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 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: 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: 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.

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: An axial flux motor drive unit for an automobile includes a stator defining a core, an output defining an axis of rotation, a first rotor, a second rotor, and a thrust bearing. The first rotor is rotatable about the axis of rotation and is coupled to the output and disposed relative to the stator to create a first air gap. The second rotor is rotatable about the axis of rotation and is coupled to the output and is disposed relative to the stator to create a second air gap. The thrust bearing is coupled to the output and supports axial loads that are substantially parallel to the axis of rotation, and the first rotor is still rotatable about the axis of rotation when the second rotor is inoperable, and the second rotor is still rotatable when the first rotor is inoperable.

Abstract: An electric drive unit clutch for an automobile includes a first rotatable shaft, a one-way clutch fixedly mounted onto the first rotatable shaft, a dog clutch slidingly mounted onto the first rotatable shaft and adapted to rotate with the first rotatable shaft, a clutch ring positioned between the one-way clutch and the dog clutch, and a second rotatable shaft rotatable engaged with the clutch ring, wherein the clutch ring is adapted to transfer rotational motion from the second rotatable shaft through the one-way clutch and the dog clutch to the first rotatable shaft.

Abstract: An electric drive unit clutch for an automobile includes a first rotatable shaft, a one-way clutch fixedly mounted onto the first rotatable shaft, a dog clutch slidingly mounted onto the first rotatable shaft and adapted to rotate with the first rotatable shaft, a clutch ring positioned between the one-way clutch and the dog clutch, and a second rotatable shaft rotatable engaged with the clutch ring, wherein the clutch ring is adapted to transfer rotational motion from the second rotatable shaft through the one-way clutch and the dog clutch to the first rotatable shaft.

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 final drive assembly for a vehicle drive axle having first and second axle-shafts that are configured to rotate about a common first axis. The final drive assembly includes a first gear-set configured to be operatively connected to the first axle-shaft. The final drive assembly also includes a second gear-set configured to be operatively connected to the second axle-shaft. The final drive assembly additionally includes an electric motor configured to provide an electric motor torque input to each of the first and second gear-sets and arranged on a second axis that is parallel to the first axis.

Abstract: A differential drive system includes an electric motor for generating an electric motor torque and an input planetary gear-set operatively connected to the electric motor to receive the electric motor torque. The input planetary gear-set has first, second, and third members. The first member receives the electric motor torque, the second member provides a first input torque in a first rotational direction in response to the electric motor torque, and the third member provides a second input torque in a second rotational direction, opposite the first direction, in response to the electric motor torque. The system also includes a first output gear-set operatively connected to the input planetary gear-set, and providing a first output torque in response to the first input torque. The system additionally includes a second output gear-set operatively connected to the input planetary gear-set and providing a second output torque in response to the second input torque.

Abstract: An electric drive-unit encased in a housing includes an electric motor, a first output member, and a second output member. The drive-unit also includes first, second, and third planetary gear-sets, each having first, second, and third nodes. The first gear-set has one node connected to the electric motor. The second gear-set has one node connected to the first planetary gear-set, another node connected to the first output member, and the remaining node fixed to the housing. The third gear-set has one node connected to the first gear-set and another node connected to the second output member. The drive-unit additionally includes a first torque-transmitting device configured to selectively connect one third gear-set node to the housing to thereby affect a first speed-ratio. Furthermore, the drive-unit includes a second torque-transmitting device configured to selectively connect one first gear-set node to one of the third gear-set nodes to thereby affect a second speed-ratio.

Abstract: A shift by wire parking system includes a park gear including a gear body and a plurality of teeth. The teeth are circumferentially spaced from one another. The park gear defines a plurality of void spaces between each pair of the plurality of teeth. The shift by wire parking system includes a circumferential body sized to fit inside each of the plurality of void spaces to lock a position of the park gear. The circumferential body is movable towards and away from the park gear between an engaged position and a disengaged position. In the disengaged position, the circumferential body is disposed outside each of the plurality of void spaces, thereby allowing the park gear to rotate. In the engaged position, the circumferential body is disposed inside one of the void spaces to lock the position of the park gear.

Abstract: An electric drive-unit encased in a housing includes an electric motor, a first output member, and a second output member. The drive-unit also includes first, second, and third planetary gear-sets, each having first, second, and third nodes. The first gear-set has one node connected to the electric motor. The second gear-set has one node connected to the first planetary gear-set, another node connected to the first output member, and the remaining node fixed to the housing. The third gear-set has one node connected to the first gear-set and another node connected to the second output member. The drive-unit additionally includes a first torque-transmitting device configured to selectively connect one third gear-set node to the housing to thereby affect a first speed-ratio. Furthermore, the drive-unit includes a second torque-transmitting device configured to selectively connect one first gear-set node to one of the third gear-set nodes to thereby affect a second speed-ratio.

Abstract: A shift by wire parking system includes a park gear including a gear body and a plurality of teeth. The teeth are circumferentially spaced from one another. The park gear defines a plurality of void spaces between each pair of the plurality of teeth. The shift by wire parking system includes a circumferential body sized to fit inside each of the plurality of void spaces to lock a position of the park gear. The circumferential body is movable towards and away from the park gear between an engaged position and a disengaged position. In the disengaged position, the circumferential body is disposed outside each of the plurality of void spaces, thereby allowing the park gear to rotate. In the engaged position, the circumferential body is disposed inside one of the void spaces to lock the position of the park gear.