Abstract: A two-stage eutectic metal brush assembly having a slip ring rigidly coupled to a shaft, the slip ring being electrically coupled to first voltage polarity. At least one brush is rigidly coupled to a second ring and slidingly engaged to the slip ring. Eutectic metal at least partially fills an annulus between the second ring and a stationary ring. At least one conductor is rigidly coupled to the stationary ring and electrically coupled to a second voltage polarity. Electrical continuity is maintained between the first voltage polarity and the second voltage polarity. Periodic rotational motion is present between the stationary ring and the second ring. Periodic rotational motion is also present between the brush and the slip ring.

Abstract: Two new High Slot Utilization (HSU) Systems for electric machines enable the use of form wound coils that have the highest fill factor and the best use of magnetic materials. The epoxy/resin/curing treatment ensures the mechanical strength of the assembly of teeth, core, and coils. In addition, the first HSU system allows the coil layers to be moved inside the slots for the assembly purpose. The second system uses the slided-in teeth instead of the plugged-in teeth. The power density of the electric machine that uses either system can reach its highest limit.

Abstract: A permanent magnet-less synchronous system includes a stator that generates a magnetic revolving field when sourced by an alternating current. An uncluttered rotor is disposed within the magnetic revolving field and spaced apart from the stator to form an air gap relative to an axis of rotation. The rotor includes a plurality of rotor pole stacks having an inner periphery biased by single polarity of a north-pole field and a south-pole field, respectively. The outer periphery of each of the rotor pole stacks are biased by an alternating polarity.

Abstract: A method and apparatus in which a rotor (11) and a stator (17) define a radial air gap (20) for receiving AC flux and at least one DC excitation coil (23, 24) positioned near the stator end turn to produce DC flux in axial air gaps (21, 22) additive to the AC flux. Side magnets (16) and flux-guiding magnets (14) are provided as boundaries separating the side poles (12a, 12b) of opposite polarity from other portions of the rotor (11) and from each other to define PM poles (12a, 12b) for conveying the DC flux to or from the primary air gap (20) and for inhibiting flux from leaking from said pole portions prior to reaching the primary air gap (20). Side magnets (16), side poles (12a and 12b), flux-guiding magnets (14), ferromagnetic end plates (11c), non-magnetic end plates (12c), and ring bands (37) are optionally provided for performance improvement.

Abstract: An electric machine (10) has a disk-shaped rotor (24) disposed in an operating space between two opposing stator assemblies (11, 12) to provide two axial air gaps (15, 16). The rotor (24) has a hub (28) and an outer ring (26) of non-magnetic material and is further provided with a plurality of permanent magnetic elements (25) for coupling flux that is induced by the magnetic field of the stator assemblies (11, 12). The permanent magnetic elements (25) are spaced apart and reluctance poles (27) are positioned in spaces between the magnetic elements (25) to couple additional flux induced by the magnetic field of the stator assemblies (11, 12). Various constructions and shapes (40-45) for the PM magnetic elements (25) are disclosed, and including PM covers (60) of ferromagnetic material for enhancing q-axis flux in the air gaps (15, 16) and for reducing harmonics where toothed stators are used. Methods of providing increased torque using the the various rotor constructions are also disclosed.

Abstract: A power system for a motor vehicle having an internal combustion engine, the power system comprises an electric machine (12) further comprising a first excitation source (47), a permanent magnet rotor (28) and a magnetic coupling rotor (26) spaced from the permanent magnet rotor and at least one second excitation source (43), the magnetic coupling rotor (26) also including a flywheel having an inertial mass to store kinetic energy during an initial acceleration to an operating speed; and wherein the first excitation source is electrically connected to the second excitation source for power cycling such that the flywheel rotor (26) exerts torque on the permanent magnet rotor (28) to assist braking and acceleration of the permanent magnet rotor (28) and consequently, the vehicle. An axial gap machine and a radial gap machine are disclosed and methods of the invention are also disclosed.

Abstract: The invention is a terminal assembly having a casing with at least one delivery tapered-cone conductor and at least one return tapered-cone conductor routed there-through. The delivery and return tapered-cone conductors are electrically isolated from each other and positioned in the annuluses of ordered concentric cones at an off-normal angle. The tapered cone conductor service can be AC phase conductors and DC link conductors. The center core has at least one service conduit of gate signal leads, diagnostic signal wires, and refrigerant tubing routed there-through. A seal material is in direct contact with the casing inner surface, the tapered-cone conductors, and the service conduits thereby hermetically filling the interstitial space in the casing interior core and center core. The assembly provides simultaneous high-current, high-pressure, low-inductance, and high-reliability service.

Abstract: The invention is a direct contact refrigerant cooling system using a refrigerant floating loop having a refrigerant and refrigeration devices. The cooling system has at least one hermetic container disposed in the refrigerant floating loop. The hermetic container has at least one electronic component selected from the group consisting of capacitors, power electronic switches and gating signal module. The refrigerant is in direct contact with the electronic component.

Abstract: A two-stage eutectic metal brush assembly having a slip ring rigidly coupled to a shaft, the slip ring being electrically coupled to first voltage polarity. At least one brush is rigidly coupled to a second ring and slidingly engaged to the slip ring. Eutectic metal at least partially fills an annulus between the second ring and a stationary ring. At least one conductor is rigidly coupled to the stationary ring and electrically coupled to a second voltage polarity. Electrical continuity is maintained between the first voltage polarity and the second voltage polarity. Periodic rotational motion is present between the stationary ring and the second ring. Periodic rotational motion is also present between the brush and the slip ring.

Abstract: A cascaded die mounting device and method using spring contacts for die attachment, with or without metallic bonds between the contacts and the dies, is disclosed. One embodiment is for the direct refrigerant cooling of an inverter/converter carrying higher power levels than most of the low power circuits previously taught, and does not require using a heat sink.

Abstract: A method for cooling vehicle components using the vehicle air conditioning system comprising the steps of: tapping the hot liquid refrigerant of said air conditioning system, flooding a heat exchanger in the vehicle component with said hot liquid refrigerant, evaporating said hot liquid refrigerant into hot vapor refrigerant using the heat from said vehicle component, and returning said hot vapor refrigerant to the hot vapor refrigerant line in said vehicle air conditioning system.

Abstract: An electric machine (40) has a stator (43), a permanent magnet rotor (38) with permanent magnets (39) and a magnetic coupling uncluttered rotor (46) for inducing a slip energy current in secondary coils (47). A dc flux can be produced in the uncluttered rotor when the secondary coils are fed with dc currents. The magnetic coupling uncluttered rotor (46) has magnetic brushes (A, B, C, D) which couple flux in through the rotor (46) to the secondary coils (47c, 47d) without inducing a current in the rotor (46) and without coupling a stator rotational energy component to the secondary coils (47c, 47d). The machine can be operated as a motor or a generator in multi-phase or single-phase embodiments and is applicable to the hybrid electric vehicle. A method of providing a slip energy controller is also disclosed.

Abstract: A radial gap brushless electric machine (30) having a stator (31) and a rotor (32) and a main air gap (34) also has at least one stationary excitation coil (35a, 36a) separated from the rotor (32) by a secondary air gap (35e, 35f, 36e, 36f) so as to induce a secondary flux in the rotor (32) which controls a resultant flux in the main air gap (34). Permanent magnetic (PM) material (38) is disposed in spaces between the rotor pole portions (39) to inhibit the second flux from leaking from the pole portions (39) prior to reaching the main air gap (34). By selecting the direction of current in the stationary excitation coil (35a, 36a) both flux enhancement and flux weakening are provided for the main air gap (34). A method of non-diffused flux enhancement and flux weakening for a radial gap machine is also disclosed.

Abstract: A power supply generates alternating current and direct current from a constant-voltage source. A multi-phase pulse width modulation voltage source inverter is connected across the source to output multi-phase alternating current. At least one waveform generator is bridged in parallel with the inverter, with each waveform generator outputting zero-sequence waveform current compensated to maintain the multi-phase current within a predetermined tolerance from a desired set point. A rectifier receives the waveform current and generates direct current.

Abstract: An electric machine drive (50) has a plurality of inverters (50a, 50b) for controlling respective electric machines (57, 62), which may include a three-phase main traction machine (57) and two-phase accessory machines (62) in a hybrid or electric vehicle. The drive (50) has a common control section (53, 54) for controlling the plurality of inverters (50a, 50b) with only one microelectronic processor (54) for controlling the plurality of inverters (50a, 50b), only one gate driver circuit (53) for controlling conduction of semiconductor switches (S1–S10) in the plurality of inverters (50a, 50b), and also includes a common dc bus (70), a common dc bus filtering capacitor (C1) and a common dc bus voltage sensor (67). The electric machines (57, 62) may be synchronous machines, induction machines, or PM machines and may be operated in a motoring mode or a generating mode.

Abstract: A floating loop vehicle component cooling and air-conditioning system having at least one compressor for compressing cool vapor refrigerant into hot vapor refrigerant; at least one condenser for condensing the hot vapor refrigerant into hot liquid refrigerant by exchanging heat with outdoor air; at least one floating loop component cooling device for evaporating the hot liquid refrigerant into hot vapor refrigerant; at least one expansion device for expanding the hot liquid refrigerant into cool liquid refrigerant; at least one air conditioning evaporator for evaporating the cool liquid refrigerant into cool vapor refrigerant by exchanging heat with indoor air; and piping for interconnecting components of the cooling and air conditioning system.

Abstract: A radial gap brushless electric machine (30) having a stator (31) and a rotor (32) and a main air gap (34) also has at least one stationary excitation coil (35a, 36a) separated from the rotor (32) by a secondary air gap (35e, 35f, 36e, 36f) so as to induce a secondary flux in the rotor (32) which controls a resultant flux in the main air gap (34). Permanent magnetic (PM) material (38) is disposed in spaces between the rotor pole portions (39) to inhibit the second flux from leaking from the pole portions (39) prior to reaching the main air gap (34). By selecting the direction of current in the stationary excitation coil (35a, 36a) both flux enhancement and flux weakening are provided for the main air gap (34). Improvements of a laminated rotor, an end pole structure, and an arrangement of the PM elements for providing an arrangement of the flux paths from the auxiliary field coil assemblies are also disclosed.

Abstract: An electric machine (40) has a stator (43), a permanent magnet rotor (38) with permanent magnets (39) and a magnetic coupling uncluttered rotor (46) for inducing a slip energy current in secondary coils (47). A dc flux can be produced in the uncluttered rotor when the secondary coils are fed with dc currents. The magnetic coupling uncluttered rotor (46) has magnetic brushes (A, B, C, D) which couple flux in through the rotor (46) to the secondary coils (47c, 47d) without inducing a current in the rotor (46) and without coupling a stator rotational energy component to the secondary coils (47c, 47d). The machine can be operated as a motor or a generator in multi-phase or single-phase embodiments and is applicable to the hybrid electric vehicle. A method of providing a slip energy controller is also disclosed.

Abstract: A method and apparatus in which a rotor (11) and a stator (17) define a radial air gap (20) for receiving AC flux and at least one, and preferably two, DC excitation assemblies (23, 24) are positioned at opposite ends of the rotor (20) to define secondary air gaps (21, 22). Portions of PM material (14a, 14b) are provided as boundaries separating the rotor pole portions (12a, 12b) of opposite polarity from other portions of the rotor (11) and from each other to define PM poles (12a, 12b) for conveying the DC flux to or from the primary air gap (20) and for inhibiting flux from leaking from the pole portions prior to reaching the primary air gap (20). The portions of PM material (14a, 14b) are spaced from each other so as to include reluctance poles (15) of ferromagnetic material between the PM poles (12a, 12b) to interact with the AC flux in the primary-air gap (20).

Abstract: A cascaded die mounting device and method using spring contacts for die attachment, with or without metallic bonds between the contacts and the dies, is disclosed. One embodiment is for the direct refrigerant cooling of an inverter/converter carrying higher power levels than most of the low power circuits previously taught, and does not require using a heat sink.