Abstract: A synchronous electric machine includes a rotor having a substantially cylindrical core with axially extending slots, a plurality of permanent magnets configured as sets defining alternating poles in a circumferential direction, the permanent magnets being located in respective ones of the slots, and a thermally conductive material contiguous with the permanent magnets and the core for transferring heat of the permanent magnets, the material having a thermal conductivity of greater than 0.3 watts per (meter * Kelvin).

Abstract: An electric machine system including an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing, and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes a switch module having a switch member. The switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A cooling system that includes an expandable coolant manifold is arranged in the switch portion of the machine housing. The expandable coolant manifold is fluidly connected to the switch module.

Abstract: An electric machine includes: a stator having stator windings; a rotor configured to interact electromagnetically with the stator; and a housing configured to house the stator and the rotor. A material matrix is disposed within the housing and in contact with the stator windings. The material matrix defines a plurality of passages configured for the cooling fluid to flow within to remove heat from the stator windings.

Abstract: An electric machine system includes an electric motor and an oil pump disposed within a housing. The oil pump is configured to disperse oil in a pattern about a rotational axis within the electric motor. A method for operating the electric machine system is also disclosed.

Abstract: An asynchronous boost assist system for a motor vehicle includes a first electric motor, a second electric motor positioned opposite the first electric motor and a differential gear system operatively connected to the first and second electric motors. The differential gear system includes a first differential gear set and a second differential gear set. The first differential gear set is operatively connected to the first and second electric motors and the second differential gear set is configured and disposed to operatively connect to first and second vehicle wheels. A controller is operatively connected to each of the first and second electric motors. The controller selectively independently controls an operational speed of each of the first and second electric motors to selectively provide an acceleration boost through the second differential gear set.

Abstract: An electric machine includes a core with a plurality of slots. A plurality of electric conductors are positioned in the slots. Each of the plurality of electric conductors includes a U-turn portion extending between two in-slot portions and connection ends extending from the in-slot portions. The connection ends are positioned on an opposite end of the core from the U-turn portions. A plurality of insulation tubes are positioned in the plurality of slots. The in-slot portions of the electric conductors extend through the insulation tubes.

Abstract: An electric machine system includes an alternating current (AC) electric machine. The AC machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. A direct current (DC) power source is electrically connected to the stator through the switch assembly. A cooling system is fluidly connected to the AC electric machine. The cooling system directs a flow of coolant onto the switch assembly in the switch portion of the machine housing, and onto at least one of the stator and the rotor in the machine portion of the machine housing.

Abstract: An electric machine system including an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing, and a rotor rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes a switch module having a switch member. The switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A cooling system that includes an expandable coolant manifold is arranged in the switch portion of the machine housing. The expandable coolant manifold is fluidly connected to the switch module.

Abstract: An electric machine system includes an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion of the machine housing and a rotor is rotatably mounted relative to the stator. A switch assembly is arranged within the switch portion of the machine housing and electrically connected to the stator. The switch assembly includes at least one switch module having at least one switch member. The at least one switch module is configured and disposed to be detachably mounted in the switch portion of the machine housing. A direct current (DC) power source is electrically connected to the stator through the switch assembly. A controller is operatively connected to the switch assembly.

Abstract: An electric machine system includes an alternating current (AC) electric machine. The AC electric machine includes a machine housing having a machine portion and a switch portion. A stator is fixedly mounted in the machine portion, a rotor rotatably mounted relative to the stator, and a plurality of switch members are arranged within the switch portion. The plurality of switch members are electrically connected to the stator. A direct current power source is electrically connected to the plurality of switch members. A controller is arranged within a controller housing and electrically connected to the plurality of switch members. The controller housing is distinct from and remotely mounted relative to the AC electric machine. The controller is configured and disposed to activate select ones of the plurality of switch member to convert DC current between the DC power source and an AC current to operate the AC electric machine.

Abstract: An electric machine system including an alternating current (AC) electric machine having a machine housing, and a plurality of switch members arranged within a switch housing. The plurality of switch members are electrically connected to the AC electric machine. A direct current (DC) power source is electrically connected to the plurality of switch members. The DC power source generates a DC current. A controller is arranged within a control housing that is remote from the switch housing. The controller is electrically connected to the plurality of switch members and is configured and disposed to selectively activate select ones of the plurality of switch members in order to convert the DC current between the DC power source and an alternating current (AC) to operate the AC electric machine.

Abstract: An electric machine system includes an electric motor and an oil pump disposed within a housing. The oil pump is configured to disperse oil in a pattern about a rotational axis within the electric motor. A method for operating the electric machine system is also disclosed.

Abstract: An electric machine includes: a stator having stator windings; a rotor configured to interact electromagnetically with the stator; and a housing configured to house the stator and the rotor. A material matrix is disposed within the housing and in contact with the stator windings. The material matrix defines a plurality of passages configured for the cooling fluid to flow within to remove heat from the stator windings.

Abstract: An electric machine system includes an electric motor, an auxiliary device configured to receive filtered electric power, and a filter. The filter is configured to receive electric power and to pass filtered electric power to the auxiliary device at a frequency not used for power conversion to rotational energy by the electric motor. A method for operating the electric machine system is also disclosed.

Abstract: An electric machine system includes: an electric motor; and an absorption cooling system driven by heat generated by the electric motor and configured to cool a primary cooling fluid that removes the heat from the electric motor to a temperature below an ambient temperature of an ultimate heat sink. A method for operating the electric machine system is also disclosed.

Abstract: An electric machine including a housing, and a stator mounted within the housing. The stator includes an outer perimetric surface and an inner perimetric surface. A rotor is mounted, at least in part, within the inner perimetric surface of the stator. The rotor is rotatable relative to the stator. A stator sleeve extends about the stator. The stator sleeve includes a first sleeve portion and a second sleeve portion. The first sleeve portion includes a first diametric edge that extends to a second diametric edge, and the second sleeve portion includes a first diametric edge section that extends to a second diametric edge section. The stator sleeve is configured and disposed to establish a coolant cavity about the outer perimetric surface of the stator.

Abstract: An electrical device includes a plurality of stacked laminates that form a tubular stator portion, a cooling passage partially defined by orifices formed in the plurality of stacked laminates, a housing including a cavity further defining the cooling passage, the cooling passage defining a fluid flow path parallel to a rotational axis of the stator portion, a sump portion communicative with the cooling passage, the sump portion including a cavity defined by the stator portion and the housing member.

Abstract: A mechanical fastener includes a main body having an outer diametric portion and an inner diametric portion and a plurality of threads provided on at least one of the outer and inner diametric portions. The mechanical fastener further includes at least one staking mechanism formed in the main body at the at least one of the outer and inner diametric portion. The at least one staking mechanism extends into and bisects at least a portion of the plurality of threads.

Abstract: An internal cooling fan assembly for use with a claw-pole segment of a rotor assembly is provided that maximizes air flow while providing a reduced sound signature. The fan assembly includes a base portion that contacts the claw-pole segment when the fan assembly is mounted to the claw-pole segment. The fan assembly also includes a number of blades extending from the base portion such that the blades project outward from a plane normal to the rotor. The plurality of blades have a geometry that aligns with roots of the claw-pole segment. In addition, a first blade of the number of blades is of a first configuration and a second blade of the number of blades is of a second configuration different from the first configuration.

Abstract: A bearing retainer for use with a bearing having an outside diameter which is to be received in the bearing retainer and to be mounted into a cavity having an inside diameter includes a bearing-engaging wall having a minimum inside diameter when the bearing retainer is in a non-deformed state approximately equal to but slightly less than the outside diameter of the bearing to be received therein, an outer cavity-engaging wall having a maximum outside diameter when the bearing retainer is in a non-deformed state approximately equal to the inside diameter of the cavity within which the bearing retainer is to be received, a web wall extending between and coupling the bearing-engaging wall and the cavity-engaging wall and wherein the bearing-engaging wall, cavity-engaging wall and web wall are fabricated from a material capable of elastic and plastic deformation so that upon insertion of the bearing into the bearing retainer the bearing-engaging wall is deformed to secure the bearing within the bearing retainer a