Abstract: A stator assembly typically includes at least one stator core assembly that generates a magnetic field to rotate a rotor. The stator core assembly includes a core and a coil wrapped around the core to receive a current thus generating the magnetic field. To improve the performance and manufacturability of the stator assembly, a stator core assembly may include an insulator, disposed between the coil and the core, formed as a single flat sheet. A flat manufacturing process allows greater control of the insulator geometry, a broader range of materials to form the insulator, and patterning of structural features into the insulator to improve assembly and performance. The coil of the stator core assembly may also be electrically coupled to a bus bar using a fastener process and/or a crimping process that consumes less energy and occurs at lower temperatures than conventional soldering or welding processes.

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: Conventional axial flux motors typically include multiple rotors and stators resulting in a larger and heavier motor. Additionally, conventional axial flux motors include a housing to protect the rotors and stators, but the housing is often difficult to seal from the environment leading to risks of contaminants (e.g., dirt, water) infiltrating the motor and causing failure over time. The present invention overcomes these limitations by disclosing an axial flux motor with a single rotor and two stators. The use of a single rotor reduces the size and weight of the motor. An inboard housing and an outboard housing mechanically support the two stators and are joined together to define an interior cavity. A ring seal is disposed between the two housings to ensure the interior cavity is sealed. Additionally, the two stators may actuate multiple degrees of freedom (DOF) including the rotation of a wheel and actuation of a suspension.

Abstract: An exemplary actuator includes a motor, a transmission, and a support structure. The motor includes two torque sources that apply respective input torques to a rotor, which rotates about a rotation axis in response to a net input torque. The torque sources are arranged such that the input torques are additive, resulting in a vector-summated torque output. The torque sources also generate corresponding reactive torques that are applied to the first stator and the second stator. The transmission couples and constrains the first stator and the second stator such that rotational motion of one stator causes counter rotation of the other stator. Thus, the reactive torques are subtractive resulting a differential torque output. In some applications, the differential torque output is used to actuate a suspension of a vehicle. The actuator is also coupled to the vehicle via the support structure, which also reflects a reaction force or torque to actuate other subsystems (e.g., anti-dive, anti-squat).

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: Conventional axial flux motors typically include multiple rotors and stators resulting in a larger and heavier motor. Additionally, conventional axial flux motors include a housing to protect the rotors and stators, but the housing is often difficult to seal from the environment leading to risks of contaminants (e.g., dirt, water) infiltrating the motor and causing failure over time. The present invention overcomes these limitations by disclosing an axial flux motor with a single rotor and two stators. The use of a single rotor reduces the size and weight of the motor. An inboard housing and an outboard housing mechanically support the two stators and are joined together to define an interior cavity. A ring seal is disposed between the two housings to ensure the interior cavity is sealed. Additionally, the two stators may actuate multiple degrees of freedom (DOF) including the rotation of a wheel and actuation of a suspension.

Abstract: An exemplary actuator includes a motor, a transmission, and a support structure. The motor includes two torque sources that apply respective input torques to a rotor, which rotates about a rotation axis in response to a net input torque. The torque sources are arranged such that the input torques are additive, resulting in a vector-summated torque output. The torque sources also generate corresponding reactive torques that are applied to the first stator and the second stator. The transmission couples and constrains the first stator and the second stator such that rotational motion of one stator causes counter rotation of the other stator. Thus, the reactive torques are subtractive resulting a differential torque output. In some applications, the differential torque output is used to actuate a suspension of a vehicle. The actuator is also coupled to the vehicle via the support structure, which also reflects a reaction force or torque to actuate other subsystems (e.g., anti-dive, anti-squat).

Abstract: A stator assembly typically includes at least one stator core assembly that generates a magnetic field to rotate a rotor. The stator core assembly includes a core and a coil wrapped around the core to receive a current thus generating the magnetic field. To improve the performance and manufacturability of the stator assembly, a stator core assembly may include an insulator, disposed between the coil and the core, formed as a single flat sheet. A flat manufacturing process allows greater control of the insulator geometry, a broader range of materials to form the insulator, and patterning of structural features into the insulator to improve assembly and performance. The coil of the stator core assembly may also be electrically coupled to a bus bar using a fastener process and/or a crimping process that consumes less energy and occurs at lower temperatures than conventional soldering or welding processes.

Abstract: Conventional axial flux motors typically include multiple rotors and stators resulting in a larger and heavier motor. Additionally, conventional axial flux motors include a housing to protect the rotors and stators, but the housing is often difficult to seal from the environment leading to risks of contaminants (e.g., dirt, water) infiltrating the motor and causing failure over time. The present invention overcomes these limitations by disclosing an axial flux motor with a single rotor and two stators. The use of a single rotor reduces the size and weight of the motor. An inboard housing and an outboard housing mechanically support the two stators and are joined together to define an interior cavity. A ring seal is disposed between the two housings to ensure the interior cavity is sealed. Additionally, the two stators may actuate multiple degrees of freedom (DOF) including the rotation of a wheel and actuation of a suspension.

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: Conventional axial flux motors typically include multiple rotors and stators resulting in a larger and heavier motor. Additionally, conventional axial flux motors include a housing to protect the rotors and stators, but the housing is often difficult to seal from the environment leading to risks of contaminants (e.g., dirt, water) infiltrating the motor and causing failure over time. The present invention overcomes these limitations by disclosing an axial flux motor with a single rotor and two stators. The use of a single rotor reduces the size and weight of the motor. An inboard housing and an outboard housing mechanically support the two stators and are joined together to define an interior cavity. A ring seal is disposed between the two housings to ensure the interior cavity is sealed. Additionally, the two stators may actuate multiple degrees of freedom (DOF) including the rotation of a wheel and actuation of a suspension.

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: An exemplary actuator includes a motor, a transmission, and a support structure. The motor includes two torque sources that apply respective input torques to a rotor, which rotates about a rotation axis in response to a net input torque. The torque sources are arranged such that the input torques are additive, resulting in a vector-summated torque output. The torque sources also generate corresponding reactive torques that are applied to the first stator and the second stator. The transmission couples and constrains the first stator and the second stator such that rotational motion of one stator causes counter rotation of the other stator. Thus, the reactive torques are subtractive resulting a differential torque output. In some applications, the differential torque output is used to actuate a suspension of a vehicle. The actuator is also coupled to the vehicle via the support structure, which also reflects a reaction force or torque to actuate other subsystems (e.g., anti-dive, anti-squat).

Abstract: Conventional axial flux motors typically include multiple rotors and stators resulting in a larger and heavier motor. Additionally, conventional axial flux motors include a housing to protect the rotors and stators, but the housing is often difficult to seal from the environment leading to risks of contaminants (e.g., dirt, water) infiltrating the motor and causing failure over time. The present invention overcomes these limitations by disclosing an axial flux motor with a single rotor and two stators. The use of a single rotor reduces the size and weight of the motor. An inboard housing and an outboard housing mechanically support the two stators and are joined together to define an interior cavity. A ring seal is disposed between the two housings to ensure the interior cavity is sealed. Additionally, the two stators may actuate multiple degrees of freedom (DOF) including the rotation of a wheel and actuation of a suspension.

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a mechanical guide system supporting the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis; and a multi-bar linkage mechanism connecting to each of the first and third rotating assemblies and connecting the hub assembly to the mechanical guide system, wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and third r

Abstract: An electric drive system including: a rotary motor system including a hub assembly, a first rotating assembly, a second rotating assembly, and a third rotating assembly, wherein the hub assembly defines a rotational axis about which the first rotating assembly, the second rotating assembly, and the third rotating assembly are coaxially aligned and are capable of independent rotational movement independent of each other; a multi-bar linkage mechanism connected to each of the first and third rotating assemblies and connected to the hub assembly and constraining movement of the hub assembly so that the rotational axis of the hub assembly moves along a defined path that is in a transverse direction relative to the rotational axis and wherein the multi-bar linkage mechanism causes the rotational axis of the hub assembly to translate along the defined path in response to relative rotation of the first rotating assembly and the third rotating assembly with respect to each other.

Abstract: An electric motor including: a hub assembly defining a rotational axis; a magnetic rotor assembly; a first coil stator assembly; a second coil stator assembly; and a system of rotor bearings rotatably supporting each of the magnetic rotor assembly, the first coil stator assembly, and the second coil stator assembly on the hub assembly so that each of the magnetic rotor assembly, the first coil stator assembly, and the second coil stator assembly are rotatable about the rotational axis independently of each other.