Abstract: A pole piece (106) for a rotor (100) of a rotary electric machine (20) includes a hub portion (104) and a plurality of pole segments (106) distributed evenly about the hub portion (104). The pole segments each have a base (116) that is connected to the hub portion (104) and a tip (118) that is disposed axially opposite the base (116) along an axis (60) of the pole piece (106). Each pole segment (106) defines circumferentially opposite side surfaces (120, 122) that extend between the base (116) and the tip (118). Each pole segment (106) also defines radially opposite outer and inner surfaces (124, 126) that extend between the side surfaces (120, 122). A groove is recessed in the side surfaces (120, 122) of each pole segment (106). A radially innermost portion (136) of the groove (130, 132) is arranged proximate to the radially outer surface.

Abstract: A drive module for a vehicle including an electric machine, an inverter, a gearing assembly, and a cooling system. A first housing member thermally coupled with the inverter has a first set of heat exchange surfaces and a second housing member thermally coupled with the electric machine has a second set of heat exchange surfaces. The first and second sets of heat exchange surfaces each project into an interior volume cooled by an externally supplied liquid coolant which thereby defines a heat exchanger. A lower oil sump for collecting oil used to cool the electric machine may also include heat exchange surfaces projecting into the same heat exchanger. The gearbox may include an elevated oil sump which is supplied by the same oil pump circulating oil on the electric machine wherein the elevated oil sump gravity feeds oil onto selected surfaces within the gearbox.

Abstract: A claw pole member for an electric machine including a plurality of claw pole segments. Each of the plurality of claw pole segments includes a radial projecting member, an axial outer surface extending to a cantilevered end portion, and an axial inner surface extending axially outwardly of the radial projecting member to a cantilevered end section. A first side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section, and a second side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section. The first and second side surfaces define a taper of the claw pole segment. Each of the first and second side surfaces includes a recessed portion that extends into the claw pole segment.

Abstract: A number of variations may include a solenoid assembly comprising: a shaft; a pinion-plunger operatively attached to the shaft and having a first end comprising a plurality of teeth; a plurality of iron cores surrounding at least a portion of the pinion-plunger and the shaft; at least one solenoid coil winding and at least one spool surrounding each of the plurality of iron cores; a stop adjacent a first end of the plurality of iron cores; a guide adjacent a second end of the plurality of iron cores opposite of the stop; a biasing member in operative communication with the first end the pinion-plunger; and wherein the solenoid assembly is constructed and arranged so that when the solenoid assembly is activated the pinion-plunger is magnetically drawn toward the stop.

Abstract: A pole piece (106) for a rotor (100) of a rotary electric machine (20) includes a hub portion (104) and a plurality of pole segments (106) distributed evenly about the hub portion (104). The pole segments each have a base (116) that is connected to the hub portion (104) and a tip (118) that is disposed axially opposite the base (116) along an axis (60) of the pole piece (106). Each pole segment (106) defines circumferentially opposite side surfaces (120, 122) that extend between the base (116) and the tip (118). Each pole segment (106) also defines radially opposite outer and inner surfaces (124, 126) that extend between the side surfaces (120, 122). A groove is recessed in the side surfaces (120, 122) of each pole segment (106). A radially innermost portion (136) of the groove (130, 132) is arranged proximate to the radially outer surface.

Abstract: An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a cooling tower having first and second axial ends. The cooling tower includes a metallic wall defining radially inner and outer wall surfaces and extending about the package central axis. The radially inner wall surface defines an axially extending air passage through the cooling tower with an inlet proximate the first axial end. Spaced metallic ribs are in conductive thermal communication with the radially inner wall surface traverse and the air passage. Power electronics devices are attached in conductive thermal communication to the radially outer wall surface. The cooling tower provides a heat sink for the power electronics devices with a primary cooling path for each of the power electronics device extending radially inwardly to the cooling tower. An electric machine including such an electronic package is also disclosed.

Abstract: An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.

Abstract: A claw pole member for an electric machine including a plurality of claw pole segments. Each of the plurality of claw pole segments includes a radial projecting member, an axial outer surface extending to a cantilevered end portion, and an axial inner surface extending axially outwardly of the radial projecting member to a cantilevered end section. A first side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section, and a second side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section. The first and second side surfaces define a taper of the claw pole segment. Each of the first and second side surfaces includes a recessed portion that extends into the claw pole segment.

Abstract: Embodiments of the invention provide a starter that includes a motor with an armature that is coupled to a pinion. In some embodiments, the starter can include a main field coil that can be configured and arranged to produce a main magnetic field flux. Some embodiments include at least one auxiliary flux assembly arranged in close proximity with the main field coil and electrically disconnected from it. In some embodiments, a control system can operatively power the main field coil to produce a magnetic field flux. In some embodiments, the at least one auxiliary flux assembly can provide a supplementary field flux adding to the main magnetic field flux that interacts with the armature.

Abstract: An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a support structure having opposite first and second axial ends spaced along a package central axis. A plurality of power electronics devices connected to the support structure and electronic control circuitry is carried by the support structure. The electronic control circuitry is substantially surrounded by and operatively connected to the power electronics devices. The control circuitry includes circuit board material having opposing substantially parallel sides, wherein the control circuitry comprises first and second control circuit portions respectively disposed on separate first and second circuit board material portions wherein the first and second circuit board material portions substantially coextend with distinct first and second imaginary planes, respectively. An electric machine employing such an electronic package is also disclosed.

Abstract: A power module for an electric machine. The power module includes a thermally conductive base having opposite first and second surfaces. The first surface is adapted for mounting the power module in conductive thermal communication with a heat sink. A MOSFET superposes the base second surface and is in conductive thermal communication with the base. A MOSFET driver superposes the base second surface and is operatively connected to the MOSFET. The transference from the power module of heat generated by the MOSFET and the MOSFET driver from the power module is directed along a primary cooling path to the heat sink through the base and a secondary cooling path to ambient air. The primary and secondary cooling paths are separate from each other. An electronics package and an electric machine including a power module are also disclosed.

Abstract: An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.

Abstract: An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a cooling tower having first and second axial ends and a central axis. The cooling tower includes a metallic first wall extending about the central axis and defining radially inner and outer first wall surfaces. An axially extending air flow passage extends through the cooling tower. Spaced metallic ribs traverse the air flow space and are in conductive thermal communication with the radially inner first wall surface. A plurality of circumferentially distributed power electronics devices are in conductive thermal communication with the cooling tower and secured to the radially outer first wall surface to thereby provide a heat sink for the power electronics devices. Electronic control circuitry is operatively connected to and substantially surrounded by the power electronics devices. An electric machine with such an electronic package is also disclosed.

Abstract: An electronic package connectable to an electric machine. The electronic package includes a support structure with a first axial end engaged with the electric machine. The support structure circumscribes the central axis and defines radially inner and outer wall surfaces. Power modules are disposed on and circumferentially distributed about the radially outer wall surface and include a power electronics device. Each module includes a phase terminal coupled with the power electronics device and disposed radially outwardly of the radially outer wall surface. The support structure defines a plurality of voids extending between the radially inner and outer wall surfaces. Each of the power modules are positioned proximate a separate one of the voids. Each void has a phase lead extending therethrough. Each phase lead is connected to a phase terminal and conductively couples it with a stator winding. An electric machine having an electronic package is also disclosed.

Abstract: An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.

Abstract: An electronic package adapted for connection to a rear frame member of an electric machine of liquid and/or air-cooled type. The electronic package includes a cooling tower having opposite first and second axial ends spaced along a package central axis. The cooling tower includes a metallic wall extending about the package central axis to define a radially outer wall surface. The cooling tower is at ground potential and defines a heat sink. The electronic package also includes a plurality of power modules mounted in conductive thermal communication to the cooling tower at positions on the radially outer wall surface. Heat transference to the cooling tower from each power module occurs along a respective primary cooling path. Transference along the primary cooling paths of heat from the cooling tower includes thermal convection to air and/or liquid. An electric machine of liquid and/or air-cooled type including an electronic package is also disclosed.

Abstract: A number of variations may include a solenoid assembly comprising: a shaft; a pinion-plunger operatively attached to the shaft and having a first end comprising a plurality of teeth; a plurality of iron cores surrounding at least a portion of the pinion-plunger and the shaft; at least one solenoid coil winding and at least one spool surrounding each of the plurality of iron cores; a stop adjacent a first end of the plurality of iron cores; a guide adjacent a second end of the plurality of iron cores opposite of the stop; a biasing member in operative communication with the first end the pinion-plunger; and wherein the solenoid assembly is constructed and arranged so that when the solenoid assembly is activated the pinion-plunger is magnetically drawn toward the stop.

Abstract: A rotor for a rotary electric machine, the rotor including first and second pole pieces each having a respective magnetic hub arranged for rotation about an axis along which they are spaced. Pluralities of magnetic first and second pole fingers are spaced from each other and extend between the hubs. Each pole finger has a proximal end connected to its respective hub, and an axially opposite distal end. The first and second pole fingers circumferentially alternate about the axis, and each pole finger has a respective radially inner surface defining a cavity that extends axially from the distal end to a cavity terminus. Relative to each pole finger, at a respective axial position between the distal end and the cavity terminus the radial distance between the axis and the radially inner surface is substantially greater inside of the cavity than outside of the cavity.

Abstract: A vehicle starter motor arrangement comprises a battery, a first vehicle starter motor including a first pinion and a second vehicle starter motor including a second pinion. The first vehicle starter motor is connected in series to the battery and the second vehicle starter motor is connected in series to the first vehicle starter motor. Accordingly, the battery, the first vehicle starter motor, and the second vehicle starter motor are all connected in series. The first pinion gear and the second pinion gear are configured to engage an engine ring gear when electrical current flows through the first vehicle starter motor and the second vehicle starter motor.

Abstract: A variable flux electric starter motor includes a frame, an armature rotatably mounted within the frame, and a primary field mounted to the frame. The primary field includes a plurality of primary windings electrically connected one to another. A relay is electrically coupled to at least one of the plurality of poles. A supplemental field is mounted to the frame. The supplemental field includes a supplemental winding electrically connected in parallel to the plurality of primary windings.