Abstract: A portable range extender can be used to supply electrical power to an electric vehicle operable by an electric traction motor. The portable range extender includes an engine, a dynamoelectric machine coupled to the engine by a shaft, an autonomous range extender controller for controlling operations of the range extender independently of a controller for the vehicle, and circuitry associated with the engine and machine. The range extender and its controlling circuitry are self contained within an enclosure. The enclosure is partitioned to form two sections, a first section housing the dynamoelectric machine and the second section housing the engine. Windows in the enclosure provide a path for air cooling of the range extender components.

Abstract: A portable range extender can be used to supply electrical power to an electric vehicle operable by an electric traction motor. The portable range extender includes an engine, a dynamoelectric machine coupled to the engine by a shaft, an autonomous range extender controller for controlling operations of the range extender independently of a controller for the vehicle, and circuitry associated with the engine and machine. To start operation, electrical energization is applied from the vehicle battery to the dynamoelectric machine for operation as a motor to drive the shaft. As the shaft accelerates, the rotational speed of the shaft and the temperature of the engine are sensed. When the speed and temperature obtain predetermined thresholds, fuel is supplied to the engine and ignition is activated. The engine then operates as a prime mover to drive the shaft in lieu of the machine.

Abstract: Sensorless fuel level and oil change indicators are provided in a range extender for an electric vehicle. The range extender includes an engine, and an electric generating device driven by the engine to generate electric power supplied to the vehicle. The fuel level is calculated based on the generated power. The oil change indicator indicates that the oil should be changed when the number of engine rotor revolutions exceeds a threshold value. The electric generating device may be a dynamoelectric machine coupled to the engine by a shaft to operate as a motor for starting the engine. In response to prescribed engine conditions, the dynamoelectric machine is switched to operate as a generator driven by the engine to generate the electric energy.

Abstract: A portable range extender is provided for an electric vehicle having a vehicle controller, and an electric traction motor powered by a battery. The portable range extender has an engine, a dynamoelectric machine coupled to the engine by a shaft and electrically connectable to the vehicle, and a range extender controller for controlling operations of the range extender independently of the vehicle controller. The range extender controller monitors voltage of the battery to automatically activate the range extender when the battery voltage is less than a first threshold value and automatically deactivate the range extender when the battery voltage reaches a second threshold value. The dynamoelectric machine operates as a motor for starting the engine when the battery voltage is less than the first threshold value. In response to prescribed engine conditions, the range extender controller operates the dynamoelectric machine as a generator driven by the engine to generate electric power supplied to the vehicle.

Abstract: Electric machine end turn connectors are used with an electromagnetic device having a ferromagnetic core with a plurality of core slots. Coils are held within the plurality of core slots. The coils are comprised of a plurality of pins positioned within the plurality of core slots. Each of the plurality of pins includes a main body and two tapered ends. When one of the pins is positioned in one of the core slots, the main body of the pin is held within the core slot and the tapered ends of the pin protrude from the stator slot. The plurality of pins form the working lengths of the coils. Two end caps are positioned upon the ferromagnetic core. Each end cap includes a plurality of jumpers. Each jumper includes a bridge portion and two perpendicular connection channels. Each connection channel includes a slit which runs along the connection channel and terminates in a mouth. A heat shrink material surrounds the connection channels.

Abstract: A powdered magnetic material stator core with embedded stator windings and a method for its manufacture. Embedding the windings within a radially compacted powdered magnetic material stator core enables equivalent or better electromagnetic performance in a significantly reduced size. Radial compaction of the powdered magnetic material minimizes the distortion of the stator windings during compaction.

Abstract: A powdered magnetic material stator core with embedded stator windings and a method for its manufacture. Embedding the windings within a radially compacted powdered magnetic material stator core enables equivalent or better electromagnetic performance in a significantly reduced size. Radial compaction of the powdered magnetic material minimizes the distortion of the stator windings during compaction.

Abstract: A powdered magnetic material stator core with embedded stator windings and a method for its manufacture. Embedding the windings within a radially compacted powdered magnetic material stator core enables equivalent or better electromagnetic performance in a significantly reduced size. Radial compaction of the powdered magnetic material minimizes the distortion of the stator windings during compaction.

Abstract: A marine propulsion system for underwater vehicles includes motor inner sor assemblies disposed in hull portions of the vehicle, fixed blades extending outwardly from an after one of the hull portions, a shroud fixed to outer ends of the fixed blades and encircling the hull portions, and a motor outer stator assembly disposed in the shroud. A rotor hub is disposed in an annular recess formed by the hull portions, the hub having permanent magnets therein adjacent the motor inner stator assemblies, and has rotor blades mounted thereon and extending outwardly therefrom and being at least in part of a permanent magnet material, outer ends of the rotor blades being adjacent the motor outer stator assembly. Activation of the stator assemblies by a polyphase A.C. power source induces movement in the permanent magnets and rotor blades to cause the rotor hub and blades to rotate. The rotation of the rotor blades serves to provide propulsive thrust to the vehicle.