Abstract: An electric vehicle drive has a first motor/generator, a second motor/generator, and a set of wheels. A gear set couples the first and second motor/generators to the set of wheels such that a total wheel torque is selectably divided between the first and second motor/generators. A torque calculator responds to an operator speed input to select a total torque target. A torque allocator substantially maximizes a combined efficiency of the first and second motor/generators by dividing the total torque target into first and second torque targets for the first and second motor/generators according to a ratio selected in response to an instantaneous motor/generator speed and the total torque target.

Abstract: A method of forming a stator core assembly for an electric machine includes providing a stator core having a plurality of radially extending slots, forming a flat wire pack having a plurality of continuous electrical wires, shaping the flat wire pack into a substantially cylindrical shape, and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core.

Abstract: A method of forming a stator core assembly for an electric machine includes providing a stator core having a plurality of radially extending slots, forming a flat wire pack having a plurality of continuous electrical wires, shaping the flat wire pack into a substantially cylindrical shape, and engaging the substantially cylindrically shaped flat wire pack with the stator core such that the continuous electrical wires are interlaced within the slots of the stator core.

Abstract: A stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots. A first electrical conductor and a second continuous electrical conductor are inserted within the winding slots circumferentially around the stator core. The conductors form a plurality of layers, each layer being defined as one substantially complete circumferential pass of the conductors around the stator core. Each of the conductors include a plurality of straight portions that lay within the winding slots, and a plurality of end loop portions that extend circumferentially to connect two of the straight portions. The length of the straight portions and end loop portions vary between the layers based upon the radial location of the particular layer within the stator core and a pre-determined axial height of the end loop portions.

Abstract: A stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots. A first electrical conductor and a second continuous electrical conductor are inserted within the winding slots circumferentially around the stator core. The conductors form a plurality of layers, each layer being defined as one substantially complete circumferential pass of the conductors around the stator core. Each of the conductors include a plurality of straight portions that lay within the winding slots, and a plurality of end loop portions that extend circumferentially to connect two of the straight portions. The length of the straight portions and end loop portions vary between the layers based upon the radial location of the particular layer within the stator core and a pre-determined axial height of the end loop portions.

Abstract: An electrical machine (20) includes a stator core (54) having slots (80) and a set of windings (58) disposed within the slots (80). The windings (58) are configured in 2N+1 phases, where N in greater than 1. Such a machine is particularly useful for automotive alternators.

Abstract: A molded rotor assembly (20) including at least one molded fan (28), a method for making the same, and a vehicle alternator (160) using the molded rotor assembly (20) are disclosed. The rotor assembly (20) includes first and second pole pieces (24,26) aligned along a longitudinal axis (40) defining a region (122) between the pole pieces (24,26). Each pole piece (24,26) has an outboard axial face (69,71). At least one molded fan (28) is integrally molded to one of the axial outboard faces (69) of a pole piece (24). Preferably, a molded insert (22) is molded in the region (122) between the pole pieces (24,26) and is integral with the molded fan (28) to secure the molded fan (28) to the pole piece (24). Alternatively, anchoring recesses (241,245) are formed in an outboard face of a pole piece (224) with a molded fan (228) having anchoring portions (249,251) secured within the recesses (241,245) to retain the fan (228) to the outboard axial face.

Abstract: A molded rotor assembly (20) for a vehicle alternator and method for making the same are disclosed. The rotor assembly includes first and second pole pieces (24,26) aligned along a longitudinal axis (40), the pair of pole pieces (24,26) defining a region therebetween. A coil wire (46) is located in the region. The pole pieces (24,26) and a slip ring assembly (36) are mounted on a rotor shaft (38). The slip ring assembly (36) has a pair of slip rings (102,104) connected to a pair of terminals (96,98) which are attached to respective free ends of the coil wire (46) to form a pair of connections (126,128). A molded insert (22) is injection molded filling the region between the pole pieces (24,26) thereby encapsulating the connections (126,128) and the coil wire (96) and forming a smooth cylindrical periphery on the rotor assembly (20).