Abstract: An electric motor comprises: a rotor; a stator comprising a stack of laminations, wherein windings of the stator comprise wires that have individual insulation, the wires forming slot windings positioned in slots of the stator, the wires further forming end windings positioned outside the slots at each end of the stator; varnish in the slots of the stator, the varnish contacting the laminations and the slot windings, and wherein the varnish does not contact the end windings of at least one of the ends of the stator; and a cooling system to apply liquid coolant to at least the end windings, wherein the liquid coolant passes between the wires of the end windings.

Abstract: A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.

Abstract: An electric motor comprises: a stator having slots; and a rotor including a stack of rotor laminations, the rotor comprising: a first substack of the rotor laminations, wherein the rotor laminations in the first substack include first rivet holes and first magnet holes with first permanent magnets; and a second substack of the rotor laminations, wherein the rotor laminations in the second substack include second rivet holes and second magnet holes with second permanent magnets, and wherein an orientation of the first sub stack and the second substack relative to each other provides the rotor with a skew.

Abstract: An electric motor comprises: a rotor having poles equaling a first number; and a stator having slots equaling a second number, the stator having stator windings formed by conductors wound in a wave pattern around the stator, wherein a third number of the conductors are located in each of the slots, wherein the conductors form three balanced parallel paths through the slots, each of the conductors in the three balanced parallel paths undergoing a same number of pitch turns, each of the pitch turns being either a standard pitch turn or a nonstandard pitch turn, the standard pitch turn involving wrapping around slots equaling the second number divided by the first number, the nonstandard pitch turn involving wrapping around more or fewer slots than the standard pitch turn, wherein each of the three balanced parallel paths forms a repeating pattern throughout the slots.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to increase the velocity of the coolant exiting the axial coolant channels, thereby improving end winding cooling uniformity, end laminations are integrated into the stator which restrict the flow of coolant from the axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. The coolant manifold includes a middle member that allows coolant to enter the axial coolant channels via transition laminations, where the transition laminations include coolant distribution channels that direct the flow of coolant entering into the manifold into the stator-integrated axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to improve end winding cooling uniformity, two or more end laminations are included on either end of the stator assembly which restrict and direct the flow of coolant exiting the axial coolant channels.

Abstract: An electric motor comprises: a rotor having poles equaling a first number; and a stator having slots equaling a second number, the stator having stator windings formed by conductors wound in a wave pattern around the stator, wherein a third number of the conductors are located in each of the slots, wherein the conductors form three balanced parallel paths through the slots, each of the conductors in the three balanced parallel paths undergoing a same number of pitch turns, each of the pitch turns being either a standard pitch turn or a nonstandard pitch turn, the standard pitch turn involving wrapping around slots equaling the second number divided by the first number, the nonstandard pitch turn involving wrapping around more or fewer slots than the standard pitch turn, wherein each of the three balanced parallel paths forms a repeating pattern throughout the slots.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. The coolant manifold includes a middle member that allows coolant to enter the axial coolant channels via transition laminations, where the transition laminations include coolant distribution channels that direct the flow of coolant entering into the manifold into the stator-integrated axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to increase the velocity of the coolant exiting the axial coolant channels, thereby improving end winding cooling uniformity, end laminations are integrated into the stator which restrict the flow of coolant from the axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to improve end winding cooling uniformity, two or more end laminations are included on either end of the stator assembly which restrict and direct the flow of coolant exiting the axial coolant channels.

Abstract: A stator assembly is provided that simplifies the process of coupling the stator windings to the winding lugs. The stator assembly includes a pre-fabricated connector that is attached to the stator via a plurality of stator winding terminations. The pre-fabricated connector includes a plurality of electrically conductive termination coupling members that form conductive pathways between at least a portion of the stator winding terminations and a plurality of bus bars, where each of the bus bars includes a lug. The pre-fabricated connector may also include a second plurality of electrically conductive termination coupling members that form conductive pathways between at least a second portion of the stator winding terminations and a plurality of lugless bus bars. An electrically insulating material is overlaid over portions of the connector ring, thereby preventing contact or partial discharge between the various bus bars.

Abstract: A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.

Abstract: A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.

Abstract: A method of manufacturing an electric motor that includes a plurality of structural cooling features is provided, where the electric motor utilizes axial cooling channels integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack. A coolant manifold assembly, incorporated into the stator between left and right stator portions, provides a means of distributing coolant to the axial cooling channels.

Abstract: A multi-mode vehicle thermal management system is provided that optimizes drive train operating efficiency by thermally de-coupling the drive train thermal control loop from other vehicle thermal control loops during initial vehicle start-up when drive train coolant/lubricant is cold, thus taking into account the temperature dependence of the coolant/lubricant characteristics (e.g., viscosity and density) and the effects of these characteristics on viscous drag and bearing/seal preload force.

Abstract: A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.

Abstract: A stator assembly is provided that simplifies the process of coupling the stator windings to the winding lugs. The stator assembly includes a pre-fabricated connector that is attached to the stator via a plurality of stator winding terminations. The pre-fabricated connector includes a plurality of electrically conductive termination coupling members that form conductive pathways between at least a portion of the stator winding terminations and a plurality of bus bars, where each of the bus bars includes a lug. The pre-fabricated connector may also include a second plurality of electrically conductive termination coupling members that form conductive pathways between at least a second portion of the stator winding terminations and a plurality of lugless bus bars. An electrically insulating material is overlaid over portions of the connector ring, thereby preventing contact or partial discharge between the various bus bars.

Abstract: A powertrain utilizing an active core motor with coaxially aligned planetary-differential-planetary gear assemblies is provided.

Abstract: A powertrain utilizing an active core motor with coaxially aligned planetary-differential-planetary gear assemblies is provided.