Abstract: A rotor for an electric machine includes a magnetic core configured for arrangement on a shaft. An end ring is arranged on opposite axial ends of the magnetic core. A composite sleeve includes an annular body including an inner surface and an outer surface, and a polymer matrix encapsulating circumferentially oriented fibers. The composite sleeve includes a first tapered portion on the inner surface arranged adjacent to an axial end thereof and configured to facilitate press-fitting of the composite sleeve onto the rotor.

Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Abstract: A vehicle, suspension system and method of dampening a force on the suspension system is disclosed. The suspension system includes a damper having a first damping element and a second damping element configured to rotate relative to each other in response to a force received at the suspension system. The second damping element induces an eddy current in the first damping element during relative rotation. A feature of one at least one of the first damping element and the second damping element provides a first electrical resistance to the eddy current during relative rotation in a first direction and a second electrical resistance to the eddy current during relative rotation in a second direction. The first electrical resistance generates a first damping force and the second electrical resistance generates a second damping force.

Abstract: A power control system for an electric vehicle includes a power inverter comprising a switch module including a plurality of power switches, a controller board, and a gate driver board in communication with the controller board and configured to drive gates of the plurality of switches. A first housing is made of polymer composite, encloses the power inverter, defines a first cooling cavity in thermal communication with a first surface of the switch module, and encapsulates a portion of at least one of the switch module, the controller board and the gate driver board.

Abstract: A rotor for an electric machine includes a rotor body formed from a plurality of rotor laminations defining a first axial end and a second axial end. Each of the plurality of rotor laminations includes a plurality of openings that are aligned so as to define a plurality of passages through the rotor body. A plurality of reinforcement elements extend through the plurality of laminations. Each of the plurality of reinforcement elements is arranged in a corresponding one of the plurality of passages and includes a first end portion and a second end portion. The first end portion and the second end portion of select ones of the plurality of reinforcement elements extend outwardly of the first axial end and the second axial end. An end ring is positioned at the first axial end. The end ring is integrally formed with the select ones of the plurality of reinforcement elements.

Abstract: A stator of an electric machine includes a stator core and a plurality of electrically conductive windings secured to the stator core. A volume of potting material supports the plurality of electrically conductive windings at the stator core. One or more stator coolant channels are defined in the volume of potting material configured to convey a flow of stator coolant therethrough to remove heat from the plurality of electrically conductive windings. A method of forming a stator of an electric machine includes arranging a plurality of electrically conductive windings on a stator core, applying a volume of potting material to the plurality of electrically conductive windings, and defining one or more stator coolant channels in the volume of potting material. The one or more stator coolant channels are configured to convey a flow of stator coolant therethrough to remove heat from the plurality of electrically conductive windings.

Abstract: A rotor of an electric machine includes: N pole pieces, each of the N pole pieces including two half pole pieces, where N is an integer greater than 2; apertures through the half pole pieces, respectively; permanent magnets disposed within the apertures, respectively, the permanent magnets including, in each of the N pole pieces, a first permanent magnet of a first magnetic polarity and a second permanent magnet of a second magnetic polarity; and structural non-magnetic portions disposed in gaps of the half pole pieces, respectively, and configured to magnetically disconnect a rotor web from a q-axis flux guide.

Abstract: A rotor core for an electric machine of an automobile includes a core stack including a plurality of lamination plates. Each lamination plate includes a plurality of apertures formed therein. The plurality of apertures of each of the lamination plates are axially aligned and define and a slot extending through the core stack and shaped to receive a corresponding insert. The rotor core also includes at least one insert received by the slot that provides radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the rotor core. The rotor core includes a load bearing polymer disposed within the aperture of the rotor core that provides contact between and the insert and the lamination plates.

Abstract: An electromagnetic interference shielding composite. The electromagnetic interference shielding composite includes a polymer substrate formed into a shape of a packaging component. The composite further includes an electromagnetic interference layer contacting the polymer substrate and a conductive coating contacting the electromagnetic interference layer. An integrated power electronic module includes packaging including the electromagnetic interference shielding composite. A method of forming the electromagnetic interference shielding composite for an integrated power electronic module includes molding a polymer substrate into a shape of a packaging component, forming an electromagnetic interference layer on the polymer substrate, and forming a conductive coating on the electromagnetic interference layer.

Abstract: According to several aspects of the present disclosure, a battery module housing cooling assembly is disclosed. The battery module housing cooling assembly can include an endwall including a first polymer plate and a second polymer plate that define a slot therebetween. At least one of the first polymer plate or the second polymer plate define a channel therein that is configured to receive a coolant fluid, and the slot is configured to receive an electrical connector. The battery module housing cooling assembly can also include a cooling plate defining a first connection port and a second connection port, wherein the first connection port and a second connection port are configured to provide the coolant fluid to the channel.

Abstract: An electric motor drive unit including an electric motor having an output shaft and a plurality of gears in driving engagement with the output shaft. The plurality of gears being supported by a plurality of laterally spaced bearings. A composite housing member includes a structural support skeleton supporting multiple ones of the plurality of laterally spaced bearings and a composite shell molded to the structural support skeleton.

Abstract: An axial retainment system for a shaft is provided. The axial retainment system includes a cylindrical body extending from an outboard end to an inboard end thereof, and a swaged ridge extending radially outward from the cylindrical body proximate the outboard end. The swaged ridge has an outboard axial surface facing toward the outboard end and extending radially outward and terminating at a radially outward facing circumferential surface. The swaged ridge has an inboard axial surface facing toward the inboard end and extending radially outward from the cylindrical body and terminating at the radially outward facing circumferential surface. The outboard axial surface of the swaged ridge is recessed axially inward from the outboard end of the shaft. The inboard axial surface of the swaged ridge is swaged against, conforms in shape to, and is compressed against a component to be axially retained on the shaft.

Abstract: A rotor assembly for a permanent magnet motor includes a first assembly including a first plurality of laminations and a second assembly including a second plurality of laminations. The first assembly is located radially inside of the second assembly. The first assembly and the second assembly define a first opening therebetween. First and second permanent magnets are located in the first opening. Polymeric material surrounds the first and second permanent magnets in the first opening. An outer layer surrounds the rotor assembly.

Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Abstract: A rotor lamination for an electric machine includes a body having a first axial surface, a second axial surface, a central opening, and an outer annular edge defining a radius. A plurality of magnet receiving openings are formed in the body. Each of the plurality of magnet receiving openings includes a first magnet receiving portion and a second magnet receiving portion. A composite insert is mounted in the body. The composite insert extending along the radius across the magnet receiving opening physically separating the first magnet receiving portion from the second magnet receiving portion.

Abstract: A rotor core for an electric machine of an automobile includes a core stack including a plurality of lamination plates. Each lamination plate includes a plurality of apertures formed therein. The plurality of apertures of each of the lamination plates are axially aligned and define and a slot extending through the core stack and shaped to receive a corresponding insert. The rotor core also includes at least one insert received by the slot that provides radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the rotor core. The rotor core includes a load bearing polymer disposed within the aperture of the rotor core that provides contact between and the insert and the lamination plates.

Abstract: A rotor for an electric machine includes a rotor body formed from a plurality of stacked laminations defining a first axial end and an opposing second axial end. Each of the plurality of stacked laminations includes a plurality of openings that are aligned so as to define a plurality of passages through the rotor body. A plurality of reinforcement elements extend through the plurality of stacked laminations. Each of the plurality of reinforcement elements is arranged in a corresponding one of the plurality of passages and includes a first end portion and a second end portion. The first end portion and the second end portion of select ones of the plurality of reinforcement elements extend outwardly of the first axial end and the second axial end.

Abstract: According to several aspects of the present disclosure, a battery module housing cooling assembly is disclosed. The battery module housing cooling assembly can include an endwall including a first polymer plate and a second polymer plate that define a slot therebetween. At least one of the first polymer plate or the second polymer plate define a channel therein that is configured to receive a coolant fluid, and the slot is configured to receive an electrical connector. The battery module housing cooling assembly can also include a cooling plate defining a first connection port and a second connection port, wherein the first connection port and a second connection port are configured to provide the coolant fluid to the channel.

Abstract: A rotor for an electric machine includes a rotor body formed from a plurality of rotor laminations defining a first axial end and a second axial end. Each of the plurality of rotor laminations includes a plurality of openings that are aligned so as to define a plurality of passages through the rotor body. A plurality of reinforcement elements extend through the plurality of laminations. Each of the plurality of reinforcement elements is arranged in a corresponding one of the plurality of passages and includes a first end portion and a second end portion. The first end portion and the second end portion of select ones of the plurality of reinforcement elements extend outwardly of the first axial end and the second axial end. An end ring is positioned at the first axial end. The end ring is integrally formed with the select ones of the plurality of reinforcement elements.

Abstract: A cam follower for a ram of a metal can necker machine is provided. The cam follower has an outer ring and an inner ring coaxially disposed in the outer ring. A plurality of rolling elements is disposed in an annular cavity between the outer ring and the inner ring. The plurality of rolling elements is disposed between a first seal and a second seal. A shaft is received in a bore in the inner ring and is fixed relative thereto about the shaft axis. The outer ring is received in a tire. The tire has a thickness and a crown radius. The composition of the tire includes a metallic material, a plastic material, a non-metallic material, and combinations thereof.