Abstract: A stator configured to rotate a rotor with a number of magnetic poles includes a yoke that includes a back portion and a first type and first quantity of integral teeth, and a second type and second quantity of insertable teeth coupled to the back portion. At least two coils are wound with a continuous electric wire. Each of the coils is placed around two different integral teeth to define a first winding section. At least two other coils are wound with a continuous electric wire. The other coils are placed around two different insertable teeth to define a second winding section.

Abstract: A rotor for an electric machine having a number of poles includes a shaft that extends along a portion of an axis and defines an outer surface. A first core portion is formed as a single inseparable component and includes a first portion that extends from the outer surface to a first outside diameter to define a first thickness, and a second portion spaced axially from the first portion that includes a reduced back portion that extends from an inside diameter to the first outside diameter to define a second thickness that is less than the first thickness. A second core portion is connected to the first core portion and includes a second outside diameter that is substantially the same as the first outside diameter.

Abstract: A rotor for an electric machine having a number of poles includes a shaft that extends along a portion of an axis and defines an outer surface. A first core portion extends along a portion of the axis to define a first core length. The first core portion includes a first reduced back portion that has an inside surface that does not contact the outer surface. A second core portion is coupled to the first core portion for rotation. In some constructions, a coupling member interconnects the shaft, the first core portion, and the second core portion such that the shaft, the first core portion, and the second core portion rotate about the axis substantially in unison.

Abstract: A rotor for an electric machine includes a shaft that is rotatable about an axis and defines a first diameter normal to the axis. A first core portion defines a first aperture having a first aperture diameter that is larger than the first diameter. The first core portion is positioned adjacent the shaft to define a first space. A second core portion defines a second aperture having a second aperture diameter that is larger than the first diameter. The second core portion is positioned adjacent the shaft to define a second space. A damping member is positioned in the first space and the second space. The damping member at least partially interconnects the shaft, the first core portion, and the second core portion.

Abstract: A stator for a multi-phase electric machine having a plurality of core segments interconnected with one another and a plurality of coils. At least one core segment includes a plurality of teeth and a back portion that at least partially interconnects the teeth. The back portion of each segment has a first arrangement in which the teeth of that segment are a first distance from one another and a second arrangement in which the teeth of that segment are a second distance from one another, the second distance being smaller than the first distance. Each coil surrounds at least a portion of one tooth, wherein all coils surrounding teeth of a single core segment interconnect to at least partially define one phase winding.

Abstract: A rotor includes a shalt that defines a rotor axis, a first end portion coupled to the shaft, and a pole piece that defines an enclosed aperture therethrough. A second end portion is positioned to dispose the pole piece between the first end portion and the second end portion. A portion of one of the first end portion and the second end portion extends through the aperture and bonds with the other of the first end portion and the second end portion. The portion is integrally-formed as a single piece with one of the first end portion and the second end portion.

Abstract: An electrical machine comprises a stator and a rotor. The rotor is adapted to magnetically interact with the stator to promote rotation of the rotor about an axis. The rotor includes a rotor core and a plurality of magnetized arcs supported by the rotor core. The plurality of magnetized arcs defines an outermost circumference. The rotor and the plurality of magnetized arcs include a first magnetized arc, a discontinuity disposed adjacent to the first magnetized arc along the outermost circumference, a second magnetized arc disposed adjacent to the discontinuity along the outermost circumference, and a magnetization pattern of alternating magnetic poles formed on the plurality of magnetized arcs. The magnetization pattern includes a first magnetic pole skewed with respect to a second magnetic pole to form an arc of magnetization skew.

Abstract: An electrical machine having a machine output rating. The electrical machine including a shaft rotatable about an electrical machine axis, a rotor coupled to the shaft and rotating with the shaft, and a stator including a stator core. The rotor is configurable to include a first rotor portion having a relation to a first output rating and a second rotor portion having a relation to a second output rating. The stator core is configurable to be disposed adjacent to the first rotor portion relative to the machine axis when the machine output rating corresponds to the first output rating and adjacent to the second rotor portion when the machine output rating corresponds to the second output rating.

Abstract: An electric machine that includes a stator core having a stator core length, a first rotor core portion, and second rotor core portion. A spacer is coupled to the first core portion and the second core portion to at least partially define a rotor core. The rotor core has a length that is greater than the stator core length. A permanent magnet is coupled to the rotor core and has a magnet length.

Abstract: An electrical machine including a rotor rotatable about an axis and a stator adapted to magnetically interact with the rotor. The stator including (t) teeth and one or more windings with compact coils disposed around the teeth. The one or more windings having (m) phases and (p) poles, where (t) is an integer and is greater than or equal to two, where (m) is an integer and is greater than or equal to two, where (p) is an integer, is greater than or equal to two, and is an even number, and where (t/p=m/2) or (t/p=m/4).

Abstract: An electric machine having a stator assembly that includes a stator core and a coil supported by the stator core and a rotor assembly that includes a shaft and a rotor supported by the shaft that is in magnetic interaction with the stator core. The electric machine may include a single sensor configured to detect magnetic polarities of the rotor as the rotor rotates relative to the sensor and to generate a signal representing the detected magnetic polarities of the rotor. The signal and an inverted version of the signal are utilized to control current through the coil. The current may be controlled indirectly by controlling the application of voltage to the coil. The sensor may be encapsulated on a circuit board to positively position the sensor relative to the circuit board. The circuit board may be mounted to a bearing housing of the electric machine. The sensor may be received in a pocket of a bearing housing of the electric machine so the sensor is positively positioned relative to the rotor.

Abstract: A spoke permanent magnet rotor that includes a shaft defining a rotor axis. A first non-magnetic end portion is coupled to the shaft and a ferromagnetic pole piece defines an aperture therethrough. A second non-magnetic end portion is positioned to dispose the pole piece between the first end portion and the second end portion. A portion of one of the first end portion and the second end portion extends through the aperture and bonds with the other of the first end portion and the second end portion.

Abstract: An electric motor stator including a yoke having a plurality of yoke laminations. A body portion is formed as part of each of the plurality of yoke laminations. A first tooth is continuous with the body portion and is formed as part of at least a portion of the plurality of yoke laminations. The first tooth defines a first tooth profile. A first tooth attachment portion is formed as part of the plurality of yoke laminations. A second tooth includes a plurality of tooth laminations. Each tooth lamination of the second tooth includes a second tooth attachment portion and defines a second tooth profile that differs from the first tooth profile. The second tooth attachment portion is engaged with the first tooth attachment portion.

Abstract: An electrical machine comprises a stator and a rotor. The stator includes a plurality of stator teeth and a winding with compact coils disposed on the teeth. The winding has (m) phases and (p) poles; where (m) is an integer and is greater than or equal to two; where (p) is an integer, is greater than or equal to two, and is an even number. The rotor has a magnetization pattern can include a magnetization skew. In some constructions, each stator includes one or more channels along a surface adjacent to the rotor. The channels can be of various shapes including a trapezoidal shape or a curvilinear shape.

Abstract: An electrical machine including a rotor and a stator. The stator includes a core and a coil disposed on the core. In one construction, the core is generally U-shaped and comprises magnetic material. The electrical machine also includes a bridge comprising magnetic material. The bridge connects the first and second legs of the generally U-shaped core. Also disclosed are methods of manufacturing the core.

Abstract: An electric drive includes a rotatable shaft, a first drive member, and a second drive member, and is supplied with power from a controller. The controller is operable to supply a first power from a power electronics converter, and a second power that is line power. Supplying the first power individually to the first drive member results in a first shaft speed and first output torque, supplying the second power individually to the second drive member results in a second shaft speed and second output torque, and supplying the first and the second drive members with power at the same time results in a third shaft speed and a third output torque.

Abstract: An electrical machine having a machine output rating. The electrical machine including a shaft rotatable about an electrical machine axis, a rotor coupled to the shaft and rotating with the shaft, and a stator including a stator core. The rotor is configurable to include a first rotor portion having a relation to a first output rating and a second rotor portion having a relation to a second output rating. The stator core is configurable to be disposed adjacent to the first rotor portion relative to the machine axis when the machine output rating corresponds to the first output rating and adjacent to the second rotor portion when the machine output rating corresponds to the second output rating.

Abstract: An electric machine having a stator assembly that includes a stator core and a coil supported by the stator core and a rotor assembly that includes a shaft and a rotor supported by the shaft that is in magnetic interaction with the stator core. The electric machine may include a single sensor configured to detect magnetic polarities of the rotor as the rotor rotates relative to the sensor and to generate a signal representing the detected magnetic polarities of the rotor. The signal and an inverted version of the signal are utilized to control current through the coil. The current may be controlled indirectly by controlling the application of voltage to the coil. The sensor may be encapsulated on a circuit board to positively position the sensor relative to the circuit board. The circuit board may be mounted to a bearing housing of the electric machine. The sensor may be received in a pocket of a bearing housing of the electric machine so the sensor is positively positioned relative to the rotor.

Abstract: An electrical machine including a rotor and a stator. The stator includes a core and a coil disposed on the core. In one construction, the core is generally U-shaped and comprises magnetic material. The electrical machine also includes a bridge comprising magnetic material. The bridge connects the first and second legs of the generally U-shaped core. Also disclosed are methods of manufacturing the core.

Abstract: A rotor assembly for an electric motor includes a spoke permanent magnet rotor and a shaft connected thereto. The spoke permanent magnet rotor has an axis of rotation, permanent magnet material, and ferro-magnetic material. The permanent magnet material extends outwardly relative to the axis of rotation to form a plurality of outwardly extending spoke portions of permanent magnet material. The ferro-magnetic material is positioned adjacent to the outwardly extending spoke portions of permanent magnet material. The shaft supports the spoke permanent magnet rotor for rotation about the axis of rotation. The permanent magnet material may circumferentially surround the axis of rotation to form a center portion of permanent magnet material. Further, the axis of rotation may pass through the permanent magnet material. The spoke permanent magnet rotor may be formed using a compaction process and/or an injection molding process.