is disposed between adjacent turn segments of the plurality of wire turns. The wire winding is formed and pressed against a shaping element to form the coolant channel within the compressed winding.

Abstract: A rotating electrical machine and a method of manufacturing a rotating electrical machine. The machine including a machine frame, a rotor, a shaft attached to the rotor and bearings supporting the shaft and the rotor in the machine frame. The rotating electrical machine includes further an electrically conducting member having a hole, the electrically conducting member being attached to the frame such that the shaft extends through the hole.

Abstract: In a rotating electrical machine, an armature includes a filmy sheet member secured to one of an inner peripheral surface and an outer peripheral surface of a base member to cover one of the inner peripheral surface and the outer peripheral surface of the base member. A sheet member is made of thermoplastic resin as non-magnetic material, and has a field-member side peripheral surface. Each conductive member has at least part embedded in the sheet member in a radial direction of the rotating electrical machine to thereby arrange a base-member side peripheral surface to be radially closer to the base member than the field-generator side peripheral surface of the sheet member is.

Abstract: An integrated hybrid rotary assembly is configured to provide power, torque and bi-directional communication to a rotatable sensor, such as a lidar, radar or optical sensor. A common ferrite core is shared by a motor, rotary transformer and radio frequency communication link. This hybrid configuration reduces cost, simplifies the manufacturing process, and can improve system reliability by employing a minimum number of parts. The assembly can be integrated with the sensor unit, which may be used in vehicles and other systems.

Abstract: A motor assembly for driving a pump or rotary device features a power plane with a circular geometry to be mounted inside a space envelope having a similar circular geometry formed on an end-plate between an inner hub portion and a peripheral portion that extends circumferentially around the space envelope of the end-plate. The power plane is a multi-layer circuit board or assembly having: a power layer with higher temperature power modules for providing power to a motor, a control layer with lower temperature control electronics modules for controlling the power provided to the motor, and a thermal barrier and printed circuit board layer between the power layer and the control layer that provides electrical connection paths between the power modules of the power plane and the control electronics modules of the control layer, and also provides insulation between the power layer and the control layer.

Abstract: The disclosure relates to a filter circuit on an electric motor which has electrical connections at a connection end for connection to a supply voltage (U). The filter circuit consists of at least one capacitor bridge arranged between the connections of the electric motor for radio interference suppression. For increased electromagnetic compatibility (EMC), the filter circuit is arranged on a circuit board and held on the connection end of the electric motor. The circuit board has a capacitor bridge with interference suppression capacitors, which is connected between the electrical connections of the electric motor, wherein an interference suppression capacitor has a longitudinal axis between its electrical connections in the longitudinal direction. The interference suppression capacitors are arranged on the circuit board with their longitudinal axes aligned in different spatial directions.

Abstract: A motor includes a stator, and includes a first substrate and a second substrate mounted on the stator. The stator has a stator core in a ring shape and a first coil of a first phase and a second coil of a second phase wound around the stator core. The first substrate includes a first power supply wiring to supply electric power to the first coil. The second substrate has a second power supply wiring to supply electric power to the second coil.

Abstract: A motor including a wound coil includes: a stator core, a cross-section of which has a ring-shape, extending in a longitudinal direction of the motor, the stator core including a plurality of teeth in the stator core, the plurality of teeth are spaced apart from each other in a circumferential direction of the stator core, and a plurality of slots arranged between the plurality of teeth; a coil extending in a longitudinal direction of the stator core and extends into the plurality of slots; and a coupling core, which includes shoes coupled to inner ends of the plurality of teeth and which is disposed inside the stator core so as to be integrally coupled to the stator core.

Abstract: A motor assembly for driving a pump or rotary device features a power plane with a circular geometry to be mounted inside a space envelope having a similar circular geometry formed on an end-plate between an inner hub portion and a peripheral portion that extends circumferentially around the space envelope of the end-plate. The power plane is a multi-layer circuit board or assembly having: a power layer with higher temperature power modules for providing power to a motor, a control layer with lower temperature control electronics modules for controlling the power provided to the motor, and a thermal barrier and printed circuit board layer between the power layer and the control layer that provides electrical connection paths between the power modules of the power plane and the control electronics modules of the control layer, and also provides insulation between the power layer and the control layer.

Abstract: The present disclosure provides a direct starting synchronous reluctance motor rotor, a motor and a rotor manufacturing method. The direct starting synchronous reluctance motor rotor comprises: a rotor core provided with a plurality of slit grooves, two ends of each of the slit grooves being provided with a filling groove respectively to form a magnetic barrier layer, a first end of the filling groove being disposed adjacent to the slit groove, a second end of the filling groove being extended towards an outside of the rotor core, and an outer peripheral surface of the rotor core being provided with a notch communicated with the second end of the filling groove.

Abstract: Presented are oleophobic surface treatments for electric machines, methods for making/using such electric machines, and vehicles employing traction motors having oleophobic treatments on select “non-target” surfaces. An electric machine includes a direct-cooling thermal management system that circulates a coolant fluid to the electric machine's outer housing. A stator assembly, which is attached to the housing, includes a stator core with one or more electromagnetic windings mounted to the stator core. A rotor assembly is rotatably mounted to the hosing adjacent the stator assembly. The rotor assembly includes a rotor core with one or more magnets mounted to the rotor core and spaced across an air gap from the winding(s). Select components of the outer housing, rotor assembly, and/or stator assembly have a target surface with an oleophobic surface treatment that reduces the non-target surface's wetted area and decreases the mass of coolant fluid contacting the non-target surface.

Abstract: A stator for a radial-flux rotary electric machine includes a yoke with a plurality of teeth, each tooth extending from a root at the yoke to a tip. The stator further includes a plurality of coils, each one of which being located on a respective one of the plurality of teeth, the coils being sized such that a slot fill factor is between zero and unity to define axial voids in the slots. The stator further includes a plurality of magnetic sealing members, each one of which being engaged with the tips of adjacent teeth to circumferentially and axially seal the axial voids in the slots for retaining an axial flow of coolant therein, the magnetic sealing members being composed of a magnetic material to provide a flux path between adjacent tooth tips to increase an amount of leakage flux.

Abstract: A printed coil assembly including a flexible dielectric material, a patterned top conductive layer formed on a top surface of the flexible dielectric material, and a patterned bottom conductive layer formed on a bottom surface of the flexible dielectric material. The patterned top conductive layer and the patterned bottom conductive layer form a plurality of printed coils arranged in a plurality of printed coil rollers concentrically arranged in a cylindrical shape. Each of the plurality of printed coils includes a top layer printed coil disposed within the patterned top conductive layer and a bottom layer printed coil disposed within the patterned bottom conductive layer. Coil pitches of the coils within each roller are chosen such that corresponding ones of the plurality of printed coils in adjacent rollers are axially aligned relative to a center of the cylindrical shape.