Abstract: A lug nut of a wheel assembly of a vehicle may include a base portion including a receiving orifice disposed at a first end of the lug nut and configured to receive a lug of a hub of the wheel assembly, and a secure lug wrench interface disposed at a second end opposite the base portion. The secure lug wrench interface may include a central portion centered along a vertical axis of the lug nut, and a plurality of columns surrounding the central portion. First outer edges of the plurality of columns disposed at the second end may define at least vertices of a first hexagonal pattern. The plurality of columns may be spaced apart from the central portion at the second end. The first outer edges of the plurality of columns may be separated by gaps between each individual column of the plurality of columns.

Abstract: A blanking machine and method for separating at least one blank from a main body of an electrical sheet include an electrically conductive punch and die controlled to contact opposite surfaces of the electrical sheet with the punch and die coupled to an energy storage arrangement, such as one or more capacitors, controlled to rapidly discharge energy between the punch and die through the electrical sheet rapidly heating the electrical sheet within a limited region of a blanking edge between the punch and the die. The punch and die may be electrically insulated except for an uninsulated region in proximity to the blanking edge. The punch may move within the die after discharging the energy storage arrangement to separate the blank from the electrical sheet.

Abstract: An electric machine that includes a core and a plurality of inserts. The core includes layered electrical steel laminations. The core further includes teeth and a plurality of slots. The plurality of inserts are disposed within the plurality of slots of the core as a slot lining. Each insert includes a soft magnetic composite material.

Abstract: A method or process for producing a battery carrier for an electric vehicle, which receives battery cells. The battery carrier is produced in a casting process, such as a rheocasting process.

Abstract: The disclosure relates in general to a method and a system for producing a stator for an electric machine. The stator has a laminated core with individual adjacently arranged steel sheets along an axial direction of the stator. At least some portion of the steel sheets has an electric insulating material. The steel sheets of a laminated core of a stator are stamped out of a raw material. The steel sheets are stacked along the axial direction of the stator to form the laminated core. The steel sheets of the laminated core are clamped along the axial direction of the stator. The clamped laminated core is accommodated in a receptacle. Cut edges of the clamped laminated core accommodated in the receptacle are heated by a heating device in such a way that eddy currents are induced in at least one external portion of the laminated core.

Abstract: An electrical sheet includes an electrical sheet main body produced by additive manufacturing (a 3D screen printing method) from at least a first and a second material. The first and second materials have magnetic properties which differ from one another, and first and second domains are formed in the electrical sheet main body from the first and second materials respectively. An electric machine is also provided. An electric machine and a method for producing an electrical sheet for use in a stator or rotor of an electric machine are also provided.

Abstract: Methods and systems are provided for an electric machine. In one example, a method may include activating an ultrasound emitter of the electric machine to provide ultrasound to a plate stack of a rotor of the electric machine. The method further includes applying ultrasound at different frequencies based on conditions of the electric machine.

Abstract: A method and a tool for manufacturing a laminated core of an electric machine includes a fluidic component being applied on at least one portion of at least one side of a metal sheet using at least one applicator employing an inkjet printing technique. At least one blank of the at least one metal sheet including the at least one fluidic component is die cut. Multiple blanks are aligned with regard to each other for forming the laminated core.

Abstract: The present disclosure relates to rotor laminations having a first region and a second region, wherein the first region is larger than the second region and a first alloy is present in the first region and a second alloy is present in the second region. In accordance with the disclosure, the second alloy is soft-magnetic and has a higher magnetic permeability than the first alloy. The present disclosure further relates to an electric machine and an electrically powered vehicle. In addition, a method for producing the aforementioned rotor laminations is disclosed. For this purpose, a corresponding green part is printed in a stencil printing process and then sintered to form the rotor lamination.

Abstract: A production method for manufacturing a hairpin coil includes positioning a plurality of hairpin-like conductor elements on a coil support such that conductor end portions of conductor elements to be connected, which protrude from the coil support, are arranged adjacent to one another as conductor end portion pairs, securing the relative position of the conductor end portions of a conductor end portion pair, and simultaneously welding the respective conductor end portions of a plurality of conductor end portion pairs by friction welding, by a friction surface of a welding tool being simultaneously moved in a frictional manner along the plurality of conductor end portion pairs.

Abstract: A method of manufacturing a tool part of a forming tool. The method includes forming a tool element of the tool part having a shape-imparting operating face and at least one first cooling duct for cooling a liquid using an additive manufacturing machine. The first cooling duct has at least one rectifier portion including a blocking direction and an opposing passing direction. The blocking direction has a higher flow resistance to cooling liquid than the passing direction.

Abstract: A structural assembly includes a fastener and an additively manufactured component. The additively manufactured component includes a base, a void defined in the base, and a support disposed across the void. The fastener is secured to the base within the void, and the support is captured within a distal end portion of the fastener.

Abstract: A method of manufacturing a plurality of conductor elements includes providing the plurality of conductor elements, each conductor element includes a conductor end section having an electrically insulating surface coating; securing the conductor end sections of the conductor elements with respect to each other; and simultaneously removing at least a portion of the electrically insulating surface coatings of the conductor end sections using a machining surface of a stripping tool being moved along the conductor end sections.

Abstract: Methods and systems are provided for an electrical machine including a shaft configured to rotate about an axis of rotation, a rotor coupled to the shaft and a stator, wherein the rotor includes a first axial end face, a second axial end face, a lateral surface, and at least two cooling channels, wherein the cooling channels each extend into the rotor from an injection opening in the first axial end face, and at least one injection nozzle configured to spray a fluid into the injection opening of the cooling channels when the rotor is rotating.

Abstract: A battery arrangement for a vehicle, comprising a plastic container, having a plastic container base, an electrical line integrated in the plastic container base, a battery unit arranged in the plastic container, an electrical connector which is partially integrated in the plastic container base and provides an electrical connection between the electrical line and the battery unit, a plastic cover, and a temperature control unit which is arranged between the plastic container base and the battery unit, wherein the temperature control unit has a fluid channel through which a temperature control fluid can flow in order to control the temperature of the battery unit.

Abstract: A structural assembly includes a fastener and an additively manufactured component. The additively manufactured component includes a base, a void defined in the base, and a support disposed across the void. The fastener is secured to the base within the void, and the support is captured within a distal end portion of the fastener.

Abstract: The disclosure relates to a method for producing a rotor element for a rotor of an electric machine. The method includes screen printing at least one permanent magnetic material and a non-permanent magnetic material to form the rotor element, simultaneously sintering the permanent magnetic material and the non-permanent magnetic material, and magnetizing the permanent magnetic material.

Abstract: An electrical sheet includes an electrical sheet main body produced by additive manufacturing (a 3D screen printing method) from at least a first and a second material. The first and second materials have magnetic properties which differ from one another, and first and second domains are formed in the electrical sheet main body from the first and second materials respectively. An electric machine is also provided. An electric machine and a method for producing an electrical sheet for use in a stator or rotor of an electric machine are also provided.

Abstract: An additive manufacturing method wherein an object is manufactured by powder being applied layer-by-layer by an application device onto a base along a buildup surface and being bonded in regions to form a matrix. To provide an efficient additive powder bed method, a position of the base is checked by at least one measurement with a sensor device and the position of the base is automatically corrected at least in relation to the application device based on the at least one measurement.

Abstract: An electric machine includes a conductor structure having at least one metallic conductor element made from at least one of aluminum, copper, and silver having a monocrystalline or columnar crystal structure. The conductor structure may be formed from a plurality of individual flat conductor elements integrally bonded together by welding or soldering to form a winding. The metallic conductor element may be cut from an aluminum, copper, or silver bar having a monocrystalline or columnar crystal structure. A wafer having a plurality of conductor elements may be cut from a bar with the conductor elements separated from the wafer.