Abstract: An electric machine system includes an electric motor. The electric motor includes a stator having a plurality of windings that define a number of phases. A plurality of switch members are operatively coupled to the plurality of windings. The plurality of switch members are no more than one less than three times the number of phases. A controller is operatively coupled to the plurality of switch members. The controller selectively changes a state of the plurality of switch members to establish one of a first electrical connection configuration of the plurality of windings and a second electrical connection configuration of the plurality of windings.

Abstract: A stator for an electric machine includes a stator winding located at a stator core. The stator winding has one or more phases, each phase including a single unitary conductor having at least two conductor segments arranged in an electrically parallel relationship. A connection portion is formed in the single unitary conductor between a first conductor segment and a second conductor segment of the at least two conductor segments to connect the conductor to an electrical component.

Abstract: An electric machine including a stator having a body provided with at least one alignment member, and a resolver positioned relative to the stator. The resolver includes at least one alignment element. An alignment adaptor is configured to receive each of the stator and the resolver. The alignment adaptor includes an alignment system that positions the alignment member and the alignment element to establish a desired alignment between the stator and the resolver.

Abstract: An electric machine includes a stator mounted within the housing, and a transmission member mounted within the housing and surrounded at least in part by the stator. The transmission member includes a gear mechanism operatively coupled to an output shaft. The transmission mechanism is rotatable relative to the stator.

Abstract: An electric machine including a housing, and a stator mounted within the housing. The stator includes an outer perimetric surface and an inner perimetric surface. A rotor is mounted, at least in part, within the inner perimetric surface of the stator. The rotor is rotatable relative to the stator. A stator sleeve extends about the stator. The stator sleeve includes a first sleeve portion and a second sleeve portion. The first sleeve portion includes a first diametric edge that extends to a second diametric edge, and the second sleeve portion includes a first diametric edge section that extends to a second diametric edge section. The stator sleeve is configured and disposed to establish a coolant cavity about the outer perimetric surface of the stator.

Abstract: Embodiments of the invention provide an electric machine module including a housing defining a machine cavity. In some embodiments, an electric machine can be positioned within the machine cavity and include a rotor hub coupled to rotor laminations. The rotor hub can include first and second axial ends and the rotor laminations can include a recess. In some embodiments, the recesses can be aligned to define a portion of a plurality of coolant channels that can be in fluid communication with the machine cavity. In some embodiments, the rotor hub can include first and second rotor hub inlets in fluid communication with at least a portion of the coolant channels. The first and the second rotor hub inlets can be adjacent to the axial ends of the rotor hub. In some embodiments, the coolant channels are in fluid communication with the rotor hub inlets are not the same coolant channels.

Abstract: An electric machine includes a rotor lamination assembly having a lamination member formed from a material having a first yield strength. The lamination member includes a first bridge portion having a first width, and a first bridge zone having a first thickness. The rotor lamination assembly also includes at least one lamination section having a second bridge zone having a second thickness. The second thickness is greater than the first thickness. The rotor lamination assembly further includes at least one lamination element formed from a second material having a second yield strength that is higher than the first yield strength, and at least one lamination component. The at least one lamination component includes a second bridge portion having a second width. The second width is greater than the first width.

Abstract: Embodiments of the invention provide an electric machine module including a module housing. The module housing can include a sleeve member coupled to at least one end cover and can define a machine cavity. In some embodiments, the sleeve member can include an inner perimeter and can be coupled to a stator assembly of an electric machine. In some embodiments, the electric machine can be positioned within the machine and at least partially enclosed by the module housing. In some embodiments, a coolant jacket can be defined by at least a portion of the sleeve member and at least a portion of the stator assembly.

Abstract: Embodiments of the invention provide an electric machine module including a module housing. In some embodiments, the module housing can at least partially define a machine cavity into which an electric machine can be positioned. The electric machine can include a rotor assembly comprising a plurality of laminations and a least one magnet positioned substantially within the rotor assembly. In some embodiments, at least one temperature sensor can be operatively coupled to, and in thermal communication with, a portion of the rotor assembly. The temperature sensor can be configured to sense a temperature of the rotor assembly. In some embodiments, at least one transmitter can be in communication with the temperature sensor and can transmit a signal from the temperature sensor to a receiver. In some embodiments, the receiver can be coupled to the module housing and in communication with a controller.

Abstract: Some embodiments of the invention provide an electric machine including a rotor assembly. In some embodiments, the rotor assembly can include a plurality of rotor laminations including at least one first aperture positioned through a portion of the rotor laminations. In some embodiments, the first apertures can form at least one magnet channel when the rotor assembly is substantially assembled. At least one permanent magnet can be positioned in each of the magnet channels. In some embodiments, at least one second aperture can be positioned through a portion of some of the laminations, along a Q-axis, and adjacent to the at magnet channel. Also, the second apertures can be configured and arranged to form at least one first coolant channel when the rotor assembly is substantially assembled.

Abstract: An electric machine includes a stator, and a rotor lamination assembly configured to rotate relative to the stator. The rotor assembly includes at least one lamination member that includes a body having an inner diametric edge that extends to an outer diametric edge, and at least one magnet receiving member. The at least one magnet receiving member is formed in the body and includes a first end that extends to a second end. The second end is spaced from the outer diametric edge to form a bridge portion. The at least one lamination member includes at least one stress concentration element positioned between the inner diametric edge and the outer diametric edge. The at least one stress concentration element is configured and disposed to reduce stress in the bridge portion.

Abstract: Embodiments of the invention provide an electric machine module including a module housing, which can at least partially define a machine cavity. In some embodiments, an electric machine can include a stator assembly and a rotor assembly and can be positioned in the machine cavity. In some embodiments, the module housing can include a coolant transport network, which can include at least one passage in fluid communication with at least one first annulus and at least one second annulus. In some embodiments, the first annulus can be substantially axially adjacent to an axial end of the stator assembly and the second annulus can be substantially axially adjacent to an axial end of the rotor assembly. In some embodiments, the annuli can include a plurality of annulus apertures.

Abstract: An electric machine includes a stator, and a rotor lamination assembly configured and disposed to rotate relative to the stator. The rotor lamination assembly includes at least one lamination member including a body member having an outer diametric edge, and at least one magnet receiving member. The at least one magnet receiving member includes a first end that extends to a second end. The second end establishes an interruption zone in the outer diametric edge.

Abstract: A stator includes a body portion having an outer portion and an inner portion that defines an interior region, a plurality of stator teeth members extending from the inner portion into the interior region, and at least one continuous conductor wound around select ones of the plurality of stator teeth members to form at least one pole. Each of the plurality of stator teeth members including a number of wraps of the at least one continuous conductor. The at least one continuous conductor including a number of twists that is fewer than the number of wraps.

Abstract: A vehicle includes a chassis, a traction member associated with the chassis, and a drive system associated with the chassis and the traction member comprising an electric traction motor, a planetary gear assembly coupled to the electric traction motor, the planetary gear assembly comprising an output member coupled to the traction member, wherein rotation of the output member provides a drive torque for the traction member.

Abstract: A planetary gear assembly includes a ring gear configured for connection to a rotor of an electric motor when in a first position and configured for connection to a housing of the electric motor when in a second position, a sun gear configured for connection to the housing when the ring gear is in the first position and configured for connection to the rotor when the ring gear is in the second position, and a plurality of planet gears configured to mesh with the ring gear and the sun gear.

Abstract: An electric motor assembly includes a stator defining a first interior space, a rotor positioned within the first interior space and configured for rotation relative to the stator, the rotor defining a second interior space, and a planetary gear assembly associated with the rotor and at least partially positioned within the second interior space.

Abstract: A winding apparatus includes a mounting fixture configured to support a plurality of stator teeth. The mounting fixture is configured to rotate about an axis defined by each of the plurality of stator teeth. A plurality of stator tooth holding elements are connected to the mounting fixture. The plurality of stator tooth holding elements retain a select one of the plurality of stator teeth relative to the mounting fixture. The mounting fixture is selectively rotated about the central axis of at least one of the plurality of teeth to apply wraps of wire to the one of the plurality of stator teeth while at the same time rotating others of the plurality of stator teeth. A wire guiding member is supported by the mounting fixture. The wire guiding member is configured and disposed to establish a desired length of wire between adjacent ones of the plurality of stator teeth.

Abstract: An electric machine includes a housing having an outer surface and an inner surface that defines an interior portion. The housing also includes a connection zone having a first end portion that extends from the outer surface to a second end portion that is exposed to the interior portion. The connection zone includes a connection passage. A terminal block extends through the connection passage. The terminal block includes a non-electrically conductive member that is sealed against the connection passage, and an electrically conductive member covered by the non-electrically conductive member. The electrically conductive member includes a first end section that extends to a second end section through an intermediate section. The first end section has a first connection zone and the second end section has a second connection zone. The second connection zone is at an angle relative to the first connection zone.

Abstract: An electric machine including a housing having an outer surface and an inner surface that defines an interior portion. The housing includes a connection zone. A fluid circuit passes, at least in part, through the housing. The fluid circuit includes an inlet portion and an outlet portion. A stator assembly is arranged within the interior portion of the housing. The stator assembly includes at least one connector lead, and a terminal block extending through the housing. The terminal block includes a non-electrically conductive member that is sealed against the housing. The non-electrically conductive member includes a fluid cavity. At least one electrically conductive member is covered, at least in part, by the non-electrically conductive member. The fluid cavity guides a fluid along a portion of the at least one electrically conductive member to absorb heat.