Abstract: An example rotor includes a rotor yoke having an outer circumference and an inner circumference. The rotor further includes a plurality of rotor ribs on a surface the rotor yoke and extending between the outer circumference and the inner circumference. The rotor further includes a plurality of magnets, each of the plurality of magnets being disposed adjacent to and between two of the plurality of rotor ribs.

Abstract: A rotor segment support member includes an annular body having an outer edge, an inner edge defining an opening, a first surface, and a second surface opposite the first surface. The rotor segment support member has a circumferential axis extending about the annular body and a radial axis extending between the outer edge and a center of the opening through the inner edge. The annular body has a non-uniform cross-section extending along one of the circumferential axis and the radial axis.

Abstract: A mixed chemistry battery is provided. The mixed chemistry battery includes a reference module having a first chemistry and a battery module having a second chemistry that is different that the first chemistry, the battery module is connected to the reference module in series. The mixed chemistry battery also includes a battery monitoring system configured to monitor an open circuit voltage of the reference module, an open circuit voltage of the battery module, and a current flow through the reference module and the battery module. The battery monitoring system is further configured to calculate a state-of-charge (SOC) and state-of-health (SOH) of the battery module based at least in part on a SOC of the reference module.

Abstract: A member for an axial flux electric machine, in accordance with a non-limiting example, includes a support member having a first surface, a second surface opposite the first surface, an outer annular edge, and an inner annular edge that defines an opening having a center point. A plurality of members is mounted on one of the first surface and the second surface. Each of the plurality of members has a centerline that passes through the outer annular edge and the inner annular edge without passing through the center point creating a torque ripple reducing asymmetry in the member.

Abstract: A cooling system includes a housing including a base portion with sides and a bottom surface that define a cavity and a cover portion to enclose the base portion and including cooling members attached thereto. A shield is arranged in the cavity. A vertical member is arranged below the shield to define a first fluid chamber between one side of the vertical member and one side of the base portion and a second fluid chamber between an opposite side of the vertical member and another side of the base portion. The electronic components are arranged in the second fluid chamber. Cooling fluid is arranged in the cavity and has a fluid level below at least a portion of the shield. The housing is mounted at an inclined angle relative to horizontal or the housing is mounted parallel to horizontal and the shield is mounted at the inclined angle.

Abstract: A stator core segment for an axial flux electric motor includes a first lamination step having a first length, a first width, and a first thickness, and a second lamination step having a second length, a second width, and a second thickness. At least one of the second length, the second width, and the second thickness is distinct from corresponding ones of the first length, the first width, and the first thickness.

Abstract: A bi-material permanent magnet for an electric machine includes a core including a first magnetic material and a shell portion located on the core and made of a second magnetic material. The first magnetic material comprises a magnet material with an energy less than 20 Mega Gauss Oersteds (MGOe). The second magnetic material comprises a magnet material with an energy greater than 30 MGOe.

Abstract: A system for bypassing a torque converter in a powertrain is provided. The system includes a torque generating device including an output shaft and a transmission assembly. The transmission assembly includes a transmission output shaft and a torque converter, a torque converter bypass shaft. The transmission assembly further includes a disconnect clutch selectively coupling the torque converter with the torque generating device and a torque converter clutch selectively coupling the torque converter bypass shaft with the torque generating device. Engaging the disconnect clutch and disengaging the torque converter clutch enables the torque generating device to transmit torque to the transmission output shaft through the torque converter. Engaging the torque converter clutch and disengaging the disconnect clutch enables the torque generating device to transmit torque to the transmission output shaft through the torque converter bypass shaft.

Abstract: A stator assembly for an axial flux motor includes a heat exchanger jacket configured to circulate a heat transfer liquid. A stator also includes a plurality of stator cores each having a conductive winding, an electrically insulating material disposed over at least a portion of the conductive wire winding, and a molded soft magnetic composite (SMC) material. The heat exchanger jacket is disposed circumferentially around at least a portion of a perimeter of the stator. Each stator core defines a peripheral surface configured to contact the heat exchanger jacket and at least a portion of the peripheral surface is defined by the molded soft magnetic composite (SMC) material. Methods of making a molded soft magnetic composite (SMC) material stator core are also provided.

Abstract: A power control system includes a battery system and a DC-DC converter with first, second, third, and fourth power switches. A second terminal of the first power switch is connected to a first terminal of the second power switch. A second terminal of the third power switch is connected to a first terminal of the fourth power switch. A first inductor includes a first terminal connected to the second terminal of the first power switch and the first terminal of the second power switch and a second terminal connected to the second terminal of the third power switch and the first terminal of the fourth power switch. A first bypass switch is connected in parallel to the first power switch. A second bypass switch is connected in parallel to the third power switch.

Abstract: An axial flux motor assembly is disclosed and includes: an axial flux motor comprising a rotor, and a first stator; and a power inverter assembly. The power module assembly includes: a printed circuit board; a control module mounted on the printed circuit board; power module assemblies connected to the printed circuit board and controlled by the control module; and a cold plate. The cold plate is disposed between the first stator and the power module assemblies and includes a first side and a second side, which is opposite the first side. The cold plate cools the power module assemblies via the first side and the first stator via the second side.

Abstract: An electric machine includes a housing having an inner surface; and a stator including a stator core mounted in the housing. The stator core includes a plurality of stator windings, a thermal bridge extends between the stator core and the inner surface of the housing. The thermal bridge is formed from a non-magnetic material and includes a plurality of individual thermal bridge elements.

Abstract: A mixed chemistry battery is provided. The mixed chemistry battery includes a reference module having a first chemistry and a battery module having a second chemistry that is different that the first chemistry, the battery module is connected to the reference module in series. The mixed chemistry battery also includes a battery monitoring system configured to monitor an open circuit voltage of the reference module, an open circuit voltage of the battery module, and a current flow through the reference module and the battery module. The battery monitoring system is further configured to calculate a state-of-charge (SOC) and state-of-health (SOH) of the battery module based at least in part on a SOC of the reference module.

Abstract: A system for a power take-off mechanism for a powertrain system is provided. The system includes an electrically powered torque generating device including a torque generating device output shaft and a transmission output shaft receiving mechanical power from the torque generating device output shaft. The system further includes a clutch selectively disengaging the transmission output shaft from the torque generating device output shaft and a power take-off module receiving mechanical power from the torque generating device.

Abstract: A charging system for a vehicle includes a conversion device configured to transfer an electric charge between a battery assembly of the vehicle and an energy storage system, the battery assembly having a first voltage and the energy storage system having a second voltage, the conversion device including a scalable buck-boost system having a plurality of buck-boost modules. Each buck-boost module of the plurality of buck-boost modules includes a set of switches and an inductor. The charging system also includes a controller configured to operate one or more buck-boost modules of the plurality of buck-boost modules during transfer of charge between the battery assembly and the energy storage system.

Abstract: An axial flux electric machine comprises a stator including a plurality of stator core segments each comprising a lamination comprising a plurality of layers. A first soft magnetic composite (SMC) portion is arranged adjacent to the plurality of layers of the lamination. An insulating layer arranged between circumferential side surfaces of the plurality of layers of the lamination and the first SMC portion. A rotor is arranged axially adjacent to the stator and including a plurality of permanent magnets. The rotor and stator are configured to generate magnetic flux that is aligned parallel to an axis of rotation of the rotor.

Abstract: A method for controlling an electric drive unit (EDU) having a motor-driven torque converter includes receiving a request signal indicative of a requested output torque of the EDU, and operating the motor at a target motor speed using the requested output torque. The target motor speed minimizes system losses while achieving the requested output torque. When the requested output torque remains below a calibrated threshold and a turbine speed is less than a corner speed of the motor, a torque converter clutch (TCC) transitions to or remains in a locked state. The controller commands the TCC to transition to an unlocked state to reach the target motor speed, thereby selectively enabling torque multiplication. A powertrain system includes a driven load and the EDU. A computer readable storage medium may include executable instructions for performing the method.

Abstract: An axial flux electric machine comprises a stator including a plurality of stator core segments each comprising a lamination comprising a plurality of layers. A first soft magnetic composite (SMC) portion is arranged adjacent to the plurality of layers of the lamination. An insulating layer arranged between circumferential side surfaces of the plurality of layers of the lamination and the first SMC portion. A rotor is arranged axially adjacent to the stator and including a plurality of permanent magnets. The rotor and stator are configured to generate magnetic flux that is aligned parallel to an axis of rotation of the rotor.

Abstract: An axial flux motor includes: a ring-shaped stator, a ring-shaped rotor and a planetary gear set. The ring-shaped stator includes a stator core and segments arranged on the stator core, where each of the segments includes a laminated stack and windings wrapped around the laminated stack. The ring-shaped rotor defines an inner open area and including a body and permanent magnets arranged on the body adjacent to and spaced from the segments. The planetary gear set is disposed within the inner open area and configured to receive an input torque from the rotor and provide an output torque, which is greater than the input torque.

Abstract: A hybrid stator core for an axial flux electric machine is described herein. The hybrid stator core includes a laminated component and at least one soft magnetic composite (SMC) component. The laminated component includes a first block section, a first tab, and a second tab, the first block section having a first end, a second end opposite the first end, a first side surface extending between the first and second ends, and a second side surface opposite the first side surface. The first tab projects from the first side surface adjacent to the first end of the first block section. The second tab projects from the first side surface adjacent to the second end of the first block section. The at least SMC component is configured to abut the first side surface of the first block section. The first and second tabs are configured to hold the at least one SMC component therebetween.