Abstract: An electrical machine stator can include a stator core having a stator core shape and made of a core material, a plurality of windings disposed in the stator core and made of a conductive material, and an insulative material surrounding the plurality of windings and configured to electrically insulate each winding from each other adjacent winding, and/or to insulate one or more of the windings from the stator core. The insulative material can be an amorphous metal.

Abstract: An electric motor system implements a redundant wye-wounded motor that includes first phase leads, second phase leads, first neutral leads, and second neutral leads. The first and second phase leads receive alternating current (AC) power from a power supply. A first phase-lead switch selectively connects the first phase leads to the power supply, and a second phase-lead switch selectively connects the second phase leads to the power supply. A first neutral-lead switch selectively connects the first neutral leads to the redundant wye-wounded motor, and a second neutral-lead switch selectively connects the second neutral leads to the redundant wye-wounded motor. A controller detects a circuit fault among a plurality of different types of circuit faults, and controls the operation of one or both of the primary neutral-lead switch and the second neutral-lead switch based on the circuit fault.

Abstract: An electric motor system implements a redundant wye-wounded motor that includes first phase leads, second phase leads, first neutral leads, and second neutral leads. The first and second phase leads receive alternating current (AC) power from a power supply. A first phase-lead switch selectively connects the first phase leads to the power supply, and a second phase-lead switch selectively connects the second phase leads to the power supply. A first neutral-lead switch selectively connects the first neutral leads to the redundant wye-wounded motor, and a second neutral-lead switch selectively connects the second neutral leads to the redundant wye-wounded motor. A controller detects a circuit fault among a plurality of different types of circuit faults, and controls the operation of one or both of the primary neutral-lead switch and the second neutral-lead switch based on the circuit fault.

Abstract: A system comprises a stator core defining a plurality of winding slots between circumferentially spaced apart teeth. A respective cooling channel is defined within each of the circumferentially spaced apart teeth for circulation of coolant fluid through the stator core. The stator core is a laminated structure, where the teeth, winding slots, and cooling channels are part of a common laminated structure with the stator core.

Abstract: A stator core is provided and includes laminations disposed in a laminated arrangement to form a stator core body having an axial length extending in a lamination dimension. The stator core body includes an annular portion extending along the axial length and teeth extending radially from the annular portion and along the axial length. Each tooth has a trapezoidal shape and is formed to define one or more triangular holes running along the axial length.

Abstract: A stator core is provided and includes laminations disposed in a laminated arrangement to form a stator core body having an axial length extending in a lamination dimension. The stator core body includes an annular portion extending along the axial length and teeth extending radially from the annular portion and along the axial length. Each tooth has a trapezoidal shape and is formed to define one or more triangular holes running along the axial length.

Abstract: An electrical machine includes a with a parallel first and second phase windings. A first neutral bus is connected to the first phase winding and a second neutral bus is connected to the second phase winding. A first voltage sensor is coupled to the first neutral bus and a second voltage sensor coupled to the second phase winding for monitoring current imbalance between the first and second phase windings.

Abstract: An electric machine includes a winding yoke defining a plurality of winding slots between circumferentially spaced apart teeth. A respective winding separator is mounted within each of the winding slots. The winding separator is mounted to a keying feature that extends from the winding yoke into the winding slot. The winding yoke can be a laminated structure, wherein the teeth and keying features are part of a common laminated structure with the winding yoke. The winding yoke can be a stator, and a rotor can be mounted within the stator for rotary movement relative to the stator.

Abstract: An electrical machine stator can include a stator core having a stator core shape and made of a core material, a plurality of windings disposed in the stator core and made of a conductive material, and an insulative material surrounding the plurality of windings and configured to electrically insulate each winding from each other adjacent winding, and/or to insulate one or more of the windings from the stator core. The insulative material can be an amorphous metal.

Abstract: An electric motor control system including an electric motor having a winding with a first and second end, a motor controller having a phase lead, the motor controller operable to direct a phase current to the phase lead. The electric motor control system also includes a first switching device that provides an electrical connection between the phase lead and the first end of the first winding when in a disabled state, and thereby flowing the phase current from the phase lead to the first end of the first winding, and a second switching device operably connected to the motor controller and providing an electrical connection between the second end of the first winding and a common point, when in an enabled state. The motor controller is operable to change the state of the first switching device to enabled, and the second switching device to disabled, under selected conditions.

Abstract: A stator core is provided and includes laminations disposed in a laminated arrangement to form a stator core body having an axial length extending in a lamination dimension. The stator core body includes an annular portion extending along the axial length and teeth extending radially from the annular portion and along the axial length. Each tooth has a trapezoidal shape and is formed to define one or more triangular holes running along the axial length.

Abstract: An assembly for an electric machine including a core with a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils, a plurality of coils, each coil wrapping around a respective tooth, a separator in one of the slots including a first leg joined at an angle to a second leg for separating adjacent coils within the slot, an insert between the first leg and the second leg for at least partially filling a space between the first leg and the second leg, and a potting filling space within the slot between the separator, the plurality of coils, and the insert.

Abstract: A generator includes a stator with a stator winding, a rotor core with a rotor tooth supported for rotation relative to the stator about a rotation axis, and a field winding. The field winding includes a field coil that is seated on the rotor tooth. The field coil includes two or more flat wire turns stacked with one another and formed such edges of the field coil tightly engage circumferential faces of the tooth. Electrical systems and methods of making generators are also described.

Abstract: A core for an electric machine includes a core body arranged along a rotation axis and a winding. The core body has two or more teeth including a first tooth and a second tooth that are circumferentially spaced from one another about the rotation axis. The winding is to the core body and includes two or more coils connected electrically in series with one another. A first of the coils is seated circumferentially about both the first tooth and the second tooth to define a distributed pole circumferentially spanning both the first tooth and the second tooth. Electric machines and methods of making cores for electric machines are also described.

Abstract: A core for an electric machine includes a core body with a tooth arranged along a rotation axis, a winding with a flat wire coil fixed to the core body and seated on the tooth of the core body, and a flat wire jumper. The flat wire jumper is supported by the core body and is connected to the flat wire coil to place the flat wire coil in electrical communication with flat wire coils of the winding. Methods of making cores with flat wire jumpers and generators having cores with flat wire jumpers are also described.

Abstract: An assembly for an electric machine including a core with a plurality of teeth extending radially inward from the core, the plurality of teeth defining a plurality of slots for receiving coils, a plurality of coils, each coil wrapping around a respective tooth, a separator in one of the slots including a first leg joined at an angle to a second leg for separating adjacent coils within the slot, an insert between the first leg and the second leg for at least partially filling a space between the first leg and the second leg, and a potting filling space within the slot between the separator, the plurality of coils, and the insert.

Abstract: An electric motor control system, including an electric motor having a first winding set including first and second parallel windings, the first and second windings operable to each current based on the combined phase current, and a differential current sensor operably coupled to the first winding and the second winding. The differential current sensor measuring a differential current flowing through the first winding and the second winding and operable to transmit a signal indicative of the differential current based on the measuring. The system also includes a motor controller connected to the electric motor, the motor controller operable to direct the combined phase current through the phase lead, receive the differential current signal, determine if the differential current flowing through the winding set exceeds a selected threshold, and identify a health status of the motor winding set as degraded if the differential current exceeds the selected threshold.

Abstract: An electric machine includes a winding yoke defining a plurality of winding slots between circumferentially spaced apart teeth. A respective winding separator is mounted within each of the winding slots. The winding separator is mounted to a keying feature that extends from the winding yoke into the winding slot. The winding yoke can be a laminated structure, wherein the teeth and keying features are part of a common laminated structure with the winding yoke. The winding yoke can be a stator, and a rotor can be mounted within the stator for rotary movement relative to the stator.

Abstract: An electric motor control system, including an electric motor having a first winding set including first and second parallel windings, the first and second windings operable to each current based on the combined phase current, and a differential current sensor operably coupled to the first winding and the second winding. The differential current sensor measuring a differential current flowing through the first winding and the second winding and operable to transmit a signal indicative of the differential current based on the measuring. The system also includes a motor controller connected to the electric motor, the motor controller operable to direct the combined phase current through the phase lead, receive the differential current signal, determine if the differential current flowing through the winding set exceeds a selected threshold, and identify a health status of the motor winding set as degraded if the differential current exceeds the selected threshold.

Abstract: An electric motor control system including an electric motor having a winding with a first and second end, a motor controller having a phase lead, the motor controller operable to direct a phase current to the phase lead. The electric motor control system also includes a first switching device that provides an electrical connection between the phase lead and the first end of the first winding when in a disabled state, and thereby flowing the phase current from the phase lead to the first end of the first winding, and a second switching device operably connected to the motor controller and providing an electrical connection between the second end of the first winding and a common point, when in an enabled state. The motor controller is operable to change the state of the first switching device to enabled, and the second switching device to disabled, under selected conditions.