Abstract: An electric machine includes a stator, a rotor configured to rotate relative to the stator, an air gap between the stator and the rotor, and a conductive winding disposed in the rotor or the stator. The conductive winding includes a first portion having a first conductivity and a second portion having a second conductivity, the second portion disposed radially between the first portion and the air gap, the first conductivity being different than the second conductivity.

Abstract: An electric propulsion motor system includes a cylindrical stator and rotor, a fluid circulation system providing pressurized fluid, and conductors within winding slots. The stator has a yoke and a plurality of teeth extending radially inward from the yoke, with winding slots defined between adjacent teeth. Respective tooth tips extend circumferentially into adjacent winding slots and are radially adjacent to a first conductor within the winding slot, with a first channel through which pressurized fluid flows.

Abstract: A rotor grounding system for an electric machine includes a rotor including a shaft assembly configured to rotate about an axis. A housing supports the shaft assembly for rotation of the rotor. A bearing assembly has an outer circumference disposed against the shaft assembly. A discharge bar extends through at least a part of the bearing assembly. The bearing assembly has an inner circumference disposed against the discharge bar. A discharge circuit is defined between the rotor and the housing, where the discharge circuit extends through the bearing assembly and the discharge bar.

Abstract: An electric machine including a stator, a rotor within the stator, and a shaft to which the rotor is mounted. The shaft extends through the stator. A first bearing and a second bearing support the shaft within the stator to allow the shaft and the rotor to rotate within the stator. The rotor is between the first bearing and the second bearing. A first magnetic core is at the shaft between the rotor and the first bearing. The first magnetic core is configured to suppress a bearing current flowing across the shaft, the first bearing, and the second bearing.

Abstract: An assembly includes a rotor assembly having a rotor stack with an outer rotor diameter and a rotor shaft extending along a rotational axis of the rotor assembly. A mandrel includes an outer mandrel diameter extending between a proximal end and a distal end with a rotor engaging surface at the distal end of mandrel. The outer mandrel diameter includes a first cylindrical portion adjacent the proximal end, a conical portion distal of the first cylindrical portion with a first transitional portion connecting the first cylindrical portion to the conical portion. The assembly also includes a sleeve having an inner sleeve diameter that is less than the outer rotor diameter when in an unexpanded state.

Abstract: An electric motor includes a stator having a stator core constructed from a ferromagnetic material and having an external stator surface. The stator core includes a stator core body and a plurality of stator teeth extending therefrom and the plurality of stator teeth define conductor slots therebetween. The electric motor also includes at least one rotor, each having an external rotor surface, a plurality of magnetic poles, and configured to rotate relative to the stator about a rotational axis. The stator also includes a plurality of stator conductors arranged within the conductor slots and configured to establish a rotating magnetic field exerting a torque on the rotor(s) via interaction with the magnetic poles. The stator additionally includes a plurality of first cooling channels, each defined by a respective stator tooth and configured to receive and pass therethrough a fluid to cool the corresponding stator tooth.

Abstract: An alternating current motor system includes a motor frame, a rotor including a rotor shaft, a stator including multi-phase AC stator windings, a power inverter producing a multi-phase AC voltage coupled to the multi-phase AC stator windings and at least one ohmic connection between the rotor shaft and the motor frame including a conductive fluid.

Abstract: A rotor for a rotary electric machine incudes an annular stack of rotor lamination layers (“rotor lams”) constructed of a magnetic core material. The rotor lams include inner axial surfaces collectively defining a first plurality of openings through the magnetic core material, a second plurality of openings through the magnetic core material, and a third plurality of openings through the magnetic core material. Each respective one of a first plurality permanent magnets, a second plurality of permanent magnets, and a third plurality of permanent magnets, is disposed respectively within a corresponding one of the first plurality of openings, the second plurality of openings, and the third plurality of openings. The first plurality and the third plurality of permanent magnets include high-coercivity magnets. The second plurality of permanent magnets includes low-coercivity magnets.

Abstract: A rotor for rotatably mounting on a rotational axis in an axial flux electric motor includes a permanent magnet (PM) disc having a continuous Halbach magnetization profile. The axial flux electric motor also includes a rotationally fixed stator having a plurality of conductive stator magnetic poles arranged radially about the rotational axis. The rotor is spaced axially from one side of the stator. A motor vehicle employing the subject axial flux electric motor is also contemplated.

Abstract: A radial flux electric motor includes a stator having a radially inner stator surface and stator windings arranged thereon. The motor also includes a rotor mounted inside the stator and configured to rotate relative thereto about an axis. The rotor has a rotor core constructed from a ferromagnetic material having relatively high magnetic permeability and defined by a rotor outer surface establishing an airgap between the rotor and the stator. The rotor also has a plurality of magnetic poles set in the rotor core and configured to generate magnetic flux. The rotor additionally has inserts constructed from a material having relatively low magnetic permeability in at least one geometric direction. Each insert is mechanically fixed to the rotor core to thereby control magnetic flux distribution and minimize flux leakage inside the rotor.

Abstract: A radial flux electric motor includes a stator having a radially inner stator surface and stator windings arranged thereon. The motor also includes a rotor mounted inside the stator and configured to rotate relative thereto about an axis. The rotor has a rotor core defined by a rotor outer surface and includes magnetic poles configured to generate magnetic flux and defining flux leakage zones. The motor additionally includes a selective permeability sleeve arranged circumferentially on the rotor and fixed to the rotor outer surface, thereby establishing an airgap between the sleeve and the stator. The sleeve provides reinforcement to the rotor core and to the magnetic poles and includes regions of relatively high and relatively low magnetic permeability alternating around the rotor outer surface. The regions of relatively low magnetic permeability are arranged radially outward and across from the flux leakage zones to control magnetic flux distribution in the motor.

Abstract: A current sensing apparatus may include a common mode core surrounding two or more current conductors and a current sensing element proximate the common mode core.

Abstract: A magnet-free electric machine. The electric machine may include a stator including a first stator winding set and a second stator winding set and a rotor including a first rotor winding set and a second rotor winding set. The electric machine may include a power transfer circuit configured for controlling a polarity and/or a phase sequence of excitation currents used in exciting the first and second stator and rotor windings, and thereby, respectively generated stator and rotor poles.

Abstract: A motor stator includes a stator core having a plurality of stator teeth on an inner diameter thereof and defining a respective plurality of slots between the plurality of stator teeth. A plurality of windings are disposed in the slots. A heat pipe network includes a plurality of evaporator portions including a hollow structure disposed in at least a portion of the plurality of slots and including an interior having a wick extending along the interior of the hollow structure. A condenser portion has an interior portion in communication with the plurality of evaporator portions and is located at an end of the stator core. The wick of each of the plurality of evaporator portions extend into the condenser portion.

Abstract: A vehicle, suspension system and method of dampening a force on the suspension system is disclosed. The suspension system includes a damper having a first damping element and a second damping element configured to rotate relative to each other in response to a force received at the suspension system. The second damping element induces an eddy current in the first damping element during relative rotation. A feature of one at least one of the first damping element and the second damping element provides a first electrical resistance to the eddy current during relative rotation in a first direction and a second electrical resistance to the eddy current during relative rotation in a second direction. The first electrical resistance generates a first damping force and the second electrical resistance generates a second damping force.

Abstract: An electric machine grounding system with low impedance includes a rotor that has a shaft assembly and that is configured to rotate about an axis. The shaft assembly has a surface. A housing supports the shaft assembly for rotation of the rotor. A holder extends from the housing. A ground assembly is held between the holder and the shaft assembly and includes a plurality of strands that extend to the surface to ground the shaft assembly to the housing.

Abstract: An enclosure for a rotary electric machine may include a housing supporting a stator of the electric machine and first and second end plates attached to the housing and rotatably supporting a rotor at opposite ends with respective first and second bearings isolated from the end plates.

Abstract: A power control system for an electric vehicle includes a power inverter comprising a switch module including a plurality of power switches, a controller board, and a gate driver board in communication with the controller board and configured to drive gates of the plurality of switches. A first housing is made of polymer composite, encloses the power inverter, defines a first cooling cavity in thermal communication with a first surface of the switch module, and encapsulates a portion of at least one of the switch module, the controller board and the gate driver board.

Abstract: A multi-phase, multi-pole permanent magnet motor/generator (electric machine) is described, and includes a rotor disposed on a rotor shaft within an annular stator, which may be arranged in a housing with an interposed insulator system. The insulator system is arranged to mitigate and isolate common mode currents in a shaft bearing system by insulating the stator core from an electrical ground return path of an electrical driving source. The electric machine includes a rotor rotatably disposed within a stator, and the stator is secured to the housing with the insulator system interposed therebetween.

Abstract: An electric machine may have a stator and a rotor including stacked plurality of electrical steel laminations forming a slot including a first end and opposing sides, the first end defined by a bridge extending between electrical steel on opposing sides of the slot, the bridge being located between the first end of the slot and an outer diameter surface of the rotor and beneath the outer diameter surface of the rotor, the bridge forming a base of a channel open at an outer diameter surface of the rotor.