Abstract: A battery and ultracapacitor device for use in a vehicle includes a positive electrode, a first negative electrode, a second negative electrode, a first separator disposed between the positive electrode and the first and second negative electrodes, and a controller communicating with the positive electrode, the first negative electrode, and the second negative electrode. A first negative electrode has a first composition and communicates with the first positive electrode. The second negative electrode has a second composition and is adjacent to the first negative electrode and a second separator. The second negative electrode communicates with the positive electrode and the first negative electrode. The first negative electrode comprises a secondary battery negative electrode. The second negative electrode comprises an ultracapacitor negative electrode.

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.

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.

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.

Abstract: A method of controlling a vehicle including a permanent magnet (PM) synchronous motor is provided. The motor is controlled based on direct-axis (d-axis) and quadrature-axis (q-axis) current commands. The method includes estimating permanent magnet flux linkage based on q-axis voltage and electrical angular speed, and estimating permanent magnet temperature based on permanent magnet flux linkage and the temperature coefficient of the permanent magnet. The vehicle is controlled based on the estimated permanent magnet temperature.

Abstract: A battery and ultracapacitor device for use in a vehicle includes a positive electrode, a first negative electrode, a second negative electrode, a first separator disposed between the positive electrode and the first and second negative electrodes, and a controller communicating with the positive electrode, the first negative electrode, and the second negative electrode. A first negative electrode has a first composition and communicates with the first positive electrode. The second negative electrode has a second composition and is adjacent to the first negative electrode and a second separator. The second negative electrode communicates with the positive electrode and the first negative electrode. The first negative electrode comprises a secondary battery negative electrode. The second negative electrode comprises an ultracapacitor negative electrode.

Abstract: A method of controlling a vehicle including a permanent magnet (PM) synchronous motor is provided. The motor is controlled based on direct-axis (d-axis) and quadrature-axis (q-axis) current commands. The method includes estimating permanent magnet flux linkage based on q-axis voltage and electrical angular speed, and estimating permanent magnet temperature based on permanent magnet flux linkage and the temperature coefficient of the permanent magnet. The vehicle is controlled based on the estimated permanent magnet temperature.

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: 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.

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.

Abstract: A stabilized electric distribution system for use in a vehicle having electric assist. The system electrically couples an electric assist bus to an accessory load bus while protecting the first electrical bus from electric assist and regenerative braking induced voltage variations. An energy management controller selectively controls each of a electric motor/generator, a DC/DC converter, and an alternator to affect electric energy distribution within the system. Preferably, the electric energy distribution is controlled to maintain the first electrical bus voltage within a predefined voltage range.

Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: An electric machine made from kinetically sprayed permanent magnet material and a binder material form a composite admixture having microstructure of permanent magnet material embedded in the binder material. The admixture has a permanent magnetic moment. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A strategy to control and diagnose the operation of an electric motor using a sensorless control system augmented by feedback from a position and speed sensor is disclosed. The strategy can improve the robustness of operation and diagnose potential faults in electric motors. The present invention includes a method for diagnosing operation of an electric motor and a method and system for controlling an electric motor. In the diagnostic method, a sensorless system and a sensor based system are checked against each other to determine if either of the systems is faulted. In the control method, the sensor based control system is used when the motor speed is below a predetermined threshold and the sensorless system is used when the motor speed is above the predetermined threshold. The position sensor can be a low resolution position sensor, an engine crankshaft sensor, an engine camshaft sensor, or a transmission sensor.

Abstract: A stabilized electric distribution system for use in a vehicle having electric assist. The system electrically couples an electric assist bus to an accessory load bus while protecting the first electrical bus from electric assist and regenerative braking induced voltage variations. An energy management controller selectively controls each of a electric motor/generator, a DC/DC converter, and an alternator to affect electric energy distribution within the system. Preferably, the electric energy distribution is controlled to maintain the first electrical bus voltage within a predefined voltage range.

Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A strategy to control and diagnose the operation of an electric motor using a sensorless control system augmented by feedback from a position and speed sensor is disclosed. The strategy can improve the robustness of operation and diagnose potential faults in electric motors. The present invention includes a method for diagnosing operation of an electric motor and a method and system for controlling an electric motor. In the diagnostic method, a sensorless system and a sensor based system are checked against each other to determine if either of the systems is faulted. In the control method, the sensor based control system is used when the motor speed is below a predetermined threshold and the sensorless system is used when the motor speed is above the predetermined threshold. The position sensor can be a low resolution position sensor, an engine crankshaft sensor, an engine camshaft sensor, or a transmission sensor.

Abstract: A method of manufacturing a permanent magnet by the steps of preparing an admixture of magnetic material and binder material, the admixture material having a particle size of less than 325 mesh. Then heating a carrier gas to a temperature substantially below the melting point of either component of the admixture. The admixture is introduced into the carrier gas and the admixture is sprayed atop a ductile carrier. The admixture adheres to the carrier and forms a solid permanent magnet. An electric field is applied to the sprayed admixture to create a permanent magnetic moment.