Abstract: Certain aspects relate to a bus bar unit for providing three phases of electric current to the windings of the stator of an electric machine while structured to have a compact footprint for fitting within the enclosure of the electric machine. Each winding can have a phase lead end and a neutral end extending above one face of the stator. The bus bar unit can include three phase lead bus bars and a neutral bus bar each having a planar branch with legs extending from the planar branch, each leg having a slot at an end thereof for electrically coupling with either the phase lead or the neutral end of one or more of the windings. The planar branches can be stacked such that they overlap from a top-down perspective but are spaced apart from a side perspective.

Abstract: Certain aspects relate to designs for an interior permanent magnet (IPM) electrical machine stator having a plurality of continuous windings wound through the stator. Compared to existing designs, the disclosed stator design has an increased number of parallel conductors, an increased number of conductors per slot, increased tooth and slot width and number, and more compacted conductors, resulting in reduction in core losses, reduction in conductor losses, reduced harmonics in flux density, and improved winding reliability.

Abstract: Systems and methods to evaluate insulation-covered stator wire are disclosed. The stator wire includes a conductor having a plurality of bent segments connected by a plurality of unbent segments, and an electrically insulating coating applied to portions of the segments. Systems and methods include translating an electrically conductive brush over one or more of the plurality of bent segments of the stator wire. Systems and methods include measuring a change in electrical current between the electrically conductive brush and an uninsulated end of the conductor when the electrically conductive brush contacts the conductor in a portion of the one or more plurality of bent segments comprising a defect in the electrically insulating coating.

Abstract: Certain aspects relate to designs for an interior permanent magnet (IPM) electrical machine stator having a plurality of continuous windings wound through the stator. Compared to existing designs, the disclosed stator design has an increased number of parallel conductors, an increased number of conductors per slot, increased tooth and slot width and number, and more compacted conductors, resulting in reduction in core losses, reduction in conductor losses, reduced harmonics in flux density, and improved winding reliability.

Abstract: Certain aspects relate to a bus bar unit for providing three phases of electric current to the windings of the stator of an electric machine while structured to have a compact footprint for fitting within the enclosure of the electric machine. Each winding can have a phase lead end and a neutral end extending above one face of the stator. The bus bar unit can include three phase lead bus bars and a neutral bus bar each having a planar branch with legs extending from the planar branch, each leg having a slot at an end thereof for electrically coupling with either the phase lead or the neutral end of one or more of the windings. The planar branches can be stacked such that they overlap from a top-down perspective but are spaced apart from a side perspective.

Abstract: Certain aspects relate to systems and methods to join leads of stator windings to components of an electric machine, such as a bus bar of a stator of the electric machine. Systems and methods include modifying a surface of the lead and laser welding the surface-modified lead to the bus bar. Systems and methods can include reducing the reflectivity of the lead by imparting a non-smooth surface on the lead, thereby allowing a laser to deliver concentrated energy onto the lead. The surface-modified lead can include knurled surface, a pattern of raised grooves stamped into the surface of the lead, or a roughened surface.

Abstract: Certain aspects relate to systems and methods to evaluate insulation-covered stator wire. The stator wire includes a conductor having a plurality of bent segments connected by a plurality of unbent segments, and an electrically insulating coating applied to portions of the segments. Systems and methods include translating an electrically conductive brush over one or more of the plurality of bent segments of the stator wire. Systems and methods include measuring a change in electrical current between the electrically conductive brush and an uninsulated end of the conductor when the electrically conductive brush contacts the conductor in a portion of the one or more plurality of bent segments comprising a defect in the electrically insulating coating.

Abstract: Certain aspects relate to a continuous winding formed from a conductor of rectangular cross-section, the winding having a compound bend in the crowns connecting successive linear segments where the compound bend does not stress the conductor insulation to its failure point. The compound bend can be formed by applying force to the conductor in a first direction, thereby shaping a first bend in the conductor to form a u-shaped conductor having a crown and two linear segments, where the crown includes a v-shaped bend and two straight segments on either side of the v-shaped bend that each connect to one of the linear segments. A second bend can be formed by applying force to the conductor in a second direction perpendicular to the first direction. The shape of the second bend can depend on the desired radius of the winding when circularly wound and positioned in a stator.

Abstract: An electric motor assembly includes a motor shaft rotatable about a longitudinal axis, an angular position sensor rotor, and a deformable pin. The motor shaft has an axial keyway formed therein, and the axial keyway has a nominal keyway dimension. The angular position sensor rotor is coupled to the motor shaft to rotate with the motor shaft. The angular position sensor rotor has an axial key to fit within the axial keyway of the motor shaft, and the axial key has a nominal key dimension that is less than the nominal keyway dimension. The deformable pin is located in the axial keyway under compression between the axial key and the motor shaft to inhibit rotational shifting of the angular position sensor rotor relative to the motor shaft.

Abstract: A stator includes a stator core, a plurality of slots, and a conductor. The plurality of slots are formed within the stator core. The conductor is disposed continuously within at least two of the plurality of openings.

Abstract: An electric motor assembly includes a motor shaft rotatable about a longitudinal axis, an angular position sensor, and a deformable pin. The motor shaft has an axial keyway formed therein, and the axial keyway has a nominal keyway dimension. The angular position is coupled to the motor shaft to rotate with the motor shaft. The angular position sensor has an axial key to fit within the axial keyway of the motor shaft, and the axial key has a nominal key dimension that is less than the nominal keyway dimension. The deformable pin is located in the axial keyway under compression between the axial key and the motor shaft to inhibit rotational shifting of the angular position sensor relative to the motor shaft.

Abstract: A permanent magnetic machine includes a stator body having a first end, a second end, and a plurality of generally radial slots formed therein for accepting a set of windings having a first set of end-turns at the first end and a second set of end-turns at the second end. The stator body has a plurality of channels adjacent to the slots and extending from the first end of the stator body to the second end of the stator body, wherein the channels are configured to allow the flow of a cooling fluid therethrough. A plurality of nozzles in fluid communication with the plurality of channels are configured to spray the cooling fluid onto the first and second set of end turns.

Abstract: Damping mechanisms and motor assemblies are provided. In an embodiment, by way of example only, a damping mechanism includes an end cap, a bearing retainer plate, a bearing damper ring, a bearing assembly, and first and second lateral dampers. The bearing damper ring is disposed in an annular cavity inwardly from an inner diameter surface of the end cap and has a radially inwardly-extending flange. The bearing assembly is disposed in the annular cavity radially inwardly relative to the bearing damper ring. The first lateral damper is disposed between a radially inwardly-extending wall of the end cap and the bearing damper ring. The second lateral damper is disposed between the bearing damper ring and the bearing retainer plate.

Abstract: Damping mechanisms and motor assemblies are provided. In an embodiment, by way of example only, a damping mechanism includes an end cap, a bearing retainer plate, a bearing damper ring, a bearing assembly, and first and second lateral dampers. The bearing damper ring is disposed in an annular cavity inwardly from an inner diameter surface of the end cap and has a radially inwardly-extending flange. The bearing assembly is disposed in the annular cavity radially inwardly relative to the bearing damper ring. The first lateral damper is disposed between a radially inwardly-extending wall of the end cap and the bearing damper ring. The second lateral damper is disposed between the bearing damper ring and the bearing retainer plate.

Abstract: An internal permanent magnet machine (“IPM machine”) of the type used, for example, with traction motors and hybrid electric vehicles, includes a rotor having a plurality of equal-sized (e.g., rectilinear) segmented ferrite magnets arranged in one or more layers. The magnets are inserted within rotor slots that are larger than the magnets themselves, such that one or more air gaps are formed adjacent to the magnets in each layer.

Abstract: Methods and apparatus are provided for stator assembly for use with an electric motor assembly. The stator assembly includes, but is not limited to a stator core that has an inner surface and a plurality of stator slots defined in the inner surface. A fractional slot winding having a plurality of conductors is coupled to the stator core. Each stator slot contains a group of the conductors arranged in a radially adjacent configuration. The groups of conductors in each of the stator slots together form a plurality of concentric rings of conductors. The conductors in each mixed group are arranged such that conductors carrying differing phases of electric current are arranged in a radially alternating configuration.

Abstract: A stator includes a stator core, a plurality of slots, and a conductor. The plurality of slots are formed within the stator core. The conductor is disposed continuously within at least two of the plurality of openings.

Abstract: A stator assembly for use with an electric motor includes, but is not limited to, a stator core having an inner surface and a plurality of open slots defined in the inner surface. The stator assembly also includes a winding having multiple conductors. The winding is coupled to the stator core such that a predetermined quantity of conductors is disposed within each open slot. The winding is configured to control a magnitude of a torque ripple produced by operation of the electric motor.

Abstract: A permanent magnetic machine includes a stator body having a first end, a second end, and a plurality of generally radial slots formed therein for accepting a set of windings having a first set of end-turns at the first end and a second set of end-turns at the second end. The stator body has a plurality of channels adjacent to the slots and extending from the first end of the stator body to the second end of the stator body, wherein the channels are configured to allow the flow of a cooling fluid therethrough. A plurality of nozzles in fluid communication with the plurality of channels are configured to spray the cooling fluid onto the first and second set of end turns.

Abstract: An internal permanent magnet machine (“IPM machine”) of the type used, for example, with traction motors and hybrid electric vehicles, includes a rotor having a plurality of equal-sized (e.g., rectilinear) segmented ferrite magnets arranged in one or more layers. The magnets are inserted within rotor slots that are larger than the magnets themselves, such that one or more air gaps are formed adjacent to the magnets in each layer.