Abstract: Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, an electric machine can be positioned within the machine cavity. In some embodiments, the electric machine can include a stator assembly including potted stator end turns. An end turn member can be positioned within the machine cavity and can include a radially inward flange and a radially outward flange axially extending from a central region. The end turn member is configured and arranged so that the flanges are substantially adjacent the stator end turns. The end turn member can include at least one second member aperture disposed through a portion of the central region.

Abstract: An electro-dynamic machine is provided and includes stator assembly end turns and a coolant chargeable bladder disposable to contact the end turns.

Abstract: A starting system for an internal combustion engine is disclosed. During a key-start, a starter assembly is used to initiate rotation of the engine crankshaft. After the engine speed reaches a transfer speed, an alternator is used to supply torque to the engine until the engine is started. In some embodiments, the starter motor is de-energized while the alternator is cranking the engine and before the engine is started. The same battery pack is used to power both the starter motor and the alternator when starting the engine. An automatic start-stop system is also disclosed. When automatically restarting the engine, the alternator alone is used to restart the engine if it is still coasting above a restart engine speed. If the engine speed is below the restart engine speed, the starter motor initially cranks the engine when restarting the engine.

Abstract: Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, a coolant jacket can be at least partially positioned within the housing. In some embodiments, a plurality of coolant apertures can be disposed through at least a portion of the housing to fluidly connect the coolant jacket and the machine cavity. The coolant apertures can include a first group configured and arranged to direct a first volume from the coolant jacket. The coolant apertures can include a second group configured and arranged to direct a second volume from the coolant jacket. In some embodiments, the first volume can be greater than the second volume.

Abstract: An access port cover system, including a housing for an item, the housing defining interior and exterior regions and including an access port through which access to the item from the exterior region is provided, a cover inhibiting access through the access port from the exterior region to the interior region, and a fastener connectable to the housing and the cover. The fastener has an actuation portion for disconnecting the housing and the cover to permit access through the access port from the exterior region to the interior region, the actuation portion being inaccessible from the exterior region when the fastener is connected to the housing and the cover.

Abstract: A stator assembly for an electric machine including a stator core supporting a plurality of electrical conductors. A plurality of elongated insulator spacers is interwoven between the conductors proximate connection ends thereof in axially spaced relation to the stator core.

Abstract: An electric machine having a stator, a rotor and a housing assembly with two end caps and inner and outer axially extending members. The outer housing member is disposed about the inner member. Ribs extend from one housing member and engage the other housing member in an interstitial space. The other housing member may be a tubular sleeve. The ribs define axially extending fluid path segments within the interstitial space and the end caps close the opposite axial ends of the interstitial space and define an inlet and an outlet for a liquid coolant. The liquid coolant path may be serpentine. The housing member with ribs may include a sleeve portion with at least some ribs having a width greater than the radial thickness of the sleeve portion. Threaded fasteners can attach the end caps to the enlarged width ribs. The inner and outer housings are advantageously extrudable.

Abstract: An electric machine that includes a stator operably coupled with a rotor. At least one axially extending housing member is thermally coupled with the stator core and defines a plurality of axially extending fluid passages. An end cap defines a plurality of end turn fluid passages interconnecting the axially extending fluid passages. The end turn fluid passages are arranged circumferentially about and proximate a first axial end of the stator whereby the axially extending fluid passages and end turn passages define a serpentine path. An electronic component thermally coupled with the end cap is disposed radially inward and axially proximate the plurality of end turn fluid passages. The electronic component may be at least partially axially positioned between the distal limit of the stator windings and the axial limit of the serpentine path. In alternative embodiments, the end cap supports a bearing assembly for the rotor shaft.

Abstract: An electric machine includes a pair of substantially aligned sheet metal housing sections each including a substantially “L” shaped portion, at least one cooling channel being formed at an axial end between the two sections, and a plurality of power electronics components engaged with at least one of the housing sections adjacent the axial end cooling channel. An embodiment includes a stator, a pair of housing sections enclosing the stator, power electronics components positioned at an axial end of the electric machine for controlling operation of the electric machine, and a coolant flow path that includes a power electronics cooling channel formed at the axial end between the housing sections. A method includes forming an axial end cooling channel between two sheet metal housing sections, and positioning power electronics components at the axial end along the cooling channel, whereby heat from the electronics components is transferred to the cooling channel.

Abstract: An electric machine includes a housing having inner and outer sheet metal members attached to one another to form a coolant channel therebetween, a plurality of power electronic components mounted to an axial end of the electric machine adjacent the coolant channel, and a cover secured to the axial end for enclosing the electronic components. A method of cooling an electric machine includes forming a coolant channel at an axial end of the machine, between inner and outer sheet metal members, attaching a power electronics component to the outer sheet metal member proximate the coolant channel, thereby cooling the electronics component by conduction with the coolant channel, and securing a cover to the axial end for enclosing the power electronics component.

Abstract: An electric machine includes a stator and a housing having at least two sheet metal sections, at least one cooling channel being formed at an axial end of the electric machine between the two sections. A method of cooling an electric machine includes forming two sheet metal housing sections to each include a radially inward extending portion at an axial end of the electric machine and an axially extending portion, and attaching the housing sections to one another at contiguous portions thereof, whereby at least one cooling channel is formed between the respective radially inward extending portions of the sections. A method of cooling an electric machine includes circulating coolant in a plurality of cavities formed between two sheet metal housing sections, the cavities including a cooling channel at an axial end of the electric machine.

Abstract: An embodiment of an electric machine includes inner and outer housing sections attached to one another to form, at an axial end of the electric machine, a cooling channel therebetween. Such electric machine also includes a bearing carrier coupled to the housing sections and radially registered to the inside diameter of the inner housing section. An embodiment of an electric machine includes annular, L-shaped inner and outer sheet metal housing sections enclosing a cooling channel at an axial end of the electric machine and otherwise being substantially parallel and contiguous, and includes a first bearing assembly coupled to the inner housing section.

Abstract: An electric machine includes a housing having a cooling jacket at an axial end thereof, a plurality of power electronic components mounted to the axial end of the housing proximate the cooling jacket, a cover for enclosing the electronic components, and a biasing member that axially urges the electronic components against the housing. An electric machine includes a cooling jacket in an axial end of a housing, power electronic components, and a spring member for urging the power electronic components against the cooling jacket. A method of cooling an electric machine includes providing a cooling jacket in an axial end of a housing and biasing power electronic components against the cooling jacket.

Abstract: A liquid-cooled rotary electric machine including jacket defining a heat transfer surface in conductive thermal communication with a stator and having an axial end portion partially enclosing an interior volume. A heat source is in conductive thermal communication with a wall of the jacket axial end portion. A fluid channel traverses the heat transfer surface between opposite axial ends of the jacket. A fluid passage in fluid communication with the fluid channel is defined by jacket axial end portion walls and substantially surrounds the heat source in an imaginary plane perpendicular to the stator axis. At least a portion of heat transferable between the heat source and the fluid passage is convectively transferable between jacket axial end portion walls and liquid coolant along a flow path of liquid coolant through the machine. Also a method for liquid-cooling a rotary electric machine.

Abstract: A liquid-cooled rotary electric machine including jacket defining a heat transfer surface in conductive thermal communication with a stator and having an axial end portion partially enclosing an interior volume. A heat source is in conductive thermal communication with a wall of the jacket axial end portion. A fluid channel traverses the heat transfer surface between opposite axial ends of the jacket, and a fluid passage in fluid communication with the fluid channel is defined by jacket axial end portion walls. A flow path of liquid coolant through the machine is defined by the fluid channel and the fluid passage between a machine coolant inlet and outlet, whereby at least a portion of heat transferable between the heat source and the fluid passage is convectively transferable between the jacket axial end portion walls and liquid coolant along the flow path. Also a method for liquid-cooling a rotary electric machine.

Abstract: A liquid-cooled rotary electric machine including a heat transfer surface traversed by a fluid channel defining a flow path for liquid coolant through the machine. A first fluid channel portion extends about and progresses in a direction parallel to the central axis, and is interconnected with a second fluid channel portion at spaced locations along the first fluid channel portion. The heat transfer surface includes a zone which the first fluid channel portion does not traverse, and is located between a jacket axial end and the first fluid channel portion. The second fluid channel portion extends into the zone between the interconnections, whereby the zone is traversed by the second fluid channel portion and heat is convectively transferable from the zone to liquid coolant along the flow path. Also, a method for liquid-cooling a rotary electric machine.

Abstract: A liquid-cooled rotary electric machine including a jacket defining a heat transfer surface and a sleeve defining a coolant containment surface. A fluid channel having an entry and an exit is located between the heat transfer and coolant containment surfaces, and traverses the heat transfer surface. The fluid channel defines a flow path for liquid coolant through the machine extending substantially circumferentially about an axis and progressing in a direction parallel with the axis, with the flow path progressing in opposite directions parallel to the axis. Also, a method of liquid-cooling a rotary electric machine that includes traversing a generally cylindrical heat transfer surface with a liquid coolant flow along a flow path extending substantially circumferentially about an axis and progressing in opposite directions parallel to the axis, between a fluid channel entry and a fluid channel exit.

Abstract: Embodiments of the invention provide an electric machine module. The module can include a housing that can define a machine cavity. The housing can include a coolant jacket that contains a first coolant. A coolant sump can be in fluid communication with the machine cavity and can contain a second coolant that is different than the first coolant. The coolant sump can be in thermal communication with the coolant jacket. An electric machine can be positioned within the machine cavity. The electric machine can include a stator assembly, a rotor assembly, and a shaft. The module can also include at least one coolant channel, at least one shaft channel, and at least one rotor channel.

Abstract: A cooling system of an electric machine first and second heat sinks respectively mounted to axial ends of a rotor core, and a thermal interfacial material interposed between respective complementary surfaces of the heat sinks and the rotor core for substantially eliminating air gaps therebetween. A method of cooling includes placing thermal interfacial material onto a heat transfer interface between the rotor core and the heat sink, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method of cooling includes coating an axially outer surface of the rotor core and/or an axially inner surface of an annular heat sink with thermal interfacial material, and attaching the heat sink to the rotor, whereby thermal interfacial material is interposed between the inner surface of the heat sink and the outer surface of the rotor core.

Abstract: A cooling system of an electric machine includes a stator core, a housing, and a thermal interfacial material interposed between complementary mating surfaces of the stator core and the housing for substantially eliminating air gaps therebetween. A method of cooling an electric machine having a housing and a stator includes placing a thermal interfacial material onto a heat transfer interface between the stator and the housing, whereby the thermal interfacial material reduces contact resistance at the heat transfer interface. A method of cooling a stator of an electric machine includes heating a housing having a radially inner surface, coating a radially outer surface of the stator and/or the radially inner surface of the housing with a thermal interfacial material, and inserting the stator into the heated housing, whereby the thermal interfacial material is interposed between the inner surface of the housing and the outer surface of the stator.