Abstract: An electric device and a stator assembly for the electric device includes a stator core defining a plurality of slots spaced from each other. The stator assembly includes a plurality of bar conductors disposed in each of the slots and arranged to present a first winding path, a second winding path and a third winding path. A first set of the bar conductors of the first, second and third winding paths are configured to receive current in a parallel circuit arrangement. The stator assembly also includes a plurality of electrical jumpers electrically connected to a predetermined number of the bar conductors such that an amount of current flowing through the first winding path and the third winding path is substantially the same and an amount of current flowing through the second winding path is different from the amount of current flowing through the first and third winding paths.

Abstract: An electric machine assembly includes an electric machine including a rotor. A controller operatively connected to the electric machine and configured to receive a torque command. The rotor is configured to rotate at a rotor speed (?) based at least partially on the torque command. The controller has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method for determining a cumulative rotor fatigue (FC) based at least partially on the rotor speed. The controller is operative to control at least one operating paramater of the electric machine based at least partially on the cumulative rotor fatigue (FC). The controller is configured to record respective occurrences of the rotor stress value exceeding respective predefined stress levels in chronological order to create a cycle dataset, such that the cycle dataset preserves a time order of the respective occurrences.

Abstract: An electric machine assembly includes an electric machine including a rotor. A controller operatively connected to the electric machine and configured to receive a torque command. The rotor is configured to rotate at a rotor speed (?) based at least partially on the torque command. The controller has a processor and tangible, non-transitory memory on which is recorded instructions for executing a method for determining a cumulative rotor fatigue (FC) based at least partially on the rotor speed. The controller is operative to control at least one operating paramater of the electric machine based at least partially on the cumulative rotor fatigue (FC). The controller is configured to record respective occurrences of the rotor stress value exceeding respective predefined stress levels in chronological order to create a cycle dataset, such that the cycle dataset preserves a time order of the respective occurrences.

Abstract: An electric device and a stator assembly for the electric device includes a stator core defining a plurality of slots spaced from each other. The stator assembly includes a plurality of bar conductors disposed in each of the slots and arranged to present a first winding path, a second winding path and a third winding path. A first set of the bar conductors of the first, second and third winding paths are configured to receive current in a parallel circuit arrangement. The stator assembly also includes a plurality of electrical jumpers electrically connected to a predetermined number of the bar conductors such that an amount of current flowing through the first winding path and the third winding path is substantially the same and an amount of current flowing through the second winding path is different from the amount of current flowing through the first and third winding paths.

Abstract: A hub assembly for an electric machine includes a rotor hub and a machine rotor. Rotation of the machine rotor generates an electromagnetic (EM) field. The hub assembly includes a resolver rotor that encodes an angular position of the machine rotor as a set of resolver signals. An EM field barrier ring between the resolver rotor and the rotor hub adds a magnetic barrier between the machine rotor and the resolver rotor to reduce noise in the resolver signals. The resolver rotor may be bonded to the EM field barrier ring. The EM field barrier ring may have an L-shaped cross section, and may be press-fitted into a pocket of the rotor hub. A vehicle includes a transmission having an input member and an electric machine having a rotor shaft connected to the input member of the transmission. The electric machine includes the hub assembly noted above.

Abstract: A slot liner is configured for insertion into a slot of an electric machine. The slot liner is an integral piece configured to be folded along a first set of fold lines to define a plurality of liner segments in a folded configuration. The liner segments include first, second, third, fourth and fifth liner segments. The first and second liner segments are configured to be substantially parallel to one another in the folded configuration. The third and fourth liner segments are configured to be substantially parallel to one another in the folded configuration. The fifth liner segment extends between the third and fourth liner segments. The fifth liner segment is configured to be folded along a second set of fold lines to define a plurality of openings, including a first opening.

Abstract: A hub assembly for an electric machine includes a rotor hub and a machine rotor. Rotation of the machine rotor generates an electromagnetic (EM) field. The hub assembly includes a resolver rotor that encodes an angular position of the machine rotor as a set of resolver signals. An EM field barrier ring between the resolver rotor and the rotor hub adds a magnetic barrier between the machine rotor and the resolver rotor to reduce noise in the resolver signals. The resolver rotor may be bonded to the EM field barrier ring. The EM field barrier ring may have an L-shaped cross section, and may be press-fitted into a pocket of the rotor hub. A vehicle includes a transmission having an input member and an electric machine having a rotor shaft connected to the input member of the transmission. The electric machine includes the hub assembly noted above.

Abstract: Systems and methods are provided for an automotive drive system using an absolute position sensor for field-oriented control of an induction motor. An automotive drive system comprises an induction motor having a rotor, and a position sensor coupled to the induction motor. The position sensor is configured to sense an absolute angular position of the rotor. A processor may be coupled to the position sensor and configured to determine a relative angular position of the rotor based on a difference between the absolute angular position and an initial angular position obtained when the induction motor is started. A controller may be coupled to the induction motor and the processor and configured to provide field-oriented control of the induction motor based on the relative angular position of the rotor.

Abstract: An internal permanent magnet machine (“IPM machine”) of the type used, for example, with traction motors and hybrid electric vehicles, includes a rotor with an additional air barrier provided above the first magnet barrier in the same rotor slot. Each magnet only fills a portion of each cavity, thereby defining the air barriers. The added air barrier above the permanent magnet of the first layer acts as a barrier to the first layer magnet and lowers the magnet flux.

Abstract: Methods and apparatus are provided for improving operational characteristics of a concentrated winding machine. According to an example embodiment, an apparatus comprises stator teeth having distal ends, the stator teeth arranged in an annular fashion about an axis to define stator slots between adjacent teeth and slot openings between the distal ends of the adjacent teeth, the stator teeth structured to prevent relative movement between adjacent teeth. The apparatus further comprises magnetic wedges structured to be inserted between the distal ends of the adjacent teeth to close the slot openings.

Abstract: Permanent magnet motors with improved torque ripple and methods for designing the same have been provided. The permanent magnet motor can include a stator having a hollow core and defining a plurality of slots; a winding disposed in each of the slots; a rotor rotatably disposed inside the hollow core of the stator; and a plurality of permanent magnets supported by the rotor. Each of the slots has a slot opening, and at least one of the slot openings can be off-center with respect to the respective slot.

Abstract: Systems and methods are provided for a motor having a concentrated winding construction with reduced torque ripple. A motor comprises a stator including a plurality of tooth segments disposed circumferentially to establish a hollow core and a rotor rotatably disposed inside the hollow core. The plurality of tooth segments define a plurality of slot openings associated with a plurality of slots. Each slot of the plurality of slots has a slot opening and at least one slot opening of the plurality of slot openings is asymmetric with respect to the plurality of slot openings.

Abstract: A permanent magnet machine includes a stator having a hollow core, a rotor rotatably disposed inside the hollow core, and a plurality of multilayered permanent magnets embedded in the rotor. Each multilayered permanent magnet has opposite first and second ends, and includes a first magnet disposed at the first end, and a second magnet disposed at the second end and coupled to the first magnet. The second magnet has higher magnet strength than the first magnet, and also has lower high-temperature stability than the first magnet.

Abstract: Methods and systems for evaluating a permanent magnet motor are provided. The method includes the steps of spinning a rotor of the permanent magnet motor; determining a total harmonic distortion of the permanent magnet motor; and comparing the determined total harmonic distortion of the permanent magnet motor with a baseline total harmonic distortion.

Abstract: An end ring for a rotor assembly in a vehicular electric machine is provided, wherein the rotor assembly has a first end and is configured to rotate on a shaft. The end ring comprises an annulus circumscribing the shaft and engaging the end of the rotor assembly, and a sleeve coupled to the annulus and circumferentially coupled to the shaft.

Abstract: Methods and systems for evaluating a permanent magnet motor are provided. The method includes the steps of spinning a rotor of the permanent magnet motor; determining a total harmonic distortion of the permanent magnet motor; and comparing the determined total harmonic distortion of the permanent magnet motor with a baseline total harmonic distortion.

Abstract: An internal permanent magnet machine (“IPM machine”) of the type used, for example, with traction motors and hybrid electric vehicles, includes a rotor with an additional air barrier provided above the first magnet barrier in the same rotor slot. Each magnet only fills a portion of each cavity, thereby defining the air barriers. The added air barrier above the permanent magnet of the first layer acts as a barrier to the first layer magnet and lowers the magnet flux.

Abstract: Methods and apparatus are provided for improving operational characteristics of a concentrated winding machine. According to an example embodiment, an apparatus comprises stator teeth having distal ends, the stator teeth arranged in an annular fashion about an axis to define stator slots between adjacent teeth and slot openings between the distal ends of the adjacent teeth, the stator teeth structured to prevent relative movement between adjacent teeth. The apparatus further comprises magnetic wedges structured to be inserted between the distal ends of the adjacent teeth to close the slot openings.

Abstract: Systems and methods are provided for an automotive drive system using an absolute position sensor for field-oriented control of an induction motor. An automotive drive system comprises an induction motor having a rotor, and a position sensor coupled to the induction motor. The position sensor is configured to sense an absolute angular position of the rotor. A processor may be coupled to the position sensor and configured to determine a relative angular position of the rotor based on a difference between the absolute angular position and an initial angular position obtained when the induction motor is started. A controller may be coupled to the induction motor and the processor and configured to provide field-oriented control of the induction motor based on the relative angular position of the rotor.

Abstract: Methods and systems for evaluating a permanent magnet motor are provided. The method includes the steps of spinning a rotor of the permanent magnet motor; determining a total harmonic distortion of the permanent magnet motor; and comparing the determined total harmonic distortion of the permanent magnet motor with a baseline total harmonic distortion.