Abstract: A system includes: a segmented rotor assembly; magnetic elements; and a stator. The segmented rotor assembly includes a set of pole pieces arranged radially about an axis. Each pole piece defines: a rim extending about a periphery of the pole piece; a first recess arranged on a first side of the pole piece; and a second recess arranged on a second side, opposite the first side, of the pole piece. Each pair of adjacent pole pieces, in the segmented rotor assembly, defines a pair of linearly-offset and angularly-offset rims that cooperate to define a tapered annular interstice in a radial array of tapered annular interstices. Each magnetic element is nested within a tapered annular interstice in the radial array of tapered annular interstices. The stator: encompasses the segmented rotor assembly; and includes windings configured to inductively couple to the magnetic elements to rotate the segmented rotor assembly about the axis.

Abstract: A system includes: a segmented stator assembly; a set of windings; and a rotor. The segmented stator assembly includes a set of pole pieces arranged radially about an axis. Each pole piece defines: a rim extending about a periphery of the pole piece; a recess arranged on a first side of the pole piece; and a shoulder arranged on a second side, opposite the first side, of the pole piece. Each pair of adjacent pole pieces, in the segmented stator assembly, defines a pair of linearly-offset and angularly-offset rims that cooperate to define a tapered annular interstice in a radial array of tapered annular interstices. Each winding is arranged about a tapered annular interstice in the radial array of tapered annular interstices. The rotor: encompasses the segmented stator assembly; and includes magnetic elements configured to magnetically couple to the set of windings to rotate the rotor about the axis.

Abstract: A method includes, at a controller: directing current through a set of coil assemblies in an electric motor based on a first commutation technique; in response to an operating speed of the electric motor exceeding a first operating speed threshold, initiating a transition from the first commutation technique to a second commutation technique; during a transition period, directing current through the set of coil assemblies based on the first commutation technique controlled according to a first pulse width modulation scheme and the second commutation technique controlled according to a second pulse width modulation scheme; and, in response to completion of the transition period, directing current through the set of coil assemblies based on the second commutation technique.

Abstract: One variation of a system for an electric motor includes a rotor including magnetic elements within a body. The system also includes a stator including coil assemblies arranged about the rotor. Each coil assembly includes an outer hook element and an inner hook element. The outer hook element extends across a first axial face and an outer radial surface of the rotor. The inner hook element: extends across a second axial face of the rotor; extends partially across the inner radial surface of the rotor; and is coupled to the outer hook element to define a throat configured to locate the rotor within the coil assembly. The system includes a shaft coupled to the inner radial surface of the rotor. Furthermore, the system includes a controller configured to drive current through the coil assemblies to generate a toroidal magnetic field configured to couple the magnetic elements to rotate the rotor.

Abstract: A motor winding includes a wire defining a rectangular cross-section and wound in a continuous direction about a coil axis to form a continuous coil including: a first coil segment spiraling in a first plane, defining a first external terminal, and defining a first interior end inset from the first external terminal and arranged on a first side of a coil axis; a second coil segment spiraling in a second plane parallel and offset from the first plane, defining a second exterior terminal parallel to the first external terminal, and defining a second interior end inset from the second exterior coil end and arranged on a second side of the coil axis opposite the first interior end; and a junction extending between the first plane and the second plane to couple the first interior end of the first coil segment to the second interior end of the second coil segment.

Abstract: A method includes, at a controller: directing current through a set of coil assemblies in an electric motor based on a first commutation technique; in response to an operating speed of the electric motor exceeding a first operating speed threshold, initiating a transition from the first commutation technique to a second commutation technique; during a transition period, directing current through the set of coil assemblies based on the first commutation technique controlled according to a first pulse width modulation scheme and the second commutation technique controlled according to a second pulse width modulation scheme; and, in response to completion of the transition period, directing current through the set of coil assemblies based on the second commutation technique.

Abstract: One variation of a system for an electric motor includes a rotor including magnetic elements within a body. The system also includes a stator including coil assemblies arranged about the rotor. Each coil assembly includes an outer hook element and an inner hook element. The outer hook element extends across a first axial face and an outer radial surface of the rotor. The inner hook element: extends across a second axial face of the rotor; extends partially across the inner radial surface of the rotor; and is coupled to the outer hook element to define a throat configured to locate the rotor within the coil assembly. The system includes a shaft coupled to the inner radial surface of the rotor. Furthermore, the system includes a controller configured to drive current through the coil assemblies to generate a toroidal magnetic field configured to couple the magnetic elements to rotate the rotor.

Abstract: A motor winding includes a wire defining a rectangular cross-section and wound in a continuous direction about a coil axis to form a continuous coil including: a first coil segment spiraling in a first plane, defining a first external terminal, and defining a first interior end inset from the first external terminal and arranged on a first side of a coil axis; a second coil segment spiraling in a second plane parallel and offset from the first plane, defining a second exterior terminal parallel to the first external terminal, and defining a second interior end inset from the second exterior coil end and arranged on a second side of the coil axis opposite the first interior end; and a junction extending between the first plane and the second plane to couple the first interior end of the first coil segment to the second interior end of the second coil segment.

Abstract: One variation of a system for an electric motor includes a rotor including magnetic elements within a body. The system also includes a stator including coil assemblies arranged about the rotor. Each coil assembly includes an outer hook element and an inner hook element. The outer hook element extends across a first axial face and an outer radial surface of the rotor. The inner hook element: extends across a second axial face of the rotor; extends partially across the inner radial surface of the rotor; and is coupled to the outer hook element to define a throat configured to locate the rotor within the coil assembly. The system includes a shaft coupled to the inner radial surface of the rotor. Furthermore, the system includes a controller configured to drive current through the coil assemblies to generate a toroidal magnetic field configured to couple the magnetic elements to rotate the rotor.

Abstract: One variation of a system for an electric motor includes a rotor including magnetic elements within a body. The system also includes a stator including coil assemblies arranged about the rotor. Each coil assembly includes an outer hook element and an inner hook element. The outer hook element extends across a first axial face and an outer radial surface of the rotor. The inner hook element: extends across a second axial face of the rotor; extends partially across the inner radial surface of the rotor; and is coupled to the outer hook element to define a throat configured to locate the rotor within the coil assembly. The system includes a shaft coupled to the inner radial surface of the rotor. Furthermore, the system includes a controller configured to drive current through the coil assemblies to generate a toroidal magnetic field configured to couple the magnetic elements to rotate the rotor.

Abstract: One variation of a system for an electric motor includes a rotor including magnetic elements within a body. The system also includes a stator including coil assemblies arranged about the rotor. Each coil assembly includes an outer hook element and an inner hook element. The outer hook element extends across a first axial face and an outer radial surface of the rotor. The inner hook element: extends across a second axial face of the rotor; extends partially across the inner radial surface of the rotor; and is coupled to the outer hook element to define a throat configured to locate the rotor within the coil assembly. The system includes a shaft coupled to the inner radial surface of the rotor. Furthermore, the system includes a controller configured to drive current through the coil assemblies to generate a toroidal magnetic field configured to couple the magnetic elements to rotate the rotor.

Abstract: Disclosed are various embodiments for winding heavy gauge coils of electric machines having fractional concentrated windings including one of more of positioning the middle of a predetermined length of heavy gauge wire in contact with an inclined chamfer in a face of a center projection of a fixture tool, simultaneously bending both ends of the heavy gauge wire in a first direction using the center projection to compete the first turn of the coil, simultaneously bending both ends of the heavy gauge wire in a seconding direction using the center projection to complete a second turn of the coil; continuing to simultaneously bend the heavy gauge wire in the first direction and the seconding direction until the required number of even or odd turns are completed, removing one of the adjoining right-angle faces of the fixture tool; and sliding the coiled heavy gauge wire off of the center projection.

Abstract: Disclosed are various embodiments for assembling a new and improved electrical motor/generator, specifically a method of producing a coil assembly is disclosed comprising: pressing a plurality of individual teeth having interlocking side features, applying a conductor around one of the interlocking side features, coupling a tooth of the coil assembly with an adjacent tooth, applying a second conductor around one of the interlocking side features of the adjacent tooth, repeating the coupling and applying steps until an entire ring has been assembled.

Abstract: Disclosed are various embodiments for a linear machine having a magnetic torque tunnel stator comprising an outer core assembly formed of a plurality of exterior permanent magnets couple to the inside retaining wall of a tube, where adjacent exterior permanent magnets are separated by an exterior ring spacer of ferromagnetic material, and an interior core assembly having a plurality of interior permanent magnets coupled to the outside wall of a central core, where adjacent interior permanent magnets are separated by an interior ring spacer of ferromagnetic material, the magnetic poles of the exterior and interior permanent magnets configured to face each other, and a coil winding assembly armature configured to be slidably positioned within the magnetic torque tunnel of the stator.

Abstract: Certain aspects relate to a continuous winding formed from a conductor of rectangular cross-section, the winding having a compound bend in the crowns connecting successive linear segments where the compound bend does not stress the conductor insulation to its failure point. The compound bend can be formed by applying force to the conductor in a first direction, thereby shaping a first bend in the conductor to form a u-shaped conductor having a crown and two linear segments, where the crown includes a v-shaped bend and two straight segments on either side of the v-shaped bend that each connect to one of the linear segments. A second bend can be formed by applying force to the conductor in a second direction perpendicular to the first direction. The shape of the second bend can depend on the desired radius of the winding when circularly wound and positioned in a stator.

Abstract: Integrated drive and motor assemblies are described herein. An example integrated drive and motor assembly includes an electric motor having a winding that concentrically surrounds an input drive shaft, an inverter for delivering power to the electric motor, a gearbox assembly coupled to the input drive shaft and an output drive shaft, the gearbox assembly having a planetary gear that includes a plurality of helical gears that couple with the input drive shaft and a ring gear. The planetary gear also includes a carrier that is rotatably coupled to the plurality of helical gears and transfers rotational forces to the output drive shaft. The assembly includes a housing that encloses the electric motor, the gearbox assembly, and the output shaft in co-axial alignment with respect to a central axis.

Abstract: A planetary gear system includes a ring gear supported by a housing, the ring gear having teeth on an inner sidewall of the ring gear, and a plurality of helical gears, each of the plurality of helical gears including a first cylindrical segment having teeth that are configured to mate with teeth of an input drive shaft, the teeth of the first cylindrical segment having helical teeth disposed at a first angle, and a second cylindrical segment extending from the first cylindrical segment, the second cylindrical segment having teeth configured to mate with teeth of the ring gear, the teeth of the second cylindrical segment having helical teeth disposed at a second angle. Advantageously, a linear axial force produced by each of the plurality of helical gears is substantially zero, which creates a thrust balancing within the planetary gear system.

Abstract: Integrated drive and motor assemblies are described herein. An example integrated drive and motor assembly includes an electric motor having a winding that concentrically surrounds an input drive shaft, an inverter for delivering power to the electric motor, a gearbox assembly coupled to the input drive shaft and an output drive shaft, the gearbox assembly having a planetary gear that includes a plurality of helical gears that couple with the input drive shaft and a ring gear. The planetary gear also includes a carrier that is rotatably coupled to the plurality of helical gears and transfers rotational forces to the output drive shaft. The assembly includes a housing that encloses the electric motor, the gearbox assembly, and the output shaft in co-axial alignment with respect to a central axis.

Abstract: Certain aspects relate to a continuous winding formed from a conductor of rectangular cross-section, the winding having a compound bend in the crowns connecting successive linear segments where the compound bend does not stress the conductor insulation to its failure point. The compound bend can be formed by applying force to the conductor in a first direction, thereby shaping a first bend in the conductor to form a u-shaped conductor having a crown and two linear segments, where the crown includes a v-shaped bend and two straight segments on either side of the v-shaped bend that each connect to one of the linear segments. A second bend can be formed by applying force to the conductor in a second direction perpendicular to the first direction. The shape of the second bend can depend on the desired radius of the winding when circularly wound and positioned in a stator.

Abstract: Thrust balanced planetary gear systems are described herein. An example planetary gear system includes a ring gear supported by a housing, the ring gear having teeth on an inner sidewall of the ring gear, and a plurality of helical gears, each of the plurality of helical gears including a first cylindrical segment having teeth that are configured to mate with teeth of an input drive shaft, the teeth of the first cylindrical segment having helical teeth disposed at a first angle, and a second cylindrical segment extending from the first cylindrical segment, the second cylindrical segment having teeth configured to mate with teeth of the ring gear, the teeth of the second cylindrical segment having helical teeth disposed at a second angle. Advantageously, a linear axial force produced by each of the plurality of helical gears is substantially zero, which creates a thrust balancing within the planetary gear system.