Abstract: An electric machine includes a rotor, a first tooth portion, and a second tooth portion spaced apart from the first tooth portion and cooperating with the first tooth portion to at least partially define a rotor opening. At least a portion of the rotor is disposed within the rotor opening. A bridge has a first end connected to the first tooth portion and a second end connected to the second tooth portion such that the bridge defines a portion of the rotor opening. An aperture is defined by the bridge and is disposed between the first end and the second end.

Abstract: A stator configured to rotate a rotor with a number of magnetic poles includes a yoke that includes a back portion and a first type and first quantity of integral teeth, and a second type and second quantity of insertable teeth coupled to the back portion. At least two coils are wound with a continuous electric wire. Each of the coils is placed around two different integral teeth to define a first winding section. At least two other coils are wound with a continuous electric wire. The other coils are placed around two different insertable teeth to define a second winding section.

Abstract: A rotor for an electric machine having a number of poles includes a shaft that extends along a portion of an axis and defines an outer surface. A first core portion is formed as a single inseparable component and includes a first portion that extends from the outer surface to a first outside diameter to define a first thickness, and a second portion spaced axially from the first portion that includes a reduced back portion that extends from an inside diameter to the first outside diameter to define a second thickness that is less than the first thickness. A second core portion is connected to the first core portion and includes a second outside diameter that is substantially the same as the first outside diameter.

Abstract: A rotor for an electric machine having a number of poles includes a shaft that extends along a portion of an axis and defines an outer surface. A first core portion extends along a portion of the axis to define a first core length. The first core portion includes a first reduced back portion that has an inside surface that does not contact the outer surface. A second core portion is coupled to the first core portion for rotation. In some constructions, a coupling member interconnects the shaft, the first core portion, and the second core portion such that the shaft, the first core portion, and the second core portion rotate about the axis substantially in unison.

Abstract: A rotor for an electric machine includes a shaft that is rotatable about an axis and defines a first diameter normal to the axis. A first core portion defines a first aperture having a first aperture diameter that is larger than the first diameter. The first core portion is positioned adjacent the shaft to define a first space. A second core portion defines a second aperture having a second aperture diameter that is larger than the first diameter. The second core portion is positioned adjacent the shaft to define a second space. A damping member is positioned in the first space and the second space. The damping member at least partially interconnects the shaft, the first core portion, and the second core portion.

Abstract: A stator for a multi-phase electric machine having a plurality of core segments interconnected with one another and a plurality of coils. At least one core segment includes a plurality of teeth and a back portion that at least partially interconnects the teeth. The back portion of each segment has a first arrangement in which the teeth of that segment are a first distance from one another and a second arrangement in which the teeth of that segment are a second distance from one another, the second distance being smaller than the first distance. Each coil surrounds at least a portion of one tooth, wherein all coils surrounding teeth of a single core segment interconnect to at least partially define one phase winding.

Abstract: An electric machine having a stator assembly that includes a stator core and a coil supported by the stator core and a rotor assembly that includes a shaft and a rotor supported by the shaft that is in magnetic interaction with the stator core. The electric machine may include a single sensor configured to detect magnetic polarities of the rotor as the rotor rotates relative to the sensor and to generate a signal representing the detected magnetic polarities of the rotor. The signal and an inverted version of the signal are utilized to control current through the coil. The current may be controlled indirectly by controlling the application of voltage to the coil. The sensor may be encapsulated on a circuit board to positively position the sensor relative to the circuit board. The circuit board may be mounted to a bearing housing of the electric machine. The sensor may be received in a pocket of a bearing housing of the electric machine so the sensor is positively positioned relative to the rotor.

Abstract: An electric motor that includes a stator, a rotor including a rotor shaft and a support member coupled to the stator. A first bearing is at least partially disposed within the support member and a printed circuit board is coupled to the stator. A second bearing is at least partially disposed within the printed circuit board. The first bearing and the second bearing cooperate to support the rotor shaft for rotation relative to the stator.

Abstract: An electric motor stator including a yoke having a plurality of yoke laminations. A body portion is formed as part of each of the plurality of yoke laminations. A first tooth is continuous with the body portion and is formed as part of at least a portion of the plurality of yoke laminations. The first tooth defines a first tooth profile. A first tooth attachment portion is formed as part of the plurality of yoke laminations. A second tooth includes a plurality of tooth laminations. Each tooth lamination of the second tooth includes a second tooth attachment portion and defines a second tooth profile that differs from the first tooth profile. The second tooth attachment portion is engaged with the first tooth attachment portion.

Abstract: An electrical machine including a rotor and a stator. The stator includes a core and a coil disposed on the core. In one construction, the core is generally U-shaped and comprises magnetic material. The electrical machine also includes a bridge comprising magnetic material. The bridge connects the first and second legs of the generally U-shaped core. Also disclosed are methods of manufacturing the core.

Abstract: An electric machine having a stator assembly that includes a stator core and a coil supported by the stator core and a rotor assembly that includes a shaft and a rotor supported by the shaft that is in magnetic interaction with the stator core. The electric machine may include a single sensor configured to detect magnetic polarities of the rotor as the rotor rotates relative to the sensor and to generate a signal representing the detected magnetic polarities of the rotor. The signal and an inverted version of the signal are utilized to control current through the coil. The current may be controlled indirectly by controlling the application of voltage to the coil. The sensor may be encapsulated on a circuit board to positively position the sensor relative to the circuit board. The circuit board may be mounted to a bearing housing of the electric machine. The sensor may be received in a pocket of a bearing housing of the electric machine so the sensor is positively positioned relative to the rotor.

Abstract: An electrical machine including a rotor and a stator. The stator includes a core and a coil disposed on the core. In one construction, the core is generally U-shaped and comprises magnetic material. The electrical machine also includes a bridge comprising magnetic material. The bridge connects the first and second legs of the generally U-shaped core. Also disclosed are methods of manufacturing the core.

Abstract: An electric machine having a stator, a rotor, a first intermediate portion, an end cap, a second intermediate portion, and a second end cap. The first and second intermediate portions partially cover the stator. The electric machine further includes a fastener that couples the first and second end caps.