Abstract: An electric drive unit having a stator, a rotor received in the stator and rotatable about a central longitudinal axis, and an inverter assembly that includes a plurality of power semiconductors, a plurality of heat sinks and an end plate. The power semiconductors are thermally coupled to the heat sinks. Each of the heat sinks has a plurality of fins that extend into a flow channel that is coaxial with the plurality of sets of field windings. The end plate is coupled to the power semiconductors and has a projection, which is sealingly coupled to the stator and which and partly defines an annular cavity, and a coolant port that is coupled in fluid communication with the annular cavity. The flow channel is in fluid communication with and disposed in a flow path between the annular cavity and the cooling channels in the stator body.

Abstract: An electric drive unit having a multi-phase electric motor and an inverter with a plurality of power semiconductors, an inverter mount, and a plurality of busbars. The power semiconductors are mounted to the base of the inverter mount in an annular arrangement and with the terminals of the power semiconductors extending through the base. Each of the busbars has a first busbar portion, which includes a first body and a set of first fingers that are fixedly coupled to the first body, and a second busbar portion that includes a second body and a set of second fingers that are fixedly coupled to the second body. Associated fingers in the first and second sets of fingers of each bus bar are mechanically and electrically coupled to opposite sides of a corresponding one of the terminals.

Abstract: A drive system with one or more electrically driven axles, a transmission subsystem, which is drivingly coupled to a drive gearbox of each of the electrically driven axles, first and second motors, which are each drivingly coupled to the transmission subsystem and have different motor characteristics, and a controller. The drive gearbox of each axle transmits rotary power to an associated set of vehicle wheels. The controller controls the first and second motors responsive to at least a torque request. Over a significant portion of the operating range of the drive system, the controller is configured to vary the respective magnitudes of the rotary power provided by the first and second motors to satisfy the torque request in a manner that maximizes a combined efficiency of the motors in a predetermined manner.

Abstract: An electric motor with a stator that is formed of a plurality of distinct laminations. Each of the distinct laminations has a radially inner lamination edge, which borders a rotor aperture configured to receive a rotor therein, a radially outer lamination edge and a plurality of cooling apertures formed there through that are disposed radially between the radially inner and outer lamination edges. Each cooling aperture in a lamination forms part of a separate and distinct cooling channel that extends helically through the laminations about a rotational axis of the electric motor.

Abstract: An electric drive module having a motor and an inverter that are disposed in a housing The motor includes a stator, which has a plurality of sets of windings. The inverter has a plurality of power semiconductors, which are mounted into a retaining member, an end plate, which is sealingly coupled to the retaining member, and an inlet port that extends through the end plate. Sets of the semiconductor devices are electrically coupled to corresponding sets of the windings. Power terminals on the semiconductor devices are coupled to a heat sink. Fins on the heat sinks extend into an annular region that is adjacent to axial ends of the windings. At least one of the retaining member and the end plate is sealingly coupled to the housing assembly. The inlet port, the annular region and cooling passages in the stator are coupled in fluid communication.

Abstract: An electric drive module having a motor and an inverter that are disposed in a housing The motor includes a stator, which has a plurality of sets of windings. The inverter has a plurality of power semiconductors, which are mounted into a retaining member, an end plate, which is sealingly coupled to the retaining member, and an inlet port that extends through the end plate. Sets of the semiconductor devices are electrically coupled to corresponding sets of the windings. Power terminals on the semiconductor devices are coupled to a heat sink. Fins on the heat sinks extend into an annular region that is adjacent to axial ends of the windings. At least one of the retaining member and the end plate is sealingly coupled to the housing assembly. The inlet port, the annular region and cooling passages in the stator are coupled in fluid communication.

Abstract: An electric motor with a stator that is formed of a plurality of laminations. Each of the laminations has a radially inner lamination edge, which borders a rotor aperture configured to receive a rotor therein, and a radially outer lamination edge. Each of the laminations has a plurality of cooling apertures formed there through. The cooling apertures formed in a given one of the laminations are disposed radially between the radially outer lamination edge and the radially inner lamination edge. Each of the laminations is sealingly coupled to at least one other lamination. Each cooling aperture in a lamination forms part of a distinct cooling channel that extends along an axial length of the stator. At least a portion of the cooling apertures in each of the cooling channels are staggered circumferentially about a motor axis of the electric motor.

Abstract: A method of forming a rotor includes inserting a conductor bar into a slot defined by a lamination stack to define a gap between the conductor bar and the lamination stack. The method further includes, after inserting, swelling the conductor bar within the slot to fill the gap and form the rotor. A rotor is also disclosed.

Abstract: A method of forming a rotor includes inserting a conductor bar into a slot defined by a lamination stack to define a gap between the conductor bar and the lamination stack. The method further includes, after inserting, swelling the conductor bar within the slot to fill the gap and form the rotor. A rotor is also disclosed.

Abstract: A BAS machine that includes a specific combination of the number of stator slots to the number of rotor bars to reduce torque ripple without the need for skewing the rotor bars. Particularly, the ratio of the number of stator slots to the number of rotor bars is selected to prevent first and second order harmonics between the stator slots and the rotor bars, where the ratio includes 36/26, 54/44, 72/56, 72/58 or 72/62 for a six pole machine, 48/36, 72/52, 72/58 or 84/86 for an eight pole machine, and 60/44 or 60/46 for a ten pole machine.

Abstract: A stator assembly comprises a stator defining S slots. First and second windings are arranged in each of the S slots. The two windings have a width in a radial direction and a thickness in a direction perpendicular to the radial direction. A ratio of the width to the thickness is between 3.0:1 and 4.5:1.

Abstract: A permanent magnet motor includes a permanent magnet rotor, a stator surrounding the rotor having a plurality of teeth radially inwardly oriented toward a longitudinal axis of the stator wherein each tooth has a tooth length and a tooth tip surface geometry. An asymmetric air gap is defined by variations in the tooth lengths and tooth tip surface geometries.

Abstract: An electric machine includes a stator core defining a number of stator slots (S) extending along a longitudinal axis and angularly spaced about the longitudinal axis. The machine includes a rotor assembly rotatable relative to the stator core and defining first and second ends. The rotor assembly includes a plurality of laminations stacked between the first and second ends. Each respective one of the plurality of laminations defines a number of rotor slots (R) positioned along an outer periphery. A stator slot pitch is defined as 360 divided by the number of stator slots (S). A rotor slot pitch is defined as 360 divided by the number of rotor slots (R) in each respective one of the plurality of laminations. The laminations are skewed relative to each other. An optimal rotor skew angle is determined by the greater of the stator slot pitch and rotor slot pitch.

Abstract: A rotor for a permanent magnet electric machine includes an axis of rotation, an outer surface, and a cross-section orthogonal to the axis of rotation with a non-circular contour of the outer surface defined by a plurality of radii angularly distributed around the axis of rotation.

Abstract: An electric machine is provided with a rotor core rotatable about a central axis. A first end ring is operatively connected to one end of the rotor core. A first housing component at least partially encloses the rotor core. At least one first rotor fin extends from the first end ring in a first direction which may be substantially parallel to the central axis. At least one first housing fin extends from the first housing component in a second direction that is substantially opposite to the first direction. The first rotor and housing fins extend circumferentially around the central axis. The first rotor fin and the first housing fin are configured to interleave, thereby enhancing heat transfer between the first rotor and housing fin, and cooling the rotor core.

Abstract: An insulator assembly for a stator assembly of an electric machine includes an annular ring attached to a stator core, and a plurality of coil separators supported by the annular ring and extending from the annular ring axially along a longitudinal axis. One of the coil separators is disposed between each adjacent pair of the coils to prevent contact between adjacent coils having a different electrical phase. The coil separators are slideably inserted between the adjacent pairs of coils, with the annular ring positioning and supporting the coil separators.

Abstract: A stir-welded rotor includes a stack of laminations, where each of the laminations defines a plurality of spaced-apart slots arrayed on an outer circumference. A conductor bar may be registered with each of the spaced-apart slots of the stack of laminations, with each conductor bar including a first metal portion and a second metal portion having substantially dissimilar compositions.

Abstract: A rotor for a permanent magnet electric machine includes an axis of rotation, an outer surface, and a cross-section orthogonal to the axis of rotation with a non-circular contour of the outer surface defined by a plurality of radii angularly distributed around the axis of rotation.

Abstract: A stator assembly includes a stator stack and a plurality of lead conductors extending from the stator stack. A plurality of conductor terminals are each connected to a respective one of the plurality of lead conductors. A plurality of wires are each connected to a respective one of the plurality of conductor terminals and a plurality of phase lead connection terminals are each connected to at least one of the plurality of wires.

Abstract: An insulator assembly for a stator assembly of an electric machine includes an annular ring attached to a stator core, and a plurality of coil separators supported by the annular ring and extending from the annular ring axially along a longitudinal axis. One of the coil separators is disposed between each adjacent pair of the coils to prevent contact between adjacent coils having a different electrical phase. The coil separators are slideably inserted between the adjacent pairs of coils, with the annular ring positioning and supporting the coil separators.