Patents by Inventor Derek F. Lahr

Derek F. Lahr has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11383696
    Abstract: A powertrain system configured to transfer torque to a driveline is described, and includes an internal combustion engine, a torque converter, a transmission, an electric machine, and a controller. The engine is configured to operate in one of an all-cylinder mode and a dynamic deactivation mode to generate an engine torque. The electric machine is configured to generate a motor torque. The motor torque and the engine torque combine to generate an output torque that is transferable to the driveline and is responsive to an output torque request. The controller is in communication with the engine, the torque converter, the transmission, and the electric machine. The controller includes an instruction set that is executable to operate the engine in the dynamic deactivation mode to generate engine torque, and operate the electric machine to generate motor torque to supplement the engine torque to generate the output torque.
    Type: Grant
    Filed: June 12, 2019
    Date of Patent: July 12, 2022
    Assignee: GM Global Technology Operations LLC
    Inventors: Neeraj S. Shidore, Norman K. Bucknor, Dongxu Li, Mark Tadrous, Derek F. Lahr, Suresh Gopalakrishnan, Venkatesh Gopalakrishnan
  • Patent number: 11387712
    Abstract: An electric motor includes a stator, a rotor, a rotor shaft and a pump. The rotor is disposed within the stator and separated from the stator by an airgap. The airgap inadvertently accumulates a fluid. The rotor shaft is connected to the rotor. The pump is configured to move the fluid out of the airgap.
    Type: Grant
    Filed: September 13, 2019
    Date of Patent: July 12, 2022
    Assignee: GM Global Technology Operations LLC
    Inventors: Derek F. Lahr, Farzad Samie, Alireza Fatemi
  • Publication number: 20220140713
    Abstract: An electric machine includes a stator and a rotor positioned in operational engagement with one another and defining a radial gap extending circumferentially between the stator and the rotor, the rotor including a plurality of rotor segments defining a plurality of segment gaps between adjacent pairs of the plurality of rotor segments, the rotor segments radially moveable relative to the stator, wherein movement of the plurality of rotor segments radially outward increases the radial gap between the stator and the rotor and the segment gaps between adjacent pairs of the plurality of rotor segments.
    Type: Application
    Filed: October 29, 2020
    Publication date: May 5, 2022
    Inventors: Alireza Fatemi, Thomas W. Nehl, Derek F. Lahr
  • Publication number: 20220103049
    Abstract: A synchronous machine having a hybrid rotor excitation. The synchronous machine includes a rotor having a plurality of permanent magnets and electromagnets embedded within a rotor body. The permanent magnets produces a constant magnet field having a magnetic axis along a direct axis (D-axis). The electromagnets produces a variable magnetic field along a magnetic axis offset from the D-axis, preferable substantially orthogonal to the D-axis. The plurality of permanent magnets are separated from the electromagnets by a rotor air-gap. The plurality of permanent magnets includes inner pairs and outer pairs of permanent magnets nested in a V-shaped configuration. In another embodiment, the outer pairs of permanent magnets are replaced with outer radius electromagnets.
    Type: Application
    Filed: September 30, 2020
    Publication date: March 31, 2022
    Inventors: Alireza Fatemi, Shawn H. Swales, Mohammad F. Momen, Derek F. Lahr
  • Patent number: 11220172
    Abstract: A vehicle powertrain includes a first power-source configured to generate a first power-source torque and a multiple speed-ratio transmission configured to transmit the first power-source torque to power the vehicle. The powertrain also includes a fluid coupling having a fluid pump shaft operatively connected to the first power-source and a turbine shaft operatively connected to the multi-speed transmission. The fluid coupling is configured to multiply the first power-source torque, and transfer the multiplied first power-source torque to the multiple speed-ratio transmission. The powertrain additionally includes a second power-source configured to generate a second power-source torque and a first torque transfer system configured to connect the second power-source to the first power-source. The powertrain further includes a second torque transfer system configured to connect the second power-source to the multi-speed transmission. A motor vehicle having such a powertrain is also envisioned.
    Type: Grant
    Filed: October 9, 2019
    Date of Patent: January 11, 2022
    Assignee: GM Global Technology Operations LLC
    Inventors: Neeraj S. Shidore, Derek F. Lahr, Lei Hao, Madhusudan Raghavan, Suresh Gopalakrishnan
  • Patent number: 11171545
    Abstract: A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.
    Type: Grant
    Filed: October 24, 2019
    Date of Patent: November 9, 2021
    Assignee: GM Global Technology Operations LLC
    Inventors: Anthony M. Coppola, Alireza Fatemi, Bradley A. Newcomb, Derek F. Lahr, Sean R. Wagner
  • Patent number: 11133724
    Abstract: A rotor for an electric machine includes a rotor core having at least one internal cavity. A pair of features are defined by the rotor core and extend into the cavity. A structural element is compressed between the features so that a preload may be established between the features and the structural element.
    Type: Grant
    Filed: September 24, 2019
    Date of Patent: September 28, 2021
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Derek F. Lahr, Alireza Fatemi, Farzad Samie
  • Patent number: 11121592
    Abstract: A rotary electric machine, e.g., a cycloidal reluctance motor, includes a stator having stator teeth connected to a cylindrical stator core, and a rotor having a cylindrical rotor core. The stator core and/or rotor core are constructed of grain-oriented, spirally-wound ferrous material having a circular or annular grain orientation. The stator teeth may be constructed of grain-oriented steel having a linear grain orientation. Notches may be spaced around an inner circumferential surface of the stator core, with each stator tooth engaged with a respective notch. The rotor may be eccentrically positioned radially within the stator. The rotor core may define notches spaced around its outer circumferential surface, with salient rotor projections engaged with a respective rotor notch. The machine in such an embodiment may be a switched reluctance rotor. An electrical system using the machine and a method of manufacturing the machine are also disclosed.
    Type: Grant
    Filed: April 8, 2019
    Date of Patent: September 14, 2021
    Assignee: GM Global Technology Operations LLC
    Inventors: Alireza Fatemi, Derek F. Lahr, James B. Borgerson
  • Patent number: 11088607
    Abstract: An axial flux-type rotary electric machine includes a rotor having a rotor axis and a stator having a stator axis. The stator is positioned adjacent to the rotor such that an axial airgap is defined between the rotor and the stator. First and second non-parallel rotor shafts are respectively collinear with the stator axis and the rotor axis. A nutating gear pair is connected to a stationary member and the rotor, and is configured to impart nutating motion to the rotor with respect to the stator, such that a size of the axial airgap changes with a rotational position of the rotor, and such that the rotor has two degrees of freedom of motion. An electrical system includes direct and alternating current voltage buses, a power inverter module connected to the voltage buses, and the axial flux-type rotary electric machine connected to the alternating current voltage bus.
    Type: Grant
    Filed: April 26, 2019
    Date of Patent: August 10, 2021
    Assignee: GM Global Technology Operations LLC
    Inventors: Derek F. Lahr, Alireza Fatemi
  • Publication number: 20210211025
    Abstract: A method for constructing a rotor assembly for use with a rotary electric machine includes forming annular rotor laminations from metal blanks. Each lamination has a radial axis and an outer diameter surface. Multiple magnet web regions are defined in proximity to the outer diameter surface. Each web regions includes asymmetrical openings defined by a radially-extending strut and arcuate peripheral bridges. The method includes coaxially stacking the laminations into a rotor stack, including positioning every other lamination a predetermined angular distance with to unmask the bridges and/or struts and mask remaining surface area of the laminations. The rotor stack is subjected to a heat-treating process to harden only the unmasked bridges and/or struts. The method includes connecting a rotor shaft to the stack to construct the rotor assembly, with the web regions corresponding to a respective rotor magnetic pole.
    Type: Application
    Filed: January 7, 2020
    Publication date: July 8, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Derek F. Lahr, Alireza Fatemi, Anthony M. Coppola, Sean R. Wagner
  • Patent number: 11009124
    Abstract: Presented are torque converters with integrated engine disconnect devices, methods for making/using such torque converters, and electric-drive vehicles equipped with such torque converters. A torque converter (TC) assembly includes a TC housing that drivingly connects to an engine output member. A TC output member projects from the TC housing and drivingly connects to a transmission input member. A turbine with a bladed turbine shell is mounted on the TC output member and rotatable within the TC's internal fluid chamber. An impeller with a bladed impeller shell is juxtaposed with the turbine and rotatable within the fluid chamber. An engine disconnect device, which is disposed within the fluid chamber between the impeller shell and TC housing, drivingly couples the impeller to and, when desired, drivingly decouples the impeller from the TC housing and engine output member to thereby transfer torque and prevent torque transfer, respectively, between the engine and transmission.
    Type: Grant
    Filed: July 22, 2019
    Date of Patent: May 18, 2021
    Assignee: GM Global Technology Operations LLC
    Inventors: Dongxu Li, Chunhao J. Lee, Farzad Samie, Derek F. Lahr
  • Publication number: 20210143693
    Abstract: A rotary electric machine includes a rotor assembly, stator, stator windings, and a coolant manifold. The rotor assembly includes a rotor and a rotor shaft. The stator is spaced apart from the rotor by a stator-rotor airgap and has stator teeth defining enclosed stator slots. Distal ends of adjacent stator teeth are joined together or integrally formed such that the enclosed stator slots are not contiguous with the airgap. The stator windings constructed from hairpin or bar-type conductors extend axially through the stator within the enclosed stator slots. The coolant manifold is in fluid communication with a coolant supply and configured to seal against an axial end surface of the stator to enclose a portion of the stator windings. The manifold receives and directs coolant from the coolant supply into the enclosed stator slots through the axial end surface to cool the stator via forced convection.
    Type: Application
    Filed: November 8, 2019
    Publication date: May 13, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Thomas W. Nehl, Farzad Samie, Alireza Fatemi, Derek F. Lahr, Tito R. Huffman
  • Publication number: 20210135533
    Abstract: A rotary electric machine for use with coolant includes a stator and rotor assembly. The rotor assembly includes a rotor, rotor shaft, and first and second end rings. The rotor has inner and outer diameter surfaces and an embedded set of rotor magnets proximate the outer diameter surface. The shaft is connected to the rotor and defines a main coolant passage along an axis of rotation. Radial shaft coolant passages are in fluid communication with the main coolant passage. The end rings are positioned at opposing distal ends of the rotor. The shaft coolant passages direct the coolant into the rotor and/or the end rings such that the coolant flows axially through rotor cavities of the rotor and cools the rotor magnets via forced convection.
    Type: Application
    Filed: November 1, 2019
    Publication date: May 6, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Farzad Samie, Alireza Fatemi, Derek F. Lahr, Erik B. Golm, Xiaofeng Yang
  • Publication number: 20210126511
    Abstract: A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.
    Type: Application
    Filed: October 24, 2019
    Publication date: April 29, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Anthony M. Coppola, Alireza Fatemi, Bradley A. Newcomb, Derek F. Lahr, Sean R. Wagner
  • Publication number: 20210107348
    Abstract: A vehicle powertrain includes a first power-source configured to generate a first power-source torque and a multiple speed-ratio transmission configured to transmit the first power-source torque to power the vehicle. The powertrain also includes a fluid coupling having a fluid pump shaft operatively connected to the first power-source and a turbine shaft operatively connected to the multi-speed transmission. The fluid coupling is configured to multiply the first power-source torque, and transfer the multiplied first power-source torque to the multiple speed-ratio transmission. The powertrain additionally includes a second power-source configured to generate a second power-source torque and a first torque transfer system configured to connect the second power-source to the first power-source. The powertrain further includes a second torque transfer system configured to connect the second power-source to the multi-speed transmission. A motor vehicle having such a powertrain is also envisioned.
    Type: Application
    Filed: October 9, 2019
    Publication date: April 15, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Neeraj S. Shidore, Derek F. Lahr, Lei Hao, Madhusudan Raghavan, Suresh Gopalakrishnan
  • Publication number: 20210091630
    Abstract: A rotor for an electric machine includes a rotor core having at least one internal cavity. A pair of features are defined by the rotor core and extend into the cavity. A structural element is compressed between the features so that a preload may be established between the features and the structural element.
    Type: Application
    Filed: September 24, 2019
    Publication date: March 25, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Derek F. Lahr, Alireza Fatemi, Farzad Samie
  • Patent number: 10955025
    Abstract: A vehicle powertrain variable vibration absorber assembly can be equipped in a hybrid electric vehicle (HEV). The vehicle powertrain variable vibration absorber assembly includes a rotary device, a drive-ratio assembly, and a spring. The rotary device, in an example, is a motor-generator unit (MGU). The drive-ratio assembly, in an example, is a planetary gear assembly. The drive-ratio assembly receives rotational drive input from the rotary device, and transmits rotational drive output to a powertrain component. The spring, in an example, is a variable stiffness spring. The spring is connected to the drive-ratio assembly and is connected to a grounded component. During use, the vehicle powertrain variable vibration absorber assembly absorbs different frequencies of vibration brought about by a vehicle engine amid different operating modes. The operating modes can involve cylinder deactivation technologies.
    Type: Grant
    Filed: May 31, 2018
    Date of Patent: March 23, 2021
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Derek F. Lahr, Neeraj S. Shidore, James B. Borgerson, Chunhao J. Lee, Norman K. Bucknor
  • Publication number: 20210083555
    Abstract: An electric motor includes a stator, a rotor, a rotor shaft and a pump. The rotor is disposed within the stator and separated from the stator by an airgap. The airgap inadvertently accumulates a fluid. The rotor shaft is connected to the rotor. The pump is configured to move the fluid out of the airgap.
    Type: Application
    Filed: September 13, 2019
    Publication date: March 18, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Derek F. Lahr, Farzad Samie, Alireza Fatemi
  • Patent number: 10941840
    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.
    Type: Grant
    Filed: December 1, 2017
    Date of Patent: March 9, 2021
    Assignee: GM Global Technology Operations LLC
    Inventors: Jian Yao, Chengwu Duan, Chunhao J. Lee, Derek F. Lahr, Farzad Samie
  • Publication number: 20210054885
    Abstract: Presented are clutch-type engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device includes a notch plate, which has multiple notches and attaches to a torque converter, and a pocket plate, which has multiple pockets and attaches to an engine's crankshaft. A pawl is movably mounted within each notch; these pawls selectively engage the notches with the pockets. A notch plate insert is nested within each notch, supporting thereon one of the pawls. A selector plate interposed between the pocket and notch plates moves from a first position, to shift the pawls out of engagement with the pockets, and a second position, to move the notch plate inserts within the notches and allow the pawls to engage the notches with the pockets to thereby lock the notch plate to the pocket plate to rotate in unison with each other.
    Type: Application
    Filed: November 5, 2020
    Publication date: February 25, 2021
    Applicant: GM Global Technology Operations LLC
    Inventors: Derek F. Lahr, Chunhao J. Lee, Farzad Samie, Dongxu Li, Dmitriy Bruder