Abstract: A vehicle electric machine includes a rotor, and a stator having a core with an end face and end windings adjacent to the end face. An annular cooling trough has an outer sidewall and a bottom. The trough is connected to the end face such that the bottom engages the core, and the sidewall, bottom and end face cooperate to define an open channel around the end windings configured to receive fluid therein.

Abstract: An electric machine includes a stator with a core having an end face and a plurality of conductors forming windings that extend adjacent to the end face defining end turns having a toroidal outline. The end turns are formed to define at least one channel in the end turns that traverses the end turns for increasing a surface area for fluid contact and directing a flow of fluid along the toroidal surface.

Abstract: A vehicle electric machine may include a rotor. The rotor may cooperate with a stator including a core having an end face, and end windings extending from the end face. A cooling tunnel may encase the end windings, sealing against the end face at opposing sides of the end windings, and defining an inlet configured to receive coolant. The cooling tunnel may be arranged to contain the coolant during passage over the end windings and direct the coolant toward an outlet.

Abstract: An electric machine for a vehicle includes a stator having slots and a yolk region defining a plurality of channels extending between the opposing end faces of the stator. Windings extend through the slots and have end windings adjacent to the end faces. A rotor is disposed within the stator. The electric machine also includes first and second annular covers each defining a cavity having a plurality of walls partitioning the cavity into a plurality of cooling chambers that are circumferentially isolated from each other. Each of the covers is attached to one of the end faces such that a corresponding one of the end windings is disposed within one of the cavities, and such that each of the channels is in direct fluid communication with a corresponding one of the cooling chambers of the first cover and with a corresponding one of the cooling chambers of the second cover.

Abstract: An encasement of an electric machine of an electrified vehicle is provided. The encasement may include a base sidewall, an inner sidewall, and an outer sidewall. The inner sidewall may extend in a circular pattern about the base sidewall. The outer sidewall may extend from the base sidewall and may be spaced apart from the inner sidewall to define a coolant channel at least partially surrounding end windings of a stator of the electric machine. The base sidewall may define features between the sidewalls to promote turbulence of coolant flowing through the coolant channel. The base sidewall may define a meandering trough between the sidewalls to form a predetermined coolant path relative to a location of the end windings.

Abstract: A vehicle electric machine includes a stator having an end face and a yoke region defining a channel. End windings are adjacent to the end face. An annular cover has inner and outer walls defining an annular cavity configured to receive the end windings. The channel opens into the cavity, and a radial distance between the inner and outer walls is less than or equal to a radial length of the end face.

Abstract: A cover for a housing of an electric machine is provided. The cover may include an inner sidewall and an outer sidewall. The outer sidewall may be spaced apart from the inner sidewall to define a coolant channel therebetween. The inner sidewall and outer sidewall may be defined by an interior surface of the cover such that the coolant channel receives end windings of a stator of the electric machine when the cover is secured to the housing. The interior surface of the cover may define features between the sidewalls to promote turbulence of coolant flowing through the coolant channel. The interior surface of the cover may define a meandering trough between the sidewalls to form a predetermined coolant path relative to a location of the end windings when the cover is secured to the housing.

Abstract: A vehicle electric machine includes a rotor, and a stator having a core with an end face and end windings adjacent to the end face. An annular cooling trough has an outer sidewall and a bottom. The trough is connected to the end face such that the bottom engages the core, and the sidewall, bottom and end face cooperate to define an open channel around the end windings configured to receive fluid therein.

Abstract: An electric machine for an electrified vehicle is provided. The electric machine may include a stator, a ring plate, an encasement, and a fastener. The stator defines a cavity, a stator recess about a portion of the cavity, and a stator aperture. The stator may include windings disposed within and partially protruding out of the cavity. The ring plate may be sized for disposal within the stator recess, and may define a tab and a plate aperture for alignment with the stator aperture. The encasement may define a key sized for engagement with the tab to secure the encasement to the ring plate, and a closed coolant channel. The fastener may be sized for insertion within the apertures to secure the plate to the stator. The stator, ring plate, and encasement may be arranged with one another such that the partially protruding windings are disposed within the closed coolant channel.

Abstract: An electric machine rotor includes a lamination configured to rotate about a central axis and a plurality of pairs of permanent magnets. Each pair of permanent magnets is arranged in a V-shaped pattern and affixed within the lamination to create a magnetic field for rotation of the lamination. The lamination also includes an outer periphery spanning circumferentially outside of the permanent magnets, wherein a mass-reduction cutout extends through the lamination nested within in a V-shape defined by the permanent magnets adjacent to an outer surface of the rotor. The lamination further includes a stress-reduction slot that extends through the outer periphery of the rotor.

Abstract: A rotor may include a planar lamination having permanent magnets arranged therein, and an inner edge defining an opening configured to receive a driveshaft. The planar lamination may include a driveshaft key, and a relief notch and scallop disposed on each side of the driveshaft key. The relief notch and scallop may distribute stress imparted to the driveshaft key and reduce deformation due to centrifugal loads during rotation of the rotor. The relief notches may be next to the driveshaft key. The relief notches may be sandwiched between the scallops. The inner edge may include additional scallops.

Abstract: An electric machine may include a plurality of stator sections each formed from one or more stator laminations stacked to form a stator. The stator may have windings arranged therein to form magnetic poles. The stator may surround a rotor. A diamagnetic or paramagnetic stator layer may be interposed between at least one adjacent pair of the stator sections.

Abstract: An electric machine may include an adjacent pair of laminations each defining pockets having permanent magnets arranged therein to form magnetic poles. The laminations may be stacked in a pole-skewed fashion to form a portion of a rotor. A stator may surround the rotor. The machine may further include a separator lamination between the adjacent pair defining cutout portions having a shape based on a superposition of shapes of the pockets to increase a reluctance of leakage paths between the permanent magnets.

Abstract: An electric machine may include a plurality of sections each having permanent magnets arranged therein to form magnetic poles. The laminations may be stacked to form a rotor. A stator may surround the rotor. A non-magnetically permeable layer may be interposed between at least one adjacent pair of the sections that has skewed magnetic poles.

Abstract: An internal permanent magnet machine has multiple rotor sections, each section having multiple rotor laminations. Permanent magnets are placed asymmetrically in lamination openings to attenuate oscillations in torque caused by harmonic components of magnetic flux. Asymmetry is achieved by placing adjacent permanent magnets or magnet sets on the rotor periphery with different rotor magnetic pole arc angles.

Abstract: A system for controlling a vehicle, the vehicle including a permanent magnet (PM) synchronous motor, includes a controller. The controller is configured to control the motor with a motor current. In the presence of a predetermined condition, the motor current results in increased winding loss and reduced torque ripple with respect to optimal motor current for minimal winding loss.

Abstract: An internal permanent magnet machine has multiple rotor sections, each section having multiple rotor laminations. Permanent magnets are placed asymmetrically in lamination openings to attenuate oscillations in torque caused by harmonic components of magnetic flux. Asymmetry is achieved by placing adjacent permanent magnets or magnet sets on the rotor periphery with different rotor magnetic pole arc angles.

Abstract: An internal permanent magnet machine has multiple rotor sections, each section having multiple rotor laminations. Permanent magnets are placed asymmetrically in lamination openings to attenuate oscillations in torque caused by harmonic components of magnetic flux. Asymmetry is achieved by placing adjacent permanent magnets or magnet sets on the rotor periphery with different rotor magnetic pole arc angles.

Abstract: A stator for an electric machine has a circular stator body surrounding a rotor with an air gap therebetween. The stator has radially extending slots that define radially extending stator teeth. Multiple electric windings are located in the slots to define peripherally spaced magnetic poles. Separate coil groups establish multiple phases for the electric machine. Motor torque ripple is attenuated by forming the stator teeth with different widths for a given coil group.

Abstract: A system for controlling a vehicle, the vehicle including a permanent magnet (PM) synchronous motor, includes a controller. The controller is configured to control the motor with a motor current. In the presence of a predetermined condition, the motor current results in increased winding loss and reduced torque ripple with respect to optimal motor current for minimal winding loss.