Abstract: A stator core includes a first lamination and a second lamination. The first lamination is formed from a plurality of first segments and has a plurality of first mounting ears. The second lamination is formed from a plurality of second segments and has a plurality of second mounting ears. The first lamination and the second lamination are aligned with a common axis and are rotated about the common axis such that the first lamination is not aligned with the second lamination.

Abstract: An electric motor includes a stator configured to receive electrical energy and generate an electromagnetic field in accordance with the electrical energy received. A rotor is in electromagnetic communication with the stator and is configured to rotate in accordance with the electromagnetic field generated by the stator. The rotor includes a plurality of poles including a first set of poles and a second set of poles. The first set of poles defines a first slot and the second set of poles defines a second slot that has a different configuration than the first slot to reduce a torque ripple effect. The electric motor may be used in a system having a power source configured to output direct current energy and an inverter configured to convert direct current energy to alternating current energy.

Abstract: A pump-motor assembly includes a motor housing, a motor disposed substantially within the motor housing, and a pumping element driven by the motor. A pressurized region is filled with a fluid pressurized by the pumping element, and a fluid passage is in fluid communication with the pressurized region and the motor housing. Fluid flows from the pressurized region to the motor housing and at least partially submerges the motor.

Abstract: A permanent magnet motor includes a permanent magnet rotor, a stator surrounding the rotor having a plurality of teeth radially inwardly oriented toward a longitudinal axis of the stator wherein each tooth has a tooth length and a tooth tip surface geometry. An asymmetric air gap is defined by variations in the tooth lengths and tooth tip surface geometries.

Abstract: A rotor assembly with a cooling mechanism having first and second channels is provided. The rotor assembly includes a shaft having a hollow portion and a rotor core having at least one rotor stack positioned at least partially around the shaft. The rotor core has a first end and a second end. The rotor stack forms an interior cavity which is only partially filled with a permanent magnet so as to define a gap in the rotor stack. The first channel is configured to direct fluid flow in a generally radial direction from the hollow portion of the shaft. The second channel is at least partially defined by the gap in the interior cavity of the rotor stack and is configured to direct the fluid flow from the first channel to at least one of the first and second ends of the rotor core.

Abstract: A stator assembly includes a stator stack and a plurality of lead conductors extending from the stator stack. A plurality of conductor terminals are each connected to a respective one of the plurality of lead conductors. A plurality of wires are each connected to a respective one of the plurality of conductor terminals and a plurality of phase lead connection terminals are each connected to at least one of the plurality of wires.

Abstract: A resolver is configured to determine the rotational position of a first member that is selectively rotatable about an axis with respect to a second member. The resolver includes a stator core, a plurality of wire windings operatively connected to the stator core, a winding support between the windings and the stator core, and a cover at least partially enclosing the windings. One of the cover and the winding support defines a pin that is fittable inside a hole in the second member. The pin functions as a locating feature, which ensures that the stator is accurately mounted to the second member. Because the pin is part of the winding support or the cover, the locating feature does not entail the use of an extra part, thereby simplifying assembly of the stator.

Abstract: An insulator assembly for a stator assembly of an electric machine includes an annular ring attached to a stator core, and a plurality of coil separators supported by the annular ring and extending from the annular ring axially along a longitudinal axis. One of the coil separators is disposed between each adjacent pair of the coils to prevent contact between adjacent coils having a different electrical phase. The coil separators are slideably inserted between the adjacent pairs of coils, with the annular ring positioning and supporting the coil separators.

Abstract: In general, the various embodiments are directed to a permanent magnet machine (“PM machine”), and more specifically an internal permanent magnet machine (“IPM machine”) that includes rotor magnets configured asymmetrically with respect to the rotor periphery, thereby producing an averaging effect similar to that achieved through traditional skewing of the rotor magnets. In alternate embodiments, the span, placement and/or shape of the magnets may vary from one pole to the next.

Abstract: An internal permanent magnet machine (“IPM machine”) of the type used, for example, with traction motors and hybrid electric vehicles, includes a rotor with an additional air barrier provided above the first magnet barrier in the same rotor slot. Each magnet only fills a portion of each cavity, thereby defining the air barriers. The added air barrier above the permanent magnet of the first layer acts as a barrier to the first layer magnet and lowers the magnet flux.

Abstract: Methods and apparatus are provided for improving operational characteristics of a concentrated winding machine. According to an example embodiment, an apparatus comprises stator teeth having distal ends, the stator teeth arranged in an annular fashion about an axis to define stator slots between adjacent teeth and slot openings between the distal ends of the adjacent teeth, the stator teeth structured to prevent relative movement between adjacent teeth. The apparatus further comprises magnetic wedges structured to be inserted between the distal ends of the adjacent teeth to close the slot openings.

Abstract: A squirrel cage rotor structure used in connection with an electrical machine is formed from a high-strength, high-conductivity, and heat-treatable aluminum alloy, e.g., a T61 tempered aluminum alloy, such as A6101-T61. The resulting structure has improved strength compared to conventional pure aluminum structures, while at the same time limiting the reduction in electrical conductivity.

Abstract: An electric machine having a stator body and a machine housing is provided. The stator body includes a stator ring of generally annular shape and a plurality of stator teeth projecting radially inward. A first bolt hole is defined in either the stator ring or machine housing, and a first receptacle is defined in the other and is coaxial with the first bolt hole. A second bolt hole is defined in either the stator ring or machine housing, and a second receptacle is defined in the other and is coaxial with the second bolt hole. A first counter bore is coaxial with the first receptacle. A first hollow dowel is mated to the first counter bore and the first bolt hole, and defines a first dowel hole, which is coaxial with the first counter bore and the first bolt hole.

Abstract: An apparatus includes structure defining a first hole that is characterized by an opening. A protuberance surrounds the opening and at least partially defines a concavity. A retention member is disposed within the concavity, and defines a second hole. The second hole has a first portion characterized by a first diameter and a second portion characterized by a second diameter. A threaded fastener has a flange characterized by a third diameter greater than the first diameter and less than the second diameter. The flange is disposed within the second portion of the second hole and between the first portion of the retention member hole and the first surface. Accordingly, the retention member retains the fastener in the concavity while permitting radial movement of the fastener.

Abstract: A bar-wound stator, which is connectable to a plurality of fixed terminal points, includes a plurality of stator teeth and a plurality of magnet wires. Each of the plurality of magnet wires has a winding portion wound about at least one of the plurality of stator teeth and a junction portion extending away therefrom. A plurality of flexible leads each have a first portion ultrasonically welded directly to a respective one of the junction portions of the plurality of magnet wires. A second portion of each of the plurality of flexible leads extends flexibly away from the first portion and is configured for attachment to a respective one of the fixed terminal points.

Abstract: A bar-wound stator includes a plurality of bar-type conductors disposed within the plurality of slots, wherein, within each slot, at least one of the bar-type conductors has an orientation that differs from the remaining bar-type conductors within that slot by a predetermined angle. For example, conductors with rectangular cross-sections can be inserted such that the conductors closest to the inner surface of the stator are rotated ninety degrees with respect to the remaining conductors.

Abstract: RF signal noise in a powertrain utilizing a power inverter module and electric motor is attenuated by providing a low impedance connection between a transmission output shaft and housing.

Abstract: An electric motor includes a rotor and a stator assembly concentrically located about the rotor. The stator assembly includes a stator stack and a plurality of spaced apart stator teeth extending radially from the stator stack. The plurality of stator teeth defines a plurality of stator slots. Each stator tooth defines a stator tooth tip.

Abstract: A resolver is configured to determine the rotational position of a first member that is selectively rotatable about an axis with respect to a second member. The resolver includes a stator core, a plurality of wire windings operatively connected to the stator core, a winding support between the windings and the stator core, and a cover at least partially enclosing the windings. One of the cover and the winding support defines a pin that is fittable inside a hole in the second member. The pin functions as a locating feature, which ensures that the stator is accurately mounted to the second member. Because the pin is part of the winding support or the cover, the locating feature does not entail the use of an extra part, thereby simplifying assembly of the stator.

Abstract: An assembly for providing electrical insulation in a stator core of a vehicular electric machine is provided. The stator core has a channel and the assembly comprises a first conductive element disposed through the channel, and a second conductive element disposed through the channel and substantially adjacent to the first conductive element. The assembly also comprises a first electrically insulating film having a first end residing between the first and second conductive elements.