Abstract: An electric machine includes a stator core defining circumferentially arranged slots alternating between odd and even slots. Each slot has radial pin positions arranged in adjacent pairs to define radial layers. A hairpin winding includes a first path of interconnected hairpins that is disposed in the stator core such that, for each of the radial layers, the first path is disposed in the odd slots and the even slots a same number of times.

Abstract: An electric machine includes an outer housing and a stator secured to the outer housing and configured to induce an electromagnetic field. The electric machine also includes a rotor configured to output rotational movement in response to the electromagnetic field of the stator. The electric machine further includes at least one retention key configured to cooperate with a retention feature of the stator to engage a channel of the outer hosing to generate a circumferential force to resist movement of the stator relative to the housing.

Abstract: An electrified vehicle assembly includes, among other things, an outer shaft that is rotatable about an axis. The outer shaft rotatably couples a motor of an electrified vehicle to a transmission component of the electrified vehicle. A shaft insert provides a conduit for a fluid and that blocks the fluid from flowing radially between the shaft insert and the outer shaft relative to the axis. The shaft insert includes a polymer-based material, a composite material, or both.

Abstract: An electric machine includes a rotor including a channel defined between a pair of magnets and a bridge assembly within the channel. The bridge assembly includes a bridge element and a spring arranged to bias the bridge element toward a center of the rotor such that responsive to spinning of the rotor, the bridge element moves radially away from the center against a force of the spring to alter a magnetic flux pattern associated with the magnets.

Abstract: An electric machine includes a stator core defining slots and a hairpin winding path disposed in the slots. The winding path includes first and second hairpins having legs with same slot spans and twist with same slot spans. The hairpins are installed in the core such that one of the twists of the first hairpin crisscrosses with one of the twists of the second hairpin. A reverse jumper joins the twists that crisscross.

Abstract: An electric machine includes a stator core defining circumferentially arranged slots alternating between odd and even slots. Each slot has radial pin positions arranged in adjacent pairs to define radial layers. A hairpin winding includes a first path of interconnected hairpins that is disposed in the stator core such that, for each of the radial layers, the first path is disposed in the odd slots and the even slots a same number of times.

Abstract: An electric machine includes an outer housing and a stator secured to the outer housing and configured to induce an electromagnetic field. The electric machine also includes a rotor configured to output rotational movement in response to the electromagnetic field of the stator. The electric machine further includes at least one retention key configured to cooperate with a retention feature of the stator to engage a channel of the outer hosing to generate a circumferential force to resist movement of the stator relative to the housing.

Abstract: An electric machine assembly including a housing and a stator is provided. The housing may define a cavity and an inner surface having pockets spaced radially about a housing central axis. The stator may be disposed within the cavity and define an outer surface having tabs spaced from one another radially about a stator central axis and each tab including opposing circumferential sides. The housing and stator may be arranged with one another such that each of the opposing circumferential sides contacts a side of a respective pocket to create interference therebetween. Each tab may further include a tab outer surface and each of the pockets may be sized such that a space is defined between each tab outer surface and a respective pocket side.

Abstract: An electric machine includes a stator core defining slots and a hairpin winding path disposed in the slots. The winding path includes first and second hairpins having legs with same slot spans and twist with same slot spans. The hairpins are installed in the core such that one of the twists of the first hairpin crisscrosses with one of the twists of the second hairpin. A reverse jumper joins the twists that crisscross.

Abstract: An electric machine includes a stator core having integrally formed resilient features circumferentially arranged around an outer diameter of the core and a cylindrical housing receiving the core with the resilient features disposed against an inner diameter of the housing. The outer diameter is larger than the inner diameter to form an interference fit between the core and housing, and the resilient features are configured to radially displace responsive to the inner diameter shrinking.

Abstract: An electric machine includes a stator core, a cylindrical housing circumscribing the core, and an annular compressible layer. The annular compressible layer is received on the core and has an outer surface disposed against the housing. A diameter of the outer surface is larger than a diameter of an inner surface of the core to form an interference fit between the housing and the compressible layer.

Abstract: An electric machine includes a cylindrical stator core and a cylindrical housing having an inner diameter. The core has an outer surface and a plurality of projections extending therefrom. An outer diameter of the core measured between tips of diametrically opposing projections is greater than the inner diameter. The core is disposed in the housing with the tips engaging the inner diameter to create an interference fit between the core and housing to reduce housing resonance.

Abstract: An electric machine is provided. The electric machine may include a rotor disposed on a shaft and an endplate. The endplate may define a coolant capture ring. The coolant capture ring may have tapered side walls that extend from an outer portion of the endplate toward the shaft at a periphery thereof. The coolant capture ring may be configured to deflect coolant captured by the coolant capture ring and expelled by the shaft due to centrifugal forces associated with the rotation of the shaft.

Abstract: An electric machine may include a plurality of sections, each defining a permanent magnet pocket and a field formation chamber. The sections may be stacked to form a rotor such that when walls of the permanent magnet pockets are aligned from end to end, walls of the chambers of at least some of the sections are offset. An adjacent pair of the sections may have different chamber to pocket relative positions to define different pole arc angles. A difference between the first pole arc angle and the second pole arc angle may be equal to a slot pitch of a stator of the electric machine. The slot pitch may be 7.5 mechanical degrees. The chamber may be defined on a radially outward edge of the pocket. The chamber may taper in a radially outward direction.

Abstract: A vehicle electric machine assembly including a stator core, a rotor, and a bridge is provided. The stator core defines a cavity. The rotor is disposed within the cavity and may include a channel defined between two magnets. The bridge is disposed within the channel for translation between at least a first and a second position. The translation of the bridge adjusts a path of magnetic flux from the rotor to the stator core based on the bridge position. The bridge may be of a ferromagnetic material. The assembly may further include a first non-magnetic guide mounted on a first side of the channel at a substantially central channel region and a second magnetic guide mounted on a second side of the channel at the substantially central channel region.

Abstract: An electric machine includes a rotor including a channel defined between a pair of magnets and a bridge assembly within the channel. The bridge assembly includes a bridge element and a spring arranged to bias the bridge element toward a center of the rotor such that responsive to spinning of the rotor, the bridge element moves radially away from the center against a force of the spring to alter a magnetic flux pattern associated with the magnets.

Abstract: An electrified vehicle assembly includes, among other things, an outer shaft that is rotatable about an axis. The outer shaft rotatably couples a motor of an electrified vehicle to a transmission component of the electrified vehicle. A shaft insert provides a conduit for a fluid and that blocks the fluid from flowing radially between the shaft insert and the outer shaft relative to the axis. The shaft insert includes a polymer-based material, a composite material, or both.

Abstract: An exemplary shaft assembly includes an outer shaft rotatable about an axis, and a shaft insert that provides a conduit for a fluid and blocks the fluid from flowing radially between the shaft insert and the outer shaft relative to the axis. An exemplary shaft assembling method includes positioning a shaft insert within an outer shaft. The shaft insert has a fluid conduit and is configured to block fluid from communicating radially between the shaft insert and the outer shaft.

Abstract: An electric machine is disclosed. The electric machine may include a rotor and an endplate. The endplate may define an aperture, an inner locknut surface and a balance-ring surface. The locknut surface may extend from a periphery of the aperture to a first diameter. The balance-ring surface may extend from a second diameter that is greater than the first diameter to an outer periphery of the endplate. Before assembly, the balance-ring surface may be adjacent to the rotor and the locknut surface may be spaced apart from the rotor.

Abstract: A vehicle electric machine assembly including a stator core, a rotor, and a bridge is provided. The stator core defines a cavity. The rotor is disposed within the cavity and may include a channel defined between two magnets. The bridge is disposed within the channel for translation between at least a first and a second position. The translation of the bridge adjusts a path of magnetic flux from the rotor to the stator core based on the bridge position. The bridge may be of a ferromagnetic material. The assembly may further include a first non-magnetic guide mounted on a first side of the channel at a substantially central channel region and a second magnetic guide mounted on a second side of the channel at the substantially central channel region.