Abstract: A drive module is employed for use in a hybrid electric vehicle (HEV) powertrain or in a battery electric vehicle (BEV) powertrain. The drive module serves to propel movement of the accompanying hybrid electric vehicle or battery electric vehicle. In an implementation, the drive module includes a housing, an electric motor, a gear assembly, a coolant sump, and a coolant passage. The electric motor has a stator and a rotor. The rotor has a shaft. The gear assembly has its movement driven by the shaft. The coolant passage resides in a wall of the housing. Amid use, coolant is drawn from the coolant sump via the coolant passage.

Abstract: A stator for an electric machine includes a stator body having a cylindrical yoke having a first diameter and a second diameter, a tooth portion having a plurality of slots extending radially from the first diameter, and at least one vibration mitigation portion including at least one gap in the yoke portion. The at least one gap extends radially from the first diameter to the second diameter, and the at least one gap has a width selected to mitigate vibration when the electric machine is operating at a selected operation frequency.

Abstract: An induction rotor for an electric machine includes a rotor shaft, a core having a plurality of axially extending conductive bars, and an end ring disposed at an end of the core and electrically connected to the plurality of conductive bars. The end ring includes a plurality of plates, the plurality of plates include a pair of adjacent plates defining a fluid passage therebetween, and the fluid passage is configured to circulate a cooling fluid through the end ring.

Abstract: A stator assembly has a substantially cylindrical core that defines a plurality of winding slots and a plurality of wedge-shaped insert slots, with the winding slots and insert slots alternating around the perimeter face of the core. Each insert slot is wedge-shaped to receive a wedge-shaped insert. The insert includes a cap at one end that is configured to be positioned at the insert slot opening when the insert is disposed within the corresponding insert slot. The cap includes a pair of wings extending therefrom that are sized and configured to overlap a portion of a winding slot on either side of the insert slot when the insert is disposed in said insert slot. The insert slots and inserts include a feature for locking engagement of the inserts in the slots.

Abstract: A starter motor controller for a starter motor operatively connected to a single coil solenoid includes a first pair of switches including a first solenoid switch and a second solenoid switch. The first solenoid switch selectively completes a first electrical circuit for delivering a first electrical current to the single coil solenoid and the second solenoid switch selectively completes a second electrical circuit for delivering a second electrical current to the single coil solenoid that is less than the first electrical current. A second pair of switches includes a first starter motor switch and a second starter motor switch. The first starter motor switch selectively completes a first electrical circuit for delivering a first electrical power to the starter motor and the second starter motor switch selectively completes a second electrical circuit for delivering a second electrical power to the starter motor that is greater than the first electrical power.

Abstract: A starter motor controller for a starter motor operatively connected to a single coil solenoid includes a first pair of switches including a first solenoid switch and a second solenoid switch. The first solenoid switch selectively completes a first electrical circuit for delivering a first electrical current to the single coil solenoid and the second solenoid switch selectively completes a second electrical circuit for delivering a second electrical current to the single coil solenoid that is less than the first electrical current. A second pair of switches includes a first starter motor switch and a second starter motor switch. The first starter motor switch selectively completes a first electrical circuit for delivering a first electrical power to the starter motor and the second starter motor switch selectively completes a second electrical circuit for delivering a second electrical power to the starter motor that is greater than the first electrical power.

Abstract: An electric machine configured to increase resistance between a brush and a commutator of the electric machine at a wear condition of the brush consistent with end of service life.

Abstract: An electric machine configured to increase resistance between a brush and a commutator of the electric machine at a wear condition of the brush consistent with end of service life.

Abstract: A starter assembly is provided and includes a shaft to transmit rotation to a ring gear via a pinion and including a first helical spline with angling directed reversely with respect to a direction of the rotation and an elastic element anchored on the first helical spline to bias the pinion in an axial direction. The ring gear and the pinion include complementary teeth and the pinion defines a bore with a second helical spline to register with the first helical spline such that the pinion teeth are forwardly rotated into ring gear teeth engagement positions as the shaft moves axially relative to the pinion in the axial direction.

Abstract: An internal combustion engine includes a ring gear, a speed sensor operatively associated with the ring gear, and a change of mind (COM) starter motor mechanically linked to the internal combustion engine. The COM starter motor includes an armature and a pinion operatively connected to the armature. A solenoid is operatively connected to the COM starter motor. The solenoid selectively moves the pinion into engagement with the ring gear. An electronic control unit (ECU) is operatively connected to the speed sensor and the solenoid. The ECU is configured and disposed to indirectly detect a rotational speed of the pinion and selectively energize the solenoid to axially shift the pinion into engagement with the ring gear when the pinion reaches a particular rotational speed relative to a rotational speed of the ring gear.

Abstract: A starter assembly is provided and includes a shaft to transmit rotation to a ring gear via a pinion and including a first helical spline with angling directed reversely with respect to a direction of the rotation and an elastic element anchored on the first helical spline to bias the pinion in an axial direction. The ring gear and the pinion include complementary teeth and the pinion defines a bore with a second helical spline to register with the first helical spline such that the pinion teeth are forwardly rotated into ring gear teeth engagement positions as the shaft moves axially relative to the pinion in the axial direction.

Abstract: An electric machine housing includes a housing body having an outer surface provided with a plurality of materially integrally formed ribs defining a plurality of coolant channels. Each of the plurality of materially integrally formed ribs has an outer surface portion. A sleeve is provided on the housing body extending about the outer surface. The sleeve has an inner surface section that is matingly engaged with the outer surface portion of each of the materially integrally formed ribs.

Abstract: An internal combustion engine includes a ring gear, a speed sensor operatively associated with the ring gear, and a change of mind (COM) starter motor mechanically linked to the internal combustion engine. The COM starter motor includes an armature and a pinion operatively connected to the armature. A solenoid is operatively connected to the COM starter motor. The solenoid selectively moves the pinion into engagement with the ring gear. An electronic control unit (ECU) is operatively connected to the speed sensor and the solenoid. The ECU is configured and disposed to indirectly detect a rotational speed of the pinion and selectively energize the solenoid to axially shift the pinion into engagement with the ring gear when the pinion reaches a particular rotational speed relative to a rotational speed of the ring gear.

Abstract: An electrical machine including a stator and a rotor assembly. The rotor assembly defines a rotational axis and has a rotor core wherein the rotor core defines first and second axial end surfaces. A balance ring is rotationally fixed to the rotor assembly and is configured to rotationally balance the rotor assembly. The balance ring comprises an electrically conductive and magnetically permeable material and is disposed proximate the first axial end surface and defines an air gap disposed axially between the balance ring and the first axial end surface. In some embodiments, the electric machine includes a plurality of spacers extending between the first axial end surface and the balance ring. The rotor core and balance ring may comprise a plurality of stacked electrical steel laminations. The balance ring can be used to provide electromagnetic interference shielding for a resolver. A method of manufacturing an electric machine is also disclosed.

Abstract: An electric machine housing includes a housing body having an outer surface provided with a plurality of materially integrally formed ribs defining a plurality of coolant channels. Each of the plurality of materially integrally formed ribs has an outer surface portion. A sleeve is provided on the housing body extending about the outer surface. The sleeve has an inner surface section that is matingly engaged with the outer surface portion of each of the materially integrally formed ribs.

Abstract: A shorting ring support structure of a rotor of an electric machine has a radially outer ring and a member extending radially inwardly from the outer ring and defining a radial length, the radially extending member being spaced axially inwardly from opposing axial surfaces of a die-cast shorting ring whereby the radially extending member is fully embedded in the shorting ring for a substantial majority of its radial length. Rotor conductor bars and the shorting ring are formed of an integrally cast material that secures the shorting ring support structure to the rotor body. A method of manufacturing includes providing a shorting ring support structure and a rotor body, and then casting conductor bars in slots of the rotor body and a shorting ring on the rotor body to form a rotor, where an outer ring of the support structure defines the outer radial limit of the shorting ring.