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: Some embodiments of the invention provide an electric machine module comprising a housing including a sleeve member and at least one end cap. In some embodiments, the sleeve member can include a first coolant jacket and a second coolant jacket. Also, in some embodiments, the end cap can include an end cap coolant jacket. Also, some embodiments provide an electric machine including stator end turns, housing at least partially enclosing the electric machine, and an end cap coolant jacket positioned substantially axially outward relative to at least one of the stator end turns.

Abstract: Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots, a weld end, and an insertion end. In some embodiments, conductors can be positioned in the slots so that portions of the conductors extend from the weld end and the insertion end. An insulation member including recesses can be coupled to at least a portion of the conductors that extend from the weld end of the stator assembly.

Abstract: Embodiments of the invention provide an electric machine module. The module can include a module housing, which can comprise a sleeve member. In some embodiments, the sleeve member can include an inner wall and an outer wall, and the module housing can at least partially define a machine cavity. In some embodiments, a coolant jacket can be positioned substantially between a portion of the inner wall and a portion of the outer wall. Also, in some embodiments, at least one boss can be positioned in the sleeve member so that the at least one boss can be substantially integral with both the inner wall and the outer wall, and can extend through a portion of the coolant jacket.

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 includes a core with a plurality of slots. A plurality of conductors are positioned in each of the plurality slots, with each slot including an equal number of conductors. At least one slot liner is also positioned in each of the plurality of slots. Each slot liner provides at least one slot liner channel in the associated slot, and each of the plurality of conductors extend through one of the slot liner channels. Differing numbers of slot liner channels are provided in the plurality of slots. Accordingly, all slots have the same number of conductors positioned therein, but all slots do not have the same number of slot liner channels.

Abstract: Some embodiments of the invention provide an electric machine module comprising an electric machine including a rotor assembly and a rotor hub. In some embodiments, the module can include a output shaft substantially circumscribed by the rotor hub and including at least one channel and at least one coolant outlet. A cavity can be formed by at least the output shaft and the rotor hub. Some embodiments can include a sleeve substantially circumscribing a portion of the output shaft with at least a portion of the sleeve positioned substantially within the cavity between the output shaft and the rotor hub. The sleeve can include at least one groove.

Abstract: A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure.

Abstract: An electric machine includes a housing, a stator mounted within the housing, and a rotor rotatably mounted within the housing relative to the stator. The rotor includes a rotor lamination assembly having a plurality of laminations. A temperature sensor is arranged within the housing. The temperature sensor includes a sensing surface configured and disposed to detect a temperature of the rotor.

Abstract: A permanent magnet electric machine that includes a housing, a stator mounted within the housing, a rotor assembly, a plurality of permanent magnets mounted within the rotor assembly, and a magnetic flux sensor arranged within the housing. The magnetic flux sensor includes a sensing surface configured and disposed to detect magnetic flux leaking from the rotor assembly.

Abstract: An electric machine includes a housing having a coolant collection area, a stator mounted within the housing, a rotor assembly rotatably mounted within the housing relative to the stator, and a coolant level sensor arranged at the coolant collection area. The coolant level sensor includes a sensing surface configured and disposed to detect a level of coolant collected in the coolant collection area.

Abstract: An electric machine includes a housing and a shaft arranged within the housing. The shaft includes a first end portion and a second end portion. At least one bearing is mounted at one of the first end portion of the shaft and the second end portion of the shaft. A stator is mounted within the housing and a rotor is mounted relative to the shaft and rotatable relative to the stator. A temperature sensor is integrated into the housing at the at least one bearing. The temperature sensor includes a sensing element that detects a temperature of the at least one bearing.

Abstract: An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a coolant system fluidly connected to the housing. The coolant system delivers a flow of coolant through the housing. A coolant temperature sensor is arranged within the housing and exposed to the flow of coolant. The coolant temperature sensor configured and disposed to detect a temperature of the coolant in the housing.

Abstract: An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a vibration sensor arranged within the housing. The vibration sensor includes a sensing member configured and disposed to detect vibrations of the electric machine.

Abstract: An electric machine including a stator, and a rotor lamination assembly configured and disposed to rotate relative to the stator. The rotor lamination assembly includes a plurality of laminations that define an outer diametric surface. A rotor lamination compression sleeve extends about the outer diametric surface of the rotor lamination assembly. The rotor lamination compression sleeve exerts a compressive radial force on the rotor lamination assembly. The rotor lamination compression sleeve is configured and disposed to expand when subjected to a centrifugal force while still maintaining a compressive radial force.

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 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 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 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.