Abstract: A hands-free charging system includes an electrical power source and a ground unit electrically connected to the power source. The ground unit includes an energy-storage device and a robotic coupler having a connector and an actuator configured to move the connector into engagement with a vehicle charge port. The energy-storage device is configured to power the actuator. A switching arrangement is configured to selectively electrically connect the power source to the energy-storage device and to the connector. A controller is programmed to, in response to a request to charge a vehicle, connect the connector to a charge port when the connector is electrically disconnected from the power source using an internal power source.

Abstract: An electric machine rotor that is configured to rotate about a first axis includes a plurality of plates and plurality of permanent magnets. The plurality of plates are stacked along the first axis. Each of the plates defines V-shaped pairs of cavities. Each V-shaped pair of cavities defines a pole arc angle. Each cavity has a permanent magnet pocket and a magnetic field guide chamber extending radially outward from the permanent magnet pocket relative to the first axis. Offset angles between the magnetic field guide chambers and the permanent magnet pockets vary within each plate. The plates are stacked such that the permanent magnet pockets between adjacent plates are axially aligned and such that the magnetic field guide chambers between adjacent plates are axially offset. Each permanent magnet extends through a set of permanent magnet pockets.

Abstract: An electric machine includes a stator formed from a plurality of stacked laminations and defining a center bore and a rotor disposed within the center bore. The rotor is configured to output a rotational torque in response to an input current delivered to the stator. At least one of the stacked laminations of the stator includes a pattern of perforations disposed at a yoke portion of the stator to attenuate structure-bore transmission of vibration during operation of the electric machine.

Abstract: This disclosure relates to thermal management for an electric machine, such as an electric motor, of an electrified vehicle. An example assembly includes a stator having a core and a jacket at least partially surrounding the core. The jacket radially encloses a slot and is configured to permit fluid to flow within the slot from a first face of the stator to a second face of the stator. The assembly further includes a first end cover covering the first face of the stator. The first end cover has an inlet port and is configured to direct fluid from the inlet into the slot. Further, the assembly includes a second end cover covering the second face of the stator and configured to direct fluid that exits the slot.

Abstract: A method includes depositing a layer of alloy particles including rare earth permanent magnet phase above a substrate, laser scanning the layer while cooling the substrate to melt the particles, selectively initiate crystal nucleation, and promote columnar grain growth in a same direction as an easy axis of the rare earth permanent magnet phase. The method also includes repeating the depositing and scanning to form bulk anisotropic rare earth alloy magnet with aligned columnar grains.

Abstract: A rotor for an electric machine includes pairs of magnets with a bridge region therebetween. Lamination that comprise the rotor may define openings in the bridge region between the magnets of each of the pairs. A clip may be installed in the openings and a bonding material may fill the remainder of the bridge region.

Abstract: A stator for an electric machine is formed in stratified layer forming a core having axial slots, and a plurality of hurdle-shaped conductors. Each conductor includes first and second uprights disposed in the slots, and a bridge connecting the uprights and extending circumferentially over a core end surface. The first upright is radially closer to a core central axis than the second upright. Each bridge steps radially outward from the first upright to the second upright. Radially adjacent bridges nest next to one another without crossing over one another. A junction between the first end of the bridge and the first upright defines a radially outward-facing ledge, and a junction between the second end and the second upright defines a radially inward-facing ledge. Each bridge passes over the outward-facing ledge of its radially inwardly adjacent conductor and passing over the inward-facing ledge of its radially outward adjacent conductor.

Abstract: Methods for tuning properties of electric machines are disclosed. A method for reducing core loss in an electric machine includes punching a plurality of laminations from one or more electrical steel sheets that results in one or more cut edges. The method further includes assembling the laminations into a core such that an outer perimeter surface of the core is defined by the cut edges. The method further includes peening the outer perimeter surface to remove residual stresses.

Abstract: According to an embodiment, a composite permanent magnet includes a matrix of magnetically hard phase grains having an average grain size of 10 nm to 50 ?m; and magnetically soft phase grains embedded within the matrix, and having an average grain size of at least 50 nm, each grain having an elongated shape with an aspect ratio of at least 2:1. According to another embodiment, a composite permanent magnet includes a matrix of magnetically hard phase grains having an average grain size of 10 nm to 50 ?m; and magnetically soft phase grains embedded within the matrix, and having an average grain width of at least 50 nm, an average grain height of 20 to 500 nm, and an aspect ratio of at least 2:1. According to yet another embodiment, a method of forming a composite permanent magnet is also provided.

Abstract: A vehicle system includes a converter, outlets, and a switching arrangement electrically between the outlets and the converter. A controller is programmed to, responsive to a first request, operate the switching arrangement to electrically connect a line and a neutral to a first outlet and operate the converter to output single-phase power to the first outlet. Responsive to a second request, the controller is configured to operate the switching arrangement to electrically connect a plurality of lines and not the neutral to a second outlet, and operate the converter to output three-phase power to the second outlet.

Abstract: A method of forming an electric machine lamination includes punching a sheet having a first composition to form a cavity and a compressed region at a perimeter of the cavity. The method further includes depositing, within the cavity and on the compressed region, a deposit material having a second composition different than the first composition. The method further includes scanning a beam along the deposit material to form a bound material within the cavity and on the compressed region.

Abstract: A method of forming a magnet is provided. The method includes disposing an anisotropic magnetic powder and a binder within a bed, the anisotropic magnetic powder having a defined magnetization direction. An energy beam selectively melts the binder such that the anisotropic magnetic powder forms a permanent magnet with the defined magnetization direction. The energy beam is a laser beam, a microwave beam and the like.

Abstract: A rotor for an electric machine includes pairs of magnets with a bridge region therebetween. Lamination that comprise the rotor may define openings in the bridge region between the magnets of each of the pairs. A clip may be installed in the openings and a bonding material may fill the remainder of the bridge region.

Abstract: A vehicle includes a pair of power converters. The vehicle includes a socket having an array of power terminals arranged to accept outlets of different power terminal configurations to interconnect the pair therewith. The vehicle includes a panel having an outlet engaged with the socket. The panel includes a controller configured to communicate an electrical rating of the outlet via the socket to define a switching scheme for the pair. The communication is responsive to detecting panel and socket engagement.

Abstract: An electric machine includes a stator core defining slots and a first hairpin assembly installed in the stator core. The first hairpin assembly includes first and second same hairpins, each having first and second ends and separately coated to have first and second outer coating surfaces, respectively. The hairpin assembly is in first and second ones of the slots such that the first and second outer surfaces are touching. A weld material joins the first ends and another weld material joins the second ends.

Abstract: A vehicle includes a power-electronics converter and an electrical outlet in electric communication with the power-electronics converter and configured to power external loads. The vehicle includes at least one electrical outlet including at least a first socket configured to power a first category of external loads and a second socket configured to power a second category of external loads. The vehicle is configured to only power one of the first and second loads at a time. This may be accomplished using physical features or electronically.

Abstract: A vehicle includes an electric machine, an IGBT, and a gate driver. The IGBT has a gate, an emitter, and a collector and is configured to flow an electric charge through a phase of the electric machine. The gate driver is configured to flow current onto the gate at a first level, and in response to a time integral of a voltage across the phase exceeding a predetermined level, transition from the first level to a second level less than the first level.

Abstract: A rotor includes a rotor core lamination. The rotor core lamination includes a first metal alloy that at least partially defines adjacent magnet pockets proximate an outer periphery of the rotor core lamination. The rotor core lamination further includes a second metal alloy different than the first metal alloy that forms at least a portion of a bridge that extends between the magnet pockets. The rotor core lamination further includes permanent magnets disposed in the magnet pockets at opposing sides of the second metal alloy.

Abstract: A vehicle includes an electric machine having a number of pole pairs, N, a position sensor having a number of pole pairs, M, that generates output indicative of a rotational position of the electric machine, and one or more controllers. The one or more controllers generate a remapped rotational position according to a product of the rotational position and L/N, generate a scaled position according to a product of the remapped rotational position and N/M, and command the electric machine to produce a specified torque or speed based on the scaled position. M is not equal to and not a factor of N, and L is a minimum common multiplier of N and M.

Abstract: A three-dimensional magnetic printer includes at least one induction head assembly including an induction heater to heat magnetic material to form an alloy melt and at least one nozzle operable to eject the alloy melt, a coating apparatus, and a base aligned with the at least one nozzle. The induction head assembly deposits at least one alloy melt layer and the coating apparatus forms at least one insulating layer onto the base in accordance with a predetermined pattern to form a three-dimensional article.