Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to increase the velocity of the coolant exiting the axial coolant channels, thereby improving end winding cooling uniformity, end laminations are integrated into the stator which restrict the flow of coolant from the axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. The coolant manifold includes a middle member that allows coolant to enter the axial coolant channels via transition laminations, where the transition laminations include coolant distribution channels that direct the flow of coolant entering into the manifold into the stator-integrated axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to improve end winding cooling uniformity, two or more end laminations are included on either end of the stator assembly which restrict and direct the flow of coolant exiting the axial coolant channels.

Abstract: A gear assembly is provided that simplifies the integration of a differential assembly into the hollow rotor of an electric motor. The gear assembly utilizes a hollow cross member that includes a central portion and a plurality of hollow extension members onto which the gears are mounted. Within each of the hollow extension members is a pin. When the pins are withdrawn, the assembly fits unimpeded within the hollow rotor. When the pins are partially extended out of the corresponding extension members, the ends of the pins fit within apertures in the rotor. A plug fits within a centrally located thru-hole in the central portion of the hollow cross member, thereby locking the pins in the extended position and locking the gear assembly in place.

Abstract: A gear assembly is provided that simplifies the integration of a differential assembly into the hollow rotor of an electric motor. The gear assembly utilizes a hollow cross member that includes a central portion and a plurality of hollow extension members onto which the gears are mounted. Within each of the hollow extension members is a pin. When the pins are withdrawn, the assembly fits unimpeded within the hollow rotor. When the pins are partially extended out of the corresponding extension members, the ends of the pins fit within apertures in the rotor. A plug fits within a centrally located thru-hole in the central portion of the hollow cross member, thereby locking the pins in the extended position and locking the gear assembly in place.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. The coolant manifold includes a middle member that allows coolant to enter the axial coolant channels via transition laminations, where the transition laminations include coolant distribution channels that direct the flow of coolant entering into the manifold into the stator-integrated axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to increase the velocity of the coolant exiting the axial coolant channels, thereby improving end winding cooling uniformity, end laminations are integrated into the stator which restrict the flow of coolant from the axial coolant channels.

Abstract: An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to improve end winding cooling uniformity, two or more end laminations are included on either end of the stator assembly which restrict and direct the flow of coolant exiting the axial coolant channels.

Abstract: A stator assembly is provided that simplifies the process of coupling the stator windings to the winding lugs. The stator assembly includes a pre-fabricated connector that is attached to the stator via a plurality of stator winding terminations. The pre-fabricated connector includes a plurality of electrically conductive termination coupling members that form conductive pathways between at least a portion of the stator winding terminations and a plurality of bus bars, where each of the bus bars includes a lug. The pre-fabricated connector may also include a second plurality of electrically conductive termination coupling members that form conductive pathways between at least a second portion of the stator winding terminations and a plurality of lugless bus bars. An electrically insulating material is overlaid over portions of the connector ring, thereby preventing contact or partial discharge between the various bus bars.

Abstract: A gear assembly is provided that simplifies the integration of a differential assembly into the hollow rotor of an electric motor. The gear assembly utilizes a hollow cross member that includes a central portion and a plurality of hollow extension members onto which the gears are mounted. Within each of the hollow extension members is a pin. When the pins are withdrawn, the assembly fits unimpeded within the hollow rotor. When the pins are partially extended out of the corresponding extension members, the ends of the pins fit within apertures in the rotor. A plug fits within a centrally located thru-hole in the central portion of the hollow cross member, thereby locking the pins in the extended position and locking the gear assembly in place.

Abstract: A method of manufacturing an electric motor that includes a plurality of structural cooling features is provided, where the electric motor utilizes axial cooling channels integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack. A coolant manifold assembly, incorporated into the stator between left and right stator portions, provides a means of distributing coolant to the axial cooling channels.

Abstract: A stator assembly is provided that simplifies the process of coupling the stator windings to the winding lugs. The stator assembly includes a pre-fabricated connector that is attached to the stator via a plurality of stator winding terminations. The pre-fabricated connector includes a plurality of electrically conductive termination coupling members that form conductive pathways between at least a portion of the stator winding terminations and a plurality of bus bars, where each of the bus bars includes a lug. The pre-fabricated connector may also include a second plurality of electrically conductive termination coupling members that form conductive pathways between at least a second portion of the stator winding terminations and a plurality of lugless bus bars. An electrically insulating material is overlaid over portions of the connector ring, thereby preventing contact or partial discharge between the various bus bars.

Abstract: A powertrain utilizing an active core motor with coaxially aligned planetary-differential-planetary gear assemblies is provided.

Abstract: A rotor fabrication method is provided. The rotor uses pre-fabricated conductive rotor bars in which the ends have been shaped and sized to fit within corresponding end cap receptacles. After assembly, the structure is compressed, thereby achieving mechanical and electrical coupling between the conductive rotor bars and the end caps. Locking members disposed at either end of the assembly maintain the desired level of axial compressive force on the structure.

Abstract: A powertrain utilizing an active core motor with coaxially aligned planetary-differential-planetary gear assemblies is provided.

Abstract: A gear assembly is provided that simplifies the integration of a differential assembly into the hollow rotor of an electric motor. The gear assembly utilizes a hollow cross member that includes a central portion and a plurality of hollow extension members onto which the gears are mounted. Within each of the hollow extension members is a pin. When the pins are withdrawn, the assembly fits unimpeded within the hollow rotor. When the pins are partially extended out of the corresponding extension members, the ends of the pins fit within apertures in the rotor. A plug fits within a centrally located thru-hole in the central portion of the hollow cross member, thereby locking the pins in the extended position and locking the gear assembly in place.

Abstract: A rotor fabrication method is provided. The rotor uses pre-fabricated conductive rotor bars in which the ends have been shaped and sized to fit within corresponding end cap receptacles. After assembly, the structure is compressed, thereby achieving mechanical and electrical coupling between the conductive rotor bars and the end caps. Locking members disposed at either end of the assembly maintain the desired level of axial compressive force on the structure.

Abstract: A method of manufacturing an electric motor that includes a plurality of structural cooling features is provided, where the electric motor utilizes axial cooling channels integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack. A coolant manifold assembly, incorporated into the stator between left and right stator portions, provides a means of distributing coolant to the axial cooling channels.

Abstract: A method of cooling an electric motor is provided utilizing axial cooling channels that are integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack and providing an efficient means of removing motor assembly heat. Additionally, as the coolant flows out of the cooling channels it impinges on the end windings, thereby providing a secondary means of cooling the motor assembly.

Abstract: An electric motor cooling system is provided utilizing axial cooling channels that are integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack and providing an efficient means of removing motor assembly heat. Additionally, as the coolant flows out of the cooling channels it impinges on the end windings, thereby providing a secondary means of cooling the motor assembly.