Abstract: A stator assembly includes a plurality of stator slots defining multiple slot layers. The assembly includes a plurality of hairpins each having a respective first leg positioned in one of the multiple slot layers and a respective second leg positioned in another of the multiple slot layers. Each hairpin is configured to allow a current to flow from the respective first leg to the respective second leg. The plurality of hairpins is divided into multiple hairpin layers. The hairpins form multiple winding sets, such as first, second, third and fourth winding sets. Each of the winding sets at least partially includes the hairpins from at least two of the multiple hairpin layers. The multiple slot layers may include six slot layers. The multiple hairpin layers may include six hairpin layers. Thus, at least one of the hairpin layers may be “shared” by two winding sets.

Abstract: An electric device and a stator assembly for the electric device includes a stator core defining a plurality of slots spaced from each other. The stator assembly includes a plurality of bar conductors disposed in each of the slots and arranged to present a first winding path, a second winding path and a third winding path. A first set of the bar conductors of the first, second and third winding paths are configured to receive current in a parallel circuit arrangement. The stator assembly also includes a plurality of electrical jumpers electrically connected to a predetermined number of the bar conductors such that an amount of current flowing through the first winding path and the third winding path is substantially the same and an amount of current flowing through the second winding path is different from the amount of current flowing through the first and third winding paths.

Abstract: A bar wound stator includes a stator core defining a plurality of slots. Bar-type conductors are disposed within each slot. Each slot includes a slot liner and an insulator cap. Each slot liner includes an end portion disposed against an inner wall surface, and side portions disposed against a first wall surface and a second wall surface respectively. Each insulator cap includes a base portion disposed against an outer wall surface, and side portions disposed against the first wall surface and the second wall surface respectively. The side portions of the insulator cap in each slot overlap the side portions of the slot liner in each slot along the first wall surface and the second wall surface respectively. Each slot includes a recessed feature in each of the first wall surface and the second wall surface to accommodate the overlapping side portions of the insulator cap and the slot liner.

Abstract: An improved rotor assembly configured for magnets with differing lengths, and methods and systems for manufacturing the same. The rotor assembly may be created by selectively creating first and second tabs extending into apertures of lamination sheets. The first and second tabs may be selectively removed, depending on the different magnet lengths and the specific lamination sheet, according to one of a first finishing schedule and a second finishing schedule. The lamination sheets are stacked with any remaining first and second tabs, and other features, aligned.

Abstract: A transmission-mounted electric machine includes an integrated rotational position sensor. The rotational position sensor includes a rotor element and a stator element. The stator element is attached to a stator element of the transmission at a plurality of mounting points and includes an alignment adjustment mechanism. The rotor element of the sensor is slip-fit against a shoulder of a rotor hub and held in place using a wave spring.

Abstract: An apparatus for providing a coolant to a stator and a rotor of an electric motor in a vehicle having a coolant pump is provided. The apparatus includes a base defining a plurality of first openings through at least one of which the coolant is flowable to the stator. The apparatus also includes at least one wall extending from the base to define a cavity configured to receive the coolant from the coolant pump. The apparatus further includes at least one first raised member within the cavity that extends from the base. The at least one first raised member defines at least one second opening substantially aligned with one of the first openings to form a first passageway through which the coolant is flowable to the rotor. The apparatus may be located above the electric motor such that the coolant is flowable by gravity to the stator and/or the rotor.

Abstract: A coil retainer for a rotor includes a flat body and a longitudinal spine. The flat body has a first thickness and the longitudinal spine has a second thickness greater than the first thickness. The coil retainer may also include a central rib, which has a third thickness. The central rib runs laterally relative to the flat body and the third thickness of the central rib is greater than the first thickness.

Abstract: A rotor defines an axial direction and a radial direction relative to an axis of rotation and includes an annular hub and a core disposed radially outward of the annular hub. The core defines a first axial side and a second axial side. First radial feed holes are formed in the annular hub, and are located between the first and second axial sides. Axial channels are formed between the core and the annular hub, and are in fluid communication with the first radial feed holes and span substantially between the first and second axial sides. The rotor also includes a first member and a second member, adjacent to the first and second axial sides, respectively. First and second apertures are formed in the first and second members, respectively. Each of the first and second apertures is in fluid communication with one of the axial channels.

Abstract: A support ring for a rotor having a core and a plurality of windings. The support ring includes an annular base, a plurality of fingers, and a plurality of loaded edges. The plurality of fingers extend radially outward from the annular base, and each generally corresponds to one of the windings. The plurality of loaded edges extend axially from the fingers and are disposed radially outward of the windings.

Abstract: A rotor assembly for an electric machine includes a plurality of lamination sheets. Each of the lamination sheets defines an aperture. The lamination sheets are disposed adjacent each other to define a laminated stack. The apertures are aligned with each other to define a slot extending parallel with a central axis of the laminated stack. A magnet is disposed within the slot. The lamination sheets include a group of recess lamination sheets and a tab lamination sheet. The tab lamination sheet includes a tab that extends into the slot, and into abutting engagement with the magnet to bias the magnet against a wall of the slot. The apertures of the group of recess lamination sheets include a groove portion that defines a groove. The tab of the tab lamination sheet is at least partially disposed within the groove defined by the recess lamination sheets.

Abstract: An interior permanent magnet machine includes a rotor having a plurality of slots. First and second slots are disposed in a first pole and the third and fourth slots are disposed in a second pole. A first angle is defined between respective centerlines of the first and second slots. A second angle is defined between respective centerlines of the third and fourth slots. The first angle is configured to be sufficiently different from the second angle so that torque ripple is reduced. Thus the rotor is configured such that the angular configuration of slots in a first pole is different from the angular configuration of slots in a second pole of the rotor.

Abstract: An apparatus for providing a coolant to a stator and a rotor of an electric motor in a vehicle having a coolant pump is provided. The apparatus includes a base defining a plurality of first openings through at least one of which the coolant is flowable to the stator. The apparatus also includes at least one wall extending from the base to define a cavity configured to receive the coolant from the coolant pump. The apparatus further includes at least one first raised member within the cavity that extends from the base. The at least one first raised member defines at least one second opening substantially aligned with one of the first openings to form a first passageway through which the coolant is flowable to the rotor. The apparatus may be located above the electric motor such that the coolant is flowable by gravity to the stator and/or the rotor.

Abstract: A stator assembly includes a plurality of stator slots defining multiple slot layers. The assembly includes a plurality of hairpins each having a respective first leg positioned in one of the multiple slot layers and a respective second leg positioned in another of the multiple slot layers. Each hairpin is configured to allow a current to flow from the respective first leg to the respective second leg. The plurality of hairpins is divided into multiple hairpin layers. The hairpins form multiple winding sets, such as first, second, third and fourth winding sets. Each of the winding sets at least partially includes the hairpins from at least two of the multiple hairpin layers. The multiple slot layers may include six slot layers. The multiple hairpin layers may include six hairpin layers. Thus, at least one of the hairpin layers may be “shared” by two winding sets.

Abstract: An interior permanent magnet machine includes a rotor having a plurality of slots. First and second slots are disposed in a first pole and the third and fourth slots are disposed in a second pole. A first barrier is defined by the first, second, third and fourth slots. The slots are configured to be symmetric relative to their respective pole axes. A first angle is defined between the first and second slots. A second angle is defined between the third and fourth slots. The first angle is configured to be sufficiently different from the second angle so that torque ripple is minimized. Thus the rotor is configured such that the angular configuration of slots in a first pole is different from the angular configuration of slots in a second pole of the rotor.

Abstract: An electric motor assembly includes a housing and a stator. The housing includes an outer housing surface, an inner housing surface defining an interior housing cavity, and a plurality of housing protrusions extending from the inner housing surface. The stator is disposed in the inner housing cavity and includes an outer stator surface, an inner stator surface, and a plurality of stator protrusions extending from the outer stator surface toward the outer housing surface. The stator protrusions are configured to mate with the housing protrusions to frictionally couple the stator to the housing in order to fix the stator relative to the housing.

Abstract: A method and assembly for forming a rotor include forming a rotor core having a plurality of voids and placing the formed rotor core into a die cavity. The method includes moving a plurality of support shoes to define an outer diameter of the die cavity, and injecting at least one of the plurality of voids with a magnetic slurry. At least one permanent magnet is formed from the magnetic slurry by applying pressure to the rotor core and the magnetic slurry within the die cavity and by applying a magnetic field to align the magnetic slurry. After forming the at least one permanent magnet within the rotor core, the plurality of support shoes are retracted and the rotor core removed with the at least one permanent magnet formed therein.

Abstract: A bar wound stator includes a stator core defining a plurality of slots. Bar-type conductors are disposed within each slot. Each slot includes a slot liner and an insulator cap. Each slot liner includes an end portion disposed against an inner wall surface, and side portions disposed against a first wall surface and a second wall surface respectively. Each insulator cap includes a base portion disposed against an outer wall surface, and side portions disposed against the first wall surface and the second wall surface respectively. The side portions of the insulator cap in each slot overlap the side portions of the slot liner in each slot along the first wall surface and the second wall surface respectively. Each slot includes a recessed feature in each of the first wall surface and the second wall surface to accommodate the overlapping side portions of the insulator cap and the slot liner.

Abstract: A coil retainer for a rotor includes a flat body and a longitudinal spine. The flat body has a first thickness and the longitudinal spine has a second thickness greater than the first thickness. The coil retainer may also include a central rib, which has a third thickness. The central rib runs laterally relative to the flat body and the third thickness of the central rib is greater than the first thickness.

Abstract: An interior permanent magnet machine includes a rotor configured to magnetically interact with a stator. First and second dividers are integrally formed within the rotor and configured to create a first layer of three respective first segments. Each of the respective first segments may be substantially arc-shaped. A plurality of first magnets may be positioned in the first layer. The first magnets may be substantially arc-shaped and defined around an arc center. A third and a fourth divider may be integrally formed within the rotor and configured to create a second layer of three respective second segments. The placement of dividers or structural webs provides for increased rotational speed and reduced rotational stress compared to an undivided arc-shaped magnet configuration.

Abstract: A method of manufacturing a stator core is disclosed. The method includes advancing a blank at each of a plurality of press cycles to form a segment at each of the press cycles and shaping the segments. Shaping the segments further includes activating a tooth punch, activating a mounting-ear punch, and activating an joint punch. The method also includes separating the segments from the blank.