Abstract: A fluid-cooled axial flux motor having a stator, a rotor disposed adjacent to the stator, and a rotor shaft rotationally fixed onto the rotor. The rotor shaft includes axial coolant passageway having an inlet and opposite outlet. The rotor includes coolant passageways extending radially from rotor shaft. The rotor coolant passageways include an inlet in fluid communication with the outlet of the axial coolant passageway and an outlet. The fluid-cooled axial flux motor further includes a coolant distribution header having an inlet in fluid communication with the outlet of the rotor coolant passageway, a coolant collection header having an inlet in fluid communication with the outlet of the coolant distribution header, and a collection header outlet. The outlet of the coolant distribution header is disposed above the stator and the inlet of the coolant collection header is disposed below the stator with respect to the direction of gravity.

Abstract: The present disclosure relates generally to rotors for electric motor assemblies and methods of making the same, and more specifically, to variable thickness rotors for axial flux motors. More specifically, annular-shaped rotors having interiorly disposed magnets for axial flux motors are provided in certain aspects. The variable thickness rotors may each include an annular-shaped body having a first thickness at a first radial position and a second thickness at a second radial position. The first radial position may be spaced apart from the second radial position. The first thickness may be greater than or equal to about 200% of the second thickness.

Abstract: The present disclosure provides hybrid stator core components for an axial flux motor stator and methods for making the same. The hybrid stator core component includes a molded soft magnetic composite material and a laminated component. In one variation, a laminated insert comprising a plurality of insulated layers is non-releasably seated within a molded soft magnetic composite material. In another variation, a hybrid stator core component has a molded soft magnetic composite core and a laminated shell comprising a plurality of layers disposed around at least a portion of the molded soft magnetic composite core.

Abstract: An axial flux motor having reduced spatial harmonics including a rotor with a plurality of magnets. A rotor shaft is coupled to the rotor. A stator faces the rotor and an air gap defined between the rotor and the stator. The stator includes a plurality of electromagnetic components defining a plurality of magnetic poles. The electromagnetic components include a plurality of posts, a plurality of slots, and a plurality of distributed electrically conductive windings disposed in and spanning across nonadjacent slots of the plurality of slots. At least one electrically conductive winding has a winding pitch span of greater than or equal to about 3 to less than or equal to about 20. The axial flux motor may include two rotors and one stator or alternatively two stators and one rotor. Such axial flux motors have short pitch provide desirable reduced spatial harmonics to enhance motor performance.

Abstract: An electric propulsion system includes a battery pack and a DC-DC converter. The converter has a bypass switch and semiconductor switches. A traction power inverter module (“TPIM”) rectifies a DC bus voltage on the voltage bus to produce an AC bus voltage. An electric machine is connected to the TPIM and energized via the AC bus voltage. A controller calculates required output power from the converter based on a requested operating mode, and speed and torque of the electric machine. When the output power exceeds a threshold, the bypass switch closes to bypass the converter. When the output power is less than the threshold, the controller uses a minimum loss voltage from a loss map as a target control voltage of the converter to optimize efficiency of the electric propulsion system.

Abstract: A powertrain for a vehicle includes a housing, a motor generator unit, a torque converter, a first and second shafts, a first and second gear sets, and a torque transmitting mechanism. The motor generator unit includes an output member. The torque converter includes a pump and a turbine. The pump is connected for common rotation with the output member of the motor generator unit. The first shaft rotatably is supported by the powertrain housing and is connected for common rotation with the turbine of the torque converter. The second shaft is rotatably supported by the powertrain housing and disposed parallel to the first shaft. An output gear is connected for common rotation to the second shaft.

Abstract: A powertrain has a continuously variable transmission including a shaft rotatable about an axis. The CVT further comprises a variator assembly that includes a pulley supported on the shaft. The pulley has a movable sheave with a ramp surface. The movable sheave is axially movable on the shaft. The variator assembly also includes an endless rotatable device frictionally engaged with the movable sheave. An actuator mechanism includes a wedge component supported on the shaft. The wedge component has a wedge surface that automatically engages the ramp surface when torque on the shaft is in a first direction. The wedge surface applies a wedge force on the ramp surface. The actuator mechanism further includes an actuator that is operatively connected to the movable sheave and is activatable to apply a force on the movable sheave.

Abstract: An axial flux motor having a stator and a rotor disposed about a rotational axis adjacent the stator defining an air gap therebetween. The rotor includes a disk having an interior face oriented toward the stator and an opposite exterior face; a plurality of magnets affixed in a predetermined arrangement on the interior face of the disk; a back plate abutting the exterior face of the disk, and a segmented cage fitted onto the interior face. The back plate includes a circumferential edge surface defining a plurality of notches. The segmented cage includes a plurality of retainer ribs configured to retain the magnets in the predetermined arrangement on the interior face of the disk. The segmented cage cooperates with the back plate to structurally support the disk therebetween, thereby inhibiting the disk from flexing in an axial direction.

Abstract: A number of variations may include a product that may include a linking member that may have links arranged in rows that have multiple pitch lengths. Each of the rows may have at least one link. Each of the multiple pitch lengths may be a discrete length that may be different from others of the multiple pitch lengths. The rows may be arranged along the linking member in a repeating sequence of the multiple pitch lengths.

Abstract: A fluid-cooled axial flux motor having a stator, a rotor disposed adjacent to the stator, and a rotor shaft rotationally fixed onto the rotor. The rotor shaft includes axial coolant passageway having an inlet and opposite outlet. The rotor includes coolant passageways extending radially from rotor shaft. The rotor coolant passageways include an inlet in fluid communication with the outlet of the axial coolant passageway and an outlet. The fluid-cooled axial flux motor further includes a coolant distribution header having an inlet in fluid communication with the outlet of the rotor coolant passageway, a coolant collection header having an inlet in fluid communication with the outlet of the coolant distribution header, and a collection header outlet. The outlet of the coolant distribution header is disposed above the stator and the inlet of the coolant collection header is disposed below the stator with respect to the direction of gravity.

Abstract: An axial flux motor having a stator and a rotor disposed about a rotational axis adjacent the stator defining an air gap therebetween. The rotor includes a disk having an interior face oriented toward the stator and an opposite exterior face; a plurality of magnets affixed in a predetermined arrangement on the interior face of the disk; a back plate abutting the exterior face of the disk, and a segmented cage fitted onto the interior face. The back plate includes a circumferential edge surface defining a plurality of notches. The segmented cage includes a plurality of retainer ribs configured to retain the magnets in the predetermined arrangement on the interior face of the disk. The segmented cage cooperates with the back plate to structurally support the disk therebetween, thereby inhibiting the disk from flexing in an axial direction.

Abstract: An electric drive system for a vehicle may include positive and negative bus rails carrying a direct current (DC) bus voltage, an energy storage system (ESS), a power inverter having a plurality of semiconductor switches operable for inverting the DC bus voltage into an alternating current (AC) bus voltage, and an electric machine. A DC-DC converter may be connected to the bus rails between the capacitor and the power inverter and may include a converter semiconductor switch disposed in the positive bus rail, an inductor coil connected to the positive bus rail and receiving current flowing through the converter semiconductor switch, at least one diode, and a bypass switch connected to the positive bus rail and configured to allow current to bypass the converter. The DC-DC converter may be configured to output a DC bus voltage to the power inverter with a same polarity as the battery polarity.

Abstract: A transmission includes a continuously variable unit (CVU) (20) arranged in parallel with an expansion gearset (120). The CVU (20) includes a first pulley (22) that is rotatably coupled to a second pulley (24) and an input member (12). The expansion gearset (120) includes a planetary gearset (130) that is arranged in series with a coplanar second gearset (140), and the second gearset (140) includes a first gear (142) engaged with a layshaft gear (144). The second pulley (24) is rotatably couplable to the first gear (142) of the second gearset (140). The layshaft gear (144) is engaged with a ring gear (136) and a carrier member (134) which is rotatably couplable to an output member (14). The first pulley (22) is rotatably couplable to the sun gear (132) via a first clutch (115). The transmission operates in a continuously variable mode when the first clutch (115) is deactivated, and operates in a power split mode when the first clutch (115) is activated.

Abstract: A powertrain for a vehicle includes a housing, a motor generator unit, a torque converter, a first and second shafts, a first and second gear sets, and a torque transmitting mechanism. The motor generator unit includes an output member. The torque converter includes a pump and a turbine. The pump is connected for common rotation with the output member of the motor generator unit. The first shaft rotatably is supported by the powertrain housing and is connected for common rotation with the turbine of the torque converter. The second shaft is rotatably supported by the powertrain housing and disposed parallel to the first shaft. An output gear is connected for common rotation to the second shaft.

Abstract: A disturbance cancellation and generation seat system includes a seat mounted to a structure of a vehicle. The seat is accelerated due to a disturbance acceleration received in the structure and transferred to the seat. A seat control unit generates a force cancellation command signal. An actuation device is connected to the structure and is in communication with the seat control unit. The actuation device in response to receipt of the force cancellation command signal induces a cancellation acceleration motion into the seat which is equal but opposite to and therefore cancels an acceleration motion of the seat induced by the disturbance acceleration.

Abstract: An electric drive unit is provided having an electric motor-generator coupled with a torque converter. Vehicles and machines employing the same, as well as methods of using the same, are also disclosed. The motor-generator may be configured to selectively drive a rotatable shaft with a motor output torque and generate electrical power from rotation of the rotatable shaft. The electric drive unit may further include a torque converter having an input and an output separated by a fluid coupling. The fluid coupling may be configured to selectively multiply torque received at the input such that a drive unit output torque at the output is selectively increased in at least a predetermined rotational speed range of the electric motor-generator.

Abstract: An electric drive unit is provided having an electric motor-generator coupled with a torque converter. Vehicles and machines employing the same, as well as methods of using the same, are also disclosed. The motor-generator may be configured to selectively drive a rotatable shaft with a motor output torque and generate electrical power from rotation of the rotatable shaft. The electric drive unit may further include a torque converter having an input and an output separated by a fluid coupling. The fluid coupling may be configured to selectively multiply torque received at the input such that a drive unit output torque at the output is selectively increased in at least a predetermined rotational speed range of the electric motor-generator.

Abstract: A method of controlling a continuously variable transmission includes monitoring powertrain operating conditions, and calculating, via an electronic controller, a commanded clamping force based on the powertrain operating conditions, wherein the commanded clamping force includes a commanded clamping force of an input pulley and a commanded clamping force of an output pulley on the endless rotatable device. The method also includes activating, via the electronic controller, at least one of the input actuator and the output actuator such that an axial component of the input wedge force and the axial force of the input actuator together provide the commanded clamping force of the input pulley, and an axial component of the output wedge force and the axial force of the output actuator together provide the commanded clamping force of the output pulley.

Abstract: A continuously-variable transmission (CVT) assembly is employed for transmitting a torque from an external power-source. The CVT includes a variable-diameter input pulley and a variable-diameter output pulley, each having a respective range of adjustment. The CVT also includes a continuous torque-transmitting element extending between the variable-diameter input pulley and the variable-diameter output pulley, and thereby operatively connecting the input pulley to the output pulley. The CVT additionally includes a first elastic element having a first zero stiffness over the range of adjustment of the variable-diameter input pulley and configured to apply a first constant spring clamping force via the input pulley to the continuous torque-transmitting element.

Abstract: A continuously variable transmission (CVT) comprises a shaft rotatable about an axis, and variator assembly, and an actuator mechanism. The variator assembly includes a pulley supported on the shaft and having a ramp surface, and an endless rotatable device frictionally engaged with the pulley. The ramp surface inclines in an axial direction along the axis toward the endless rotatable device. The CVT further comprises an actuator mechanism that includes a wedge component that has a wedge surface interfacing with the ramp surface, and a rotary piston operatively connected to the wedge component. The rotary piston defines a first fluid chamber pressurizable to apply a rotational force that provides relative motion between the ramp surface and the wedge surface resulting in a wedge force on the ramp surface and a clamping force of the endless rotatable device on the pulley.