Abstract: A rotor for mounting on a rotational axis in an axial flux electric motor includes a ferromagnetic rotor core. The rotor also includes a plurality of alternating south and north pole permanent magnets (PMs) arranged on the ferromagnetic rotor core symmetrically around the rotational axis and facing the stator. The ferromagnetic rotor core includes a plurality of core saliencies extending to the rotor exterior surface. Each of the core saliencies is arranged between one south pole PM and one north pole PM. The plurality of core saliencies is phase-angle shifted relative to the plurality of alternating south and north pole PMs to thereby alter magnetic reluctance of the electric motor. An axial flux electric motor employing the above-described rotor is also contemplated.

Abstract: A cooled axial flux electric motor includes a rotationally-fixed stator defining a rotational axis and having a plurality of conductive stator magnetic poles arranged radially about the axis. The motor also includes a rotor spaced axially from one side from the stator and rotatably mounted coaxially with the rotational axis and defined by inside and outside diameters. The rotor has a first exterior surface facing the stator and a second exterior surface arranged opposite the first exterior surface. A ferromagnetic rotor core defines the rotor second exterior surface. The rotor also includes alternating south and north pole permanent magnets (PMs) arranged on the rotor core symmetrically around the axis and facing the stator. The rotor additionally includes channels extending radially outwardly across the rotor and configured to direct a coolant, via centrifugal force, from the inside diameter toward the outside diameter as the rotor rotates about the axis.

Abstract: An integrated electrified propulsion system for a vehicle includes a single electric machine, a mechanical geartrain, a rechargeable energy storage device, an integrated cooling system, and a power electronics system. The single electric machine, the mechanical geartrain, the integrated cooling system, the rechargeable energy storage device, and the power electronics system are arranged in a single housing. The single electric machine is rotatably coupled to the mechanical geartrain to transfer mechanical power therebetween.

Abstract: A vehicle's electrified powertrain includes a battery pack linked to a traction power inverter module (TPIM) converting DC voltage from the battery pack into AC voltage. A rotary electric machine includes a stator energized by the TPIM's AC voltage, enclosing a rotor core capable of rotation. The rotor core contains slots holding conductive bars and permanent magnets, with conductive bars positioned closer to the rotor core's center. The conductive bars and permanent magnets are separated by gaps within each slot. An annular end ring assembly is present at one end of the rotor core, featuring terminal conductors connected to subsets of conductive bars and a secondary coil of a rotary transformer. When the stator is energized, the rotor shaft, connected to the rotor, rotates. The electric machine powers a transmission, which is coupled to the rotor shaft.

Abstract: A rotor assembly for a permanent magnet motor includes a first assembly including a first plurality of laminations and a second assembly including a second plurality of laminations. The first assembly is located radially inside of the second assembly. The first assembly and the second assembly define a first opening therebetween. First and second permanent magnets are located in the first opening. Polymeric material surrounds the first and second permanent magnets in the first opening. An outer layer surrounds the rotor assembly.

Abstract: Rotor for electric machines and methods for fabricating rotors for electric machines are provided. An exemplary method includes assembling a stack of laminations to form a rotor core having an external surface. The rotor core defines one to five layers of internal cavities and an interior permanent magnet is positioned in a selected internal cavity. The method also includes locating a non-magnetic structural element in the selected internal cavity. Further, the method includes applying a compressive force on the external surface of the rotor core with an annular sleeve.

Abstract: The present disclosure includes a rotor core assembly for an electric motor. The rotor core assembly includes a plurality of laminations secured together. A center bore is defined by the plurality of laminations. A longitudinal axis of the rotor core assembly extends along an axial center of the center bore. A carbon fiber sleeve surrounds the plurality of laminations. Magnet slots are defined by the plurality of laminations. The magnet slots extend parallel to the longitudinal axis. Magnets are seated in the magnet slots. Reinforcing bores are defined by, and extend across, the plurality of laminations. Reinforcing members are seated in the reinforcing bores.

Abstract: An axial flux motor may include a stator, a rotor including a rotor frame and having a rotational axis, an axial air gap separating the stator and the rotor, the axial air gap corresponding to an axial position of the rotor frame, and at least one hydraulic actuator including a variable volume hydraulic fluid chamber defined within the rotor frame, wherein a change in the volume of the variable volume hydraulic fluid chamber causes a change in the axial position of the rotor frame and a corresponding change in the axial air gap separating the stator and the rotor.

Abstract: A rotor for an electric machine includes a magnetic core configured for arrangement on a shaft. An end ring is arranged on opposite axial ends of the magnetic core. A composite sleeve includes an annular body including an inner surface and an outer surface, and a polymer matrix encapsulating circumferentially oriented fibers. The composite sleeve includes a first tapered portion on the inner surface arranged adjacent to an axial end thereof and configured to facilitate press-fitting of the composite sleeve onto the rotor.

Abstract: An example rotor includes a rotor yoke having an outer circumference and an inner circumference. The rotor further includes a plurality of rotor ribs on a surface the rotor yoke and extending between the outer circumference and the inner circumference. The rotor further includes a plurality of magnets, each of the plurality of magnets being disposed adjacent to and between two of the plurality of rotor ribs.

Abstract: A stator core segment for an axial flux electric motor includes a first lamination step having a first length, a first width, and a first thickness, and a second lamination step having a second length, a second width, and a second thickness. At least one of the second length, the second width, and the second thickness is distinct from corresponding ones of the first length, the first width, and the first thickness.

Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Abstract: An integrated electrified propulsion system for a vehicle includes a single electric machine, a mechanical geartrain, a rechargeable energy storage device, an integrated cooling system, and a power electronics system. The single electric machine, the mechanical geartrain, the integrated cooling system, the rechargeable energy storage device, and the power electronics system are arranged in a single housing. The single electric machine is rotatably coupled to the mechanical geartrain to transfer mechanical power therebetween.

Abstract: A method of manufacturing a permanent magnet for a rotor of an axial flux electric machine is described herein. The method includes forming multiple permanent magnet (PM) pieces to have the same shape. Each of the PM pieces has an inner radial surface, an outer radial surface, and a pair of side surfaces extending between the inner and outer radial surfaces. The method further includes attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor.

Abstract: A method of manufacturing a permanent magnet for a rotor of an axial flux electric machine is described herein. The method includes forming multiple permanent magnet (PM) pieces to have the same shape. Each of the PM pieces has an inner radial surface, an outer radial surface, and a pair of side surfaces extending between the inner and outer radial surfaces. The method further includes attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor.

Abstract: An electric motor drive unit including an electric motor having an output shaft and a plurality of gears in driving engagement with the output shaft. The plurality of gears being supported by a plurality of laterally spaced bearings. A composite housing member includes a structural support skeleton supporting multiple ones of the plurality of laterally spaced bearings and a composite shell molded to the structural support skeleton.

Abstract: An electric machine includes a stator with stator slots securing therein electrically conductive windings. A rotor is rotatably mounted adjacent the stator and includes a stack of rotor laminates. Each laminate includes circumferentially spaced poles, each of which includes a magnet slot spaced from an insert slot. These laminate magnet slots cooperatively define the rotor's magnet slots. Likewise, the laminates' insert slots cooperatively define the rotor's insert slots. Magnets are mounted inside the rotor's magnet slots, and non-magnetic inserts are mounted inside the rotor's insert slots. One or more poles of each laminate includes a structural web that extends radially through the magnet and insert slots of that pole. Multiple poles of each rotor laminate lack a radially extending structural web. Each rotor laminate is rotated with respect to a neighboring rotor laminate such that each pole with a structural web axially aligns with a pole without a structural web.

Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Abstract: A rotor assembly for a permanent magnet motor includes a first assembly including a first plurality of laminations and a second assembly including a second plurality of laminations. The first assembly is located radially inside of the second assembly. The first assembly and the second assembly define a first opening therebetween. First and second permanent magnets are located in the first opening. Polymeric material surrounds the first and second permanent magnets in the first opening. An outer layer surrounds the rotor assembly.

Abstract: Motor driven systems with optimized performance and efficiency are provided. A drive system includes a motor and a gear system coupled with the motor by a shaft. The gear system includes a pair of input gears disposed on the shaft, and a pair of transfer shafts including transfer gears meshing with the input gears. The gear system is configured to cancel axial, radial and/or tangential forces for minimized net force at the shaft.