Abstract: Targeted cold working and nitriding is added to specific spots to decrease flux in bridge areas of motor steel laminations to alter the electromagnetic properties of these areas to reduce flux loss and increase the efficiency by using insulations coatings on the lamination steels as a nitriding barrier. The reduction in flux allows for the use of smaller magnets, which decreases costs and results in an increase in performance.

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: An electric machine is disclosed having a stator and a rotor, the stator comprising one or more windings that “turn” between passes through the stator. The turn portions of the windings are cast within a heat-conductive material such as aluminum that conducts heat away from the turn portions. The casting also defines a cavity for the flow of a heat-carrying fluid (such as water) to remove heat more efficiently from the turn portions. In some embodiments, the windings are electrically insulated (for example, using a ceramic insulator) before the casting.

Abstract: A method of manufacturing an electric machine that includes providing a core defining a slot, coating a magnet body prior to installation of the magnet body into the slot and installing the magnet body into the slot wherein the coating on the magnet body has a thermal conductivity of at least about 0.3 W·m?1·K?1, advantageously of at least about 0.5 W·m?1·K?1, and even more advantageously of at least about 2 or 3 W·m?1·K?1 and wherein the coating is in a partially cured condition when the magnet body is inserted into the slot. The coating may form a substantially voidless material bridge between the magnet body and the core over at least a portion of the magnet body and thereby thermally couple the magnet body with the core. An electric machine manufactured in accordance with the method is also disclosed.

Abstract: A stator assembly includes a first conductor having a first leg portion, and second leg portion. Each of the first and second leg portions includes corresponding first and second free end portions. The first free end portion includes first and second surface portions and the second free end portion includes first and second surface segments. A second conductor includes a first leg section, and a second leg section including corresponding first and second free end sections. The first free end section includes first and second surface zones and the second free end section including first and second surface sectors. The second free end portion and the first free end section are twisted creating a cross-over region causing the first surface portion to abut the second surface zone. The second free end portion is joined to the first free end section through a bond that exists at the cross-over region.

Abstract: A method of joining a plurality of electrical conductors in an electric machine comprises the steps of providing a core with a plurality of circumferentially spaced openings, and positioning a plurality of conductors within the openings of the core in a plurality of concentric layers. Each conductor includes an end that extends from the core. The ends of the conductors have a first shape. The method also includes the step of shaping the ends of the conductors with a set of forming dies to form a second shape. Additionally, the method includes the step of joining a pair of adjacent ends with a joining tool to form a joint with a third shape after shaping the ends to form the second shape. The method further includes the step of removing the set of forming dies and the joining tool from the joint after the joining step.

Abstract: Disclosed is a rotor for a fluid cooled electric machine including a rotor shaft rotably located at a central axis and a plurality of rotating coolant passages extending outwardly from the rotor shaft to direct a flow of coolant to a desired impingement location on the electric machine thereby removing thermal energy from the impingement location. Further disclosed is a fluid cooled electric machine including a plurality of coolant passages each including at least one coolant passage inlet and at least one coolant passage outlet, the plurality of coolant passages configured to rotate about the central axis and direct a flow of coolant therethrough to a desired impingement location thereby removing thermal energy from the impingement location.

Abstract: A method of joining a plurality of electrical conductors in an electric machine. The method comprises the steps of providing a core and positioning the plurality of conductors within the core in concentric rings. The conductors include ends extending from the core. The method further comprises the steps of holding together at least two adjacent ends of the conductors, joining the adjacent ends to form a joint, and forming the joint to include at least a substantially planar portion. The method further comprises the step of releasing the adjacent ends of the conductors.

Abstract: A stator winding for an electric machine includes two or more conductors defining one or more phases about the stator winding. Each phase includes at least two conductors of the two or more conductors arranged in an electrically switchable relationship. An end of each conductor of the two or more conductors extends to an exterior of the electric machine and is configured for independent electrical connection to a component at the exterior of the electric machine. An electric machine includes a stator having a stator winding including two or more conductors defining one or more phases about the stator winding including at least two conductors of the two or more conductors arranged in an electrically switchable relationship. An end of each conductor of the two or more conductors extends to an exterior of the electric machine for independent electrical connection to a component at the exterior of the electric machine.

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: An electric motor core member includes a body having an inner diametric portion including an inner arcuate surface and an outer diametric portion including an outer arcuate surface. The electric motor core member further includes a plurality of wall members provided on the main body. Each of the plurality of wall members projects outwardly from the outer arcuate surface and is arranged in a spaced relationship to define a plurality of conductor isolation channels. Each of the plurality of conductor isolation channels is adapted to receive one of a plurality of conductors with the plurality of wall members providing electrical isolation between adjacent ones of the plurality of conductors.

Abstract: A method of winding an electric motor core member includes continuously winding a single conductor about a portion of an electric motor core member, and separating the single, continuously wound conductor into multiple phase windings.

Abstract: A method of winding an electric motor core member includes continuously winding a single conductor about a portion of an electric motor core member, and separating the single, continuously wound conductor into multiple phase windings.

Abstract: Disclosed is a rotor for a fluid cooled electric machine including a rotor shaft rotably located at a central axis and a plurality of rotating coolant passages extending outwardly from the rotor shaft to direct a flow of coolant to a desired impingement location on the electric machine thereby removing thermal energy from the impingement location. Further disclosed is a fluid cooled electric machine including a plurality of coolant passages each including at least one coolant passage inlet and at least one coolant passage outlet, the plurality of coolant passages configured to rotate about the central axis and direct a flow of coolant therethrough to a desired impingement location thereby removing thermal energy from the impingement location.

Abstract: A sensor assembly includes a main body having an outer wall member, an inner wall member, and an intermediate portion. The main body including a central opening defined by the inner wall member. The sensor assembly further includes at least one anti-rotation mechanism formed on the inner wall member. The at least one anti-rotation mechanism is adapted to deflect radially toward the outer wall member upon engagement with a component to be sensed. Upon deflection, the at least one anti-rotation mechanism fixedly secures the sensor assembly to the component to be sensed.

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 electric motor core member includes a body having an inner diametric portion including an inner arcuate surface and an outer diametric portion including an outer arcuate surface. The electric motor core member further includes a plurality of wall members provided on the main body. Each of the plurality of wall members projects outwardly from the outer arcuate surface and is arranged in a spaced relationship to define a plurality of conductor isolation channels. Each of the plurality of conductor isolation channels is adapted to receive one of a plurality of conductors with the plurality of wall members providing electrical isolation between adjacent ones of the plurality of conductors.