Abstract: The present disclosure relates to electric motors. The electric motor assembly may include a rotor mounted coaxially on a shaft. The rotor may include a center lamination stack mounted on a balance ring. The center lamination stack may have slots along the outer circumference which hold pole pieces attached to a plurality of magnets. The magnets may be situated between the pole pieces and the center lamination stack. The magnets may not be fully enclosed by the metal body of the rotor. The described components of the rotor may be encased in a wound fiber sleeve. The rotor is rotably mounted within a stator.

Abstract: In various embodiments, aluminum alloys having yield strengths greater than 120 MPa, and typically in the range from 140 MPa to 175 MPa, are described. Further, such alloys can have electrical conductivity of greater than 45% IACS, typically in the range from 45-55% IACS. In one embodiment, the aluminum alloy comprises Si from 1 to 4.5 wt %, Mg from 0.3 to 0.5 wt %, TiB2 from 0.02 to 0.07 wt %, Fe less than 0.1 wt %, Zn less than 0.01 wt %, Cu less than 0.01 wt %, Mn less than 0.01 wt %, the remaining wt % being Al and incidental impurities. Such alloys can be used to cast a variety of automotive parts, including rotors, stators, busbars, inverters, and other parts.

Abstract: In various embodiments, aluminum alloys having yield strengths greater than 120 MPa, and typically in the range from 140 MPa to 175 MPa, are described. Further, such alloys can have electrical conductivity of greater than 45% IACS, typically in the range from 45-55% IACS. In one embodiment, the aluminum alloy comprises Si from 1 to 4.5 wt %, Mg from 0.3 to 0.5 wt %, TiB2 from 0.02 to 0.07 wt %, Fe less than 0.1 wt %, Zn less than 0.01 wt %, Cu less than 0.01 wt %, Mn less than 0.01 wt %, the remaining wt % being Al and incidental impurities. Such alloys can be used to cast a variety of automotive parts, including rotors, stators, busbars, inverters, and other parts.

Abstract: A high performance die castable aluminum alloy is described, wherein the aluminum alloy is characterized as having a high yield strength and high conductivity, and also a high flowability and low susceptibility to hot tearing when die cast.

Abstract: In various embodiments, aluminum alloys having yield strengths greater than 120 MPa, and typically in the range from 140 MPa to 175 MPa, are described. Further, such alloys can have electrical conductivity of greater than 45% IACS, typically in the range from 45-55% IACS. In one embodiment, the aluminum alloy comprises Si from 1 to 4.5 wt %, Mg from 0.3 to 0.5 wt %, TiB2 from 0.02 to 0.07 wt %, Fe less than 0.1 wt %, Zn less than 0.01 wt %, Cu less than 0.01 wt %, Mn less than 0.01 wt %, the remaining wt % being Al and incidental impurities. Such alloys can be used to cast a variety of automotive parts, including rotors, stators, busbars, inverters, and other parts.

Abstract: An improved fluid cooling arrangement for an electric machine, such as an electric motor, a generator, or a motor/generator assembly, is provided. In its most general sense, the fluid-cooled electric machine includes a rotor disposed on a motor shaft, a stator surrounding the rotor, and a motor housing surrounding the stator, with the stator formed of a laminated stack of stator plates that is plated at its outer surface.

Abstract: A stator arrangement for a balanced multiple voltage device operable as an electric motor, a generator, or a motor-generator includes a plurality of arc sectors configured so as to surround a rotor of the device. Each of the arc sectors includes a set of stator windings with at least one winding in each set. Those windings in pairs of the arc sectors located at diametrically opposed locations of the stator arrangement are concurrently energized and deenergized in order to eliminate load imbalance on the device.

Abstract: A rotor arrangement with decreased fluid flow impedance and improved rotary motor cooling is mountable on a shaft for rotation relative to the stator of a rotary motor arrangement The rotor arrangement has a plurality of laminations joined together to form a multilayer laminated rotor with a plurality of magnet receptacles. Each of the laminations has a solid central section surrounding an opening within which the shaft is receivable, spokes extending substantially radially outwardly from said solid central section, ribs interposed between adjacent spokes, and bridges interconnecting the spokes and ribs. At least some of the bridges are inset from an outer diameter of the lamination toward the solid central section to decrease fluid flow impedance and improve rotary motor cooling.

Abstract: A rotatable device, such as a pulley, includes an annular rotatable member having a bore extending therethrough and an outer surface disposed about the bore. A bearing is located in the bore. The bearing is operably connected to the annular rotatable member to form an axis of rotation about which the annular rotatable member can rotate relative to an inner race of the bearing. A combination dust cover and bearing retaining member spans the bore at a location spaced axially from the bearing. The cover includes a flange received by a groove extending outwardly from the bore in a direction toward the outer surface of the rotatable member to attach the combination dust cover and bearing retaining member to the rotatable member.