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.

Abstract: A method of operating a variable flux electric machine includes passing an electrical current through a plurality of wound poles of a wound field to generate a first flux, rotating an armature at a first crank point having a first speed in response to the first flux, shorting at least one of the plurality of wound poles, generating a second flux through a permanent magnet (PM) field having a plurality of PM poles, and rotating the armature at a second crank point having a second speed in response to the second flux, the second speed being greater than the first speed.

Abstract: A variable flux electric machine including a frame, an armature rotatably mounted within the frame, a first field having a plurality of windings that defines at least one wound pole fixedly mounted relative to the frame, a second field having at least one permanent magnet (PM) that defines at least one PM pole fixedly mounted relative to the frame, and a relay electrically coupled to the plurality of windings of the first field.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine with a stator assembly. The stator assembly includes a plurality of stator laminations coupled together and a plurality of conductors positioned through axial slots of the plurality of stator laminations. The electric machine module also includes a coolant channel at least partially defined within the axial slots and a housing. The housing at least partially circumscribes the electric machine and at least partially defines a machine cavity which is in fluid communication with the coolant channel.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine module. The electric machine module includes an electric machine including a stator with stator end turns, a liquid-cooled housing at least partially enclosing the electric machine, and a potting material in contact with and at least partially surrounding the stator end turns. The method includes potting at least some of the stator end turns with the potting material to provide a thermally-conductive path from the stator end turns to the housing and circulating a coolant through the housing to at least remove heat energy conducted from the stator end turns to the housing.

Abstract: Embodiments of the invention provide an electric machine module including module housing with an inner wall and at least one end cap. The module can at least partially define a machine cavity. The electric machine module can also include at least two drain holes positioned substantially circumferentially apart from one another and extending through a lower portion of the module housing. The at least two drain holes can provide gravity-fed fluid pathways out of the machine cavity.

Abstract: A solenoid for a vehicle starter comprises a spool including a first coil bay, a second coil bay, and an interior passage defining an axial direction. A first coil is positioned in the first coil bay of the spool, and a second coil positioned in the second coil bay of the spool. A plunger is positioned within the interior passage of the spool and configured to move in the axial direction when the first coil is energized. The first coil bay is positioned adjacent to the second coil bay in the axial direction. The spool further includes two end flanges and a middle flange. The middle flange separates the first coil bay from the second coil bay.

Abstract: Embodiments of the invention provide a starter machine control system including an electronic control unit. The control system can include a starter machine that is in communication with the electronic control unit. The starter machine can comprise a solenoid assembly that includes a plurality of biasing members and a first and a second coil winding. The starter machine can also include a motor that is coupled to a pinion. The starter machine can comprise an electromagnetic switch that is coupled to the first coil winding and is configured to regulate a priming current passing through the first coil winding. In some embodiments, the motor can be electrically coupled to the first winding and the control unit can be capable of closing the electromagnetic switch to circulate the priming current from a power source to the motor through the first coil winding.

Abstract: Embodiments of the invention provide a starter machine control system including an electronic control unit. The electronic control unit can be in communication with one or more sensors. The control system can include a starter machine that is in communication with the electronic control unit. The starter machine can comprise a solenoid assembly that includes a plurality of biasing members and a motor that is coupled to a pinion. In some embodiments, the motor can be electrically coupled to at least one of the first coil winding and the second coil winding. In some embodiments, the electronic control unit can be capable of being configured and arranged to circulate a priming current from a power source to the motor through at least one of the first coil winding and the second coil winding.

Abstract: Embodiments of the invention provide a starter machine including an electronic control unit. The electronic control unit can be in communication with one or more sensors. The control system can include a starter machine that is in communication with the electronic control unit. The starter machine can comprise a solenoid assembly that includes a plurality of biasing members, a motor that is coupled to a pinion, and power module and controller that is coupled to the motor. In some embodiments, at least one of the power module and the controller are configured to control a speed of the pinion to substantially synchronize the pinion speed and the speed of an engine component.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The apparatus and method include providing the electric machine including a rotor and a stator with stator end turns and enclosing at least a portion of the electric machine within a housing. The method also includes introducing a coolant into a machine cavity, directing the coolant toward the stator end turns, and returning a portion of the coolant which flows past the stator end turns back toward the stator end turns using a rotating agitator member operatively coupled to the rotor.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine with a stator assembly. The stator assembly includes a plurality of stator laminations coupled together and a plurality of conductors positioned through axial slots of the plurality of stator laminations. The electric machine module also includes a coolant channel at least partially defined within the axial slots and a housing. The housing at least partially circumscribes the electric machine and at least partially defines a machine cavity which is in fluid communication with the coolant channel.

Abstract: Embodiments of the invention provide an electric machine module including an electric machine with a stator assembly. The stator assembly includes a plurality of stator laminations and the plurality of stator laminations include a plurality of different outer diameters. The plurality of stator laminations are positioned relative to one another to form radially-extending fins. At least one circumferential coolant channel is defined along the circumference of the stator assembly by the plurality of stator laminations at least partially between the radially-extending fins.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module includes the electric machine including a stator with stator end turns, a through bolt, and a housing with at least two removably-coupled frame members. Each of the at least two removably-coupled frame members include an inner wall, an outer wall, a coolant cavity defined between the inner wall and the outer wall, and a bolt channel. The coolant cavity can be positioned substantially around at least one of the stator end turns radially. The bolt channel can be positioned through a portion of each of the at least two removably-coupled frame members and can be located radially inward from an outer substantially circular periphery of the housing.

Abstract: A solenoid in an engine starter assembly includes an electromagnetic coil operable on a plunger coupled to a shift lever to move a pinion gear into contact with the engine ring gear. The solenoid is provided with a return spring to restore the plunger to an initial position in which the pinion and ring gears are disengaged, in the absence of a coil force. A contact plate is supported on the plunger to engage open electrical contacts when the plunger is in a first position to complete an electrical circuit to drive the starter motor rotating the pinion gear at a faster speed. An over-travel spring resists movement of the plunger once the contact plate engages the electrical contacts. An auxiliary spring is disposed on the plunger to resist movement of the plunger only when the plunger travels to a position offset between the initial position and the first position.

Abstract: A control system for the starter assembly of an engine includes a first field effect transistor (FET) electrically connected between an electrical power supply and the starter motor and a second FET electrically connected between the power supply and the solenoid. A control unit is electrically connected to the gate of each FET and is configured to selectively apply a voltage to each gate, wherein the FET provides a current to the respective starter motor and solenoid as a function of the applied voltage. The control unit can selectively apply the gate voltages for cold start, soft start, and start-stop operation of the engine, and in response to sensor signals received by the control unit, such as ring gear rotational speed.

Abstract: A starter motor arrangement comprises a battery, a first starter motor including a first pinion and a second starter motor including a second pinion. The first starter motor is connected in series to the battery and the second starter motor is connected in series to the first starter motor. Accordingly, the battery, the first starter motor, and the second 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 starter motor and the second starter motor.

Abstract: A solenoid for a vehicle starter includes a pull-in coil made of a length of rectangular wire and a hold-in coil adjacent to the pull-in coil. A plunger is configured to move in an axial direction when the pull-in coil made of rectangular wire is energized. The pull-in coil and the hold-in coil are positioned on a spool with the plunger slideably positioned within a central passage of the spool. The plunger is configured to engage a plunger stop when the pull-in coil is energized. In at least one embodiment, the hold-in coil is separated from the plunger stop in the axial direction and the hold-in coil encircles the plunger stop.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module includes an electric machine and a housing enclosing the electric machine within a machine cavity. The housing can include at least one end cap positioned axially adjacent to the electric machine and including a shroud protruding into the machine cavity. The shroud can include a step with an angled rotor feed path.

Abstract: Embodiments of the invention provide an electric machine module comprising an electric machine with a stator and housing at least partially circumscribing the electric machine. The housing includes at least two housing members coupled together and substantially securing the electric machine within the housing. The electric machine module also includes a coolant jacket at least partially defined by an outer diameter of the stator and an inner diameter portion of the housing.