Abstract: An electric machine having a plurality of AC power phases comprises a rotor, a stator defining a plurality of slots, and a plurality of pins inserted into the slots. The pins are each joined together with circumferentially adjacent pins arranged in an even number of paired parallel winding paths. Each of the paired winding paths include five pitch pins and seven pitch pins that are radially adjacent and insulated from each other. The five pitch pins are electrically connected and circumferentially followed by seven pitch pins in the winding paths in a repeating pattern throughout the paired winding paths from separate phase terminals to a neutral bridge terminal. Neutral terminals and lead terminals are connected to the conductive paths by various combinations of I-pins and half-crown pins.

Abstract: An electric machine includes a stator core and a hairpin winding. The stator core defines slots that are circumferentially arranged between an inner diameter and an outer diameter of the stator core. Each slot has a plurality of pin positions that is arranged in a direction that extends from the inner diameter toward the outer diameter. The hairpin winding has a plurality of electrical paths of interconnected hairpins disposed within the slots. Each of the plurality of electrical paths of interconnected hairpins has a plurality of typical hairpins and an atypical hairpin. Each typical hairpin has a crown pitch of eight, nine, or ten, slots and opposing outwardly extending twist pitches along each end of the typical hairpin of four and one half slots. Each atypical hairpin, has an outwardly extending twist pitch and an inwardly extending twist pitch on opposing respective ends of the atypical hairpin.

Abstract: An electric machine having a plurality of AC power phases comprises a rotor, a stator defining a plurality of slots, and a plurality of pins inserted into the slots. The pins are each joined together with circumferentially adjacent pins arranged in an even number of paired parallel winding paths. Each of the paired winding paths include five pitch pins and seven pitch pins that are radially adjacent and insulated from each other. The five pitch pins are electrically connected and circumferentially followed by seven pitch pins in the winding paths in a repeating pattern throughout the paired winding paths from separate phase terminals to a neutral bridge terminal. Neutral terminals and lead terminals are connected to the conductive paths by various combinations of I-pins and half-crown pins.

Abstract: An electric machine includes a stator core and hairpin windings. The stator core defines slots that are circumferentially arranged between an inner diameter and an outer diameter of the stator core. Each slot has a plurality of pin positions that is arranged in a direction that extends from the inner diameter of the stator core toward the outer diameter of the stator core. The hairpin windings have a plurality of electrical paths of interconnected hairpins disposed within the slots. Each of the plurality of electrical paths of interconnected hairpins have a plurality of typical hairpins and a plurality of atypical hairpins. Each typical hairpin has first and second opposing inwardly extending twist portions. Each atypical hairpin has a third inwardly extending twist portion and an outwardly extending twist portion disposed on an opposing end of the atypical hairpin relative to the third inwardly extending twist portion.

Abstract: An electric machine includes a stator core and a hairpin winding. The stator core defines slots that are circumferentially arranged between an inner diameter and an outer diameter of the stator core. Each slot has a plurality of pin positions that is arranged in a direction that extends from the inner diameter toward the outer diameter. The hairpin winding has a plurality of electrical paths of interconnected hairpins disposed within the slots. Each of the plurality of electrical paths of interconnected hairpins has a plurality of typical hairpins and an atypical hairpin. Each typical hairpin has a crown pitch of eight, nine, or ten, slots and opposing outwardly extending twist pitches along each end of the typical hairpin of four and one half slots. Each atypical hairpin, has an outwardly extending twist pitch and an inwardly extending twist pitch on opposing respective ends of the atypical hairpin.

Abstract: An electric machine includes a stator core and a hairpin winding. The stator core defines slots that are circumferentially arranged between an inner diameter and an outer diameter of the stator core. Each slot has a plurality of pin positions that is arranged in a direction that extends from the inner diameter toward the outer diameter. The hairpin winding has a plurality of paths of interconnected hairpins that correspond to a first electrical phase of the electric machine. The hairpins are arranged to occupy a portion of the pin positions according to a pattern that repeats at angular intervals along a circumference of the stator core. The pattern includes hairpins occupying each pin position within a first of the slots, harpins occupying exactly half the pin positions within a second of the slots, and harpins occupying exactly half the pin positions within a third of the slots.

Abstract: An electric machine includes a stator and a rotor. The stator defines a central orifice and has an inner diameter. The rotor has an outer diameter and is disposed within the stator. An airgap is defined between inner diameter and the outer diameter. The rotor defines a plurality of cavities. The rotor has magnets disposed within each of the cavities. The magnets define a plurality of pole arc angles. Each pole arc angle is centered about a D-axis. The rotor has an outer periphery. The outer periphery forms smooth spline curves positioned within each pole arc angle. The smooth spline curves deviate radially inward relative to the outer diameter.

Abstract: An electric machine is disclosed that includes a rotor, a stator and a plurality of pins. The stator is received inside the rotor and defines a plurality of slots for receiving the pins. The pins are conductors that are each joined with a circumferentially adjacent pins to form a conductive path for each power phase. The pins each have a first axial leg and a second axial leg that are each disposed in one of the plurality of slots. The first and second axial legs are joined by an asymmetric crown portion of the pin conductors. The crown portion includes a long arm and a short arm that are joined at an apex that is radially and circumferentially offset to be closer to the second leg than the first leg.

Abstract: An electric machine includes a stator core defining slots and a single-layer winding disposed in the core and having first and second parallel paths. Each path includes hairpins interconnected to form a continuous circuit between a terminal and a neutral. The hairpins of the first path include a first type of hairpins each having a first leg, a second leg, a crown connecting between the legs, an outwardly extending twist joined to the first leg, and an inwardly extending twist joined to the second leg, wherein the legs are spaced apart by a span of five slots, and a second type of hairpins each having a first leg, a second leg, a crown connecting between the legs, an inwardly extending twist joined to the first leg, and an outwardly extending twist joined to the second leg, wherein the legs are spaced apart by a span of seven slots.

Abstract: An electric machine is disclosed that includes a rotor, a stator and a plurality of pins. The stator is received inside the rotor and defines a plurality of slots for receiving the pins. The pins are conductors that are each joined with a circumferentially adjacent pins to form a conductive path for each power phase. The pins each have a first axial leg and a second axial leg that are each disposed in one of the plurality of slots. The first and second axial legs are joined by an asymmetric crown portion of the pin conductors. The crown portion includes a long arm and a short arm that are joined at an apex that is radially and circumferentially offset to be closer to the second leg than the first leg.

Abstract: An electric machine includes a stator core defining slots and a winding disposed in the core and having three phases. Each of the phases has at least two parallel paths including hairpins interconnected to form at least two continuous circuits between a terminal and a neutral. The hairpins of each path include: a first type of hairpins (first hairpins) each having first and second legs spaced apart by a span of five slots; a second type of hairpins (second hairpins) each having first and second legs spaced apart by a span of seven slots; and a third type of hairpins (first hairpins) each having first and second legs spaced apart by a span of five or seven slots.

Abstract: An electric machine includes a stator and a rotor. The stator defines a central orifice and has an inner diameter. The rotor has an outer diameter and is disposed within the stator. An airgap is defined between inner diameter and the outer diameter. The rotor defines a plurality of cavities. The rotor has magnets disposed within each of the cavities. The magnets define a plurality of pole arc angles. Each pole arc angle is centered about a D-axis. The rotor has an outer periphery. The outer periphery forms smooth spline curves positioned within each pole arc angle. The smooth spline curves deviate radially inward relative to the outer diameter.

Abstract: A three-phase electric machine includes a stator core defining slots, a terminal associated with one of the three phases, and a neutral. A first phase of hairpin windings is disposed in the core and has first and second parallel paths that are each continuous between the terminal and the neutral. The first path includes a first hairpin having a first leg disposed in a first of the slots and a second leg disposed in a second of the slots that is five slots away from the first slot. The first path further includes a second hairpin having a first leg disposed in a third of the slots and a second leg disposed in the second slot, wherein the second slot is seven slots away from the third slot.

Abstract: An electric machine includes a stator core defining slots and a single-layer winding disposed in the core and having first and second parallel paths. Each path includes hairpins interconnected to form a continuous circuit between a terminal and a neutral. The hairpins of the first path include a first type of hairpins each having a first leg, a second leg, a crown connecting between the legs, an outwardly extending twist joined to the first leg, and an inwardly extending twist joined to the second leg, wherein the legs are spaced apart by a span of five slots, and a second type of hairpins each having a first leg, a second leg, a crown connecting between the legs, an inwardly extending twist joined to the first leg, and an outwardly extending twist joined to the second leg, wherein the legs are spaced apart by a span of seven slots.

Abstract: An electric machine includes a stator core defining circumferentially arranged slots alternating between odd and even slots. Each slot has radial pin positions arranged in adjacent pairs to define radial layers. A hairpin winding includes a first path of interconnected hairpins that is disposed in the stator core such that, for each of the radial layers, the first path is disposed in the odd slots and the even slots a same number of times.

Abstract: Various examples related to stator and rotor configurations for the improvement in torque density and/or efficiency in AC machines are presented. In one example, a bar wound stator includes a stator core with winding slots; a first group of bar type conductors in the winding slots adjacent to a proximal end adjacent to a rotor air gap surface of the stator core; and a second group of bar type conductors in the winding slots adjacent to a distal end adjacent to a back-iron section of the stator core. The first group of bar type conductors having a first cross-sectional area and the second group of bar type conductors having a second cross-sectional area greater than the first cross-sectional area. In another example, a motor includes the bar wound stator and a rotor such as, e.g., a permanent magnet rotor. The motor can be utilized in hybrid or battery electric vehicles.

Abstract: An electric machine includes a stator core defining slots and a winding disposed in the core and having three phases. Each of the phases has at least two parallel paths including hairpins interconnected to form at least two continuous circuits between a terminal and a neutral. The hairpins of each path include: a first type of hairpins (first hairpins) each having first and second legs spaced apart by a span of five slots; a second type of hairpins (second hairpins) each having first and second legs spaced apart by a span of seven slots; and a third type of hairpins (first hairpins) each having first and second legs spaced apart by a span of five or seven slots.

Abstract: An electric machine includes a stator core defining slots and a single-layer winding disposed in the core and having first and second parallel paths. Each path includes hairpins interconnected to form a continuous circuit between a terminal and a neutral. The hairpins of the first path include a first type of hairpins each having a first leg, a second leg, a crown connecting between the legs, an outwardly extending twist joined to the first leg, and an inwardly extending twist joined to the second leg, wherein the legs are spaced apart by a span of five slots, and a second type of hairpins each having a first leg, a second leg, a crown connecting between the legs, an inwardly extending twist joined to the first leg, and an outwardly extending twist joined to the second leg, wherein the legs are spaced apart by a span of seven slots.

Abstract: A three-phase electric machine includes a stator core defining slots, a terminal associated with one of the three phases, and a neutral. A first phase of hairpin windings is disposed in the core and has first and second parallel paths that are each continuous between the terminal and the neutral. The first path includes a first hairpin having a first leg disposed in a first of the slots and a second leg disposed in a second of the slots that is five slots away from the first slot. The first path further includes a second hairpin having a first leg disposed in a third of the slots and a second leg disposed in the second slot, wherein the second slot is seven slots away from the third slot.

Abstract: An electric machine includes a stator core defining circumferentially-arranged slots each having radial pin positions arranged to define radial layers and a hairpin winding including a first path of interconnected hairpins disposed in the stator core. The hairpins are arranged such that a leg portion of each hairpin is routed through a radial pin position of each slot wherein at least one uniquely-pitched hairpin is provided along the first path to induce a first shift in a trailing portion of the first path.