Abstract: A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.

Abstract: A synchronous reluctance motor includes a stator and a rotor. The rotor is configured to rotate relative to the stator about a rotational axis. The rotor is spaced apart from the stator to define an air gap between the stator and the rotor and includes a rotor core defines an outermost rotor surface and an innermost rotor surface opposite the innermost rotor surface. The rotor core includes a plurality of ribs separating rotor cavities from each other and includes a plurality of rotor bridges separating the air gap and the rotor cavities. Permanent magnets are each disposed in one of the rotor cavities. The magnet surface area of the permanent magnets is less than cavity surface area of the rotor cavities. Each of the permanent magnets is adjacent to the outermost rotor surface to maximize magnetic saturation at the ribs and the rotor bridges.

Abstract: The present disclosure provides a method for manufacturing a stator which includes the following steps: (1) providing a plurality of stator laminations; (2) stacking the plurality of stator laminations in a stator housing; (3) providing a plurality of conductors; (4) sliding at least two linear portions of each conductor into a corresponding dual position slot for the linear portion; (5) applying a jig to the plurality of dual position slots so as to close the dual position slots into a closed position. The plurality of stator laminations defining a plurality of dual position slots being in an open position when the stator laminations are stacked in the stator housing.

Abstract: A synchronous reluctance electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of packets assembled from anisotropic material are disposed in the slots.

Abstract: A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.

Abstract: An interior permanent magnet electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of permanent magnets are disposed in a first subset of the slots, and plurality of packets assembled from anisotropic material are disposed in a second subset of the slots.

Abstract: A synchronous reluctance motor includes a stator and a rotor. The rotor is configured to rotate relative to the stator about a rotational axis. The rotor is spaced apart from the stator to define an air gap between the stator and the rotor and includes a rotor core defines an outermost rotor surface and an innermost rotor surface opposite the innermost rotor surface. The rotor core includes a plurality of ribs separating rotor cavities from each other and includes a plurality of rotor bridges separating the air gap and the rotor cavities. Permanent magnets are each disposed in one of the rotor cavities. The magnet surface area of the permanent magnets is less than cavity surface area of the rotor cavities. Each of the permanent magnets is adjacent to the outermost rotor surface to maximize magnetic saturation at the ribs and the rotor bridges.

Abstract: A synchronous reluctance electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of packets assembled from anisotropic material are disposed in the slots.

Abstract: An interior permanent magnet electric machine is described, and includes a stator including a plurality of electrical windings and a rotor disposed in a cylindrically-shaped void formed within the stator. The rotor includes a plurality of steel laminations assembled onto a shaft, wherein the shaft defines a longitudinal axis. Each of the steel laminations includes a plurality of poles and each of the poles includes a plurality of slots disposed near an outer periphery. The slots of the steel laminations are longitudinally aligned. A plurality of permanent magnets are disposed in a first subset of the slots, and plurality of packets assembled from anisotropic material are disposed in a second subset of the slots.

Abstract: An electrical system includes an alternating current (AC) connector rod assembly and a polyphase electric machine. The electric machine has a plurality of phase leads each electrically connected to the AC connector rod assembly. The assembly includes spaced AC connector rods each having a center axis. The assembly also includes insulating housings and a carrier plate defining through holes that receive and space the AC connector rods. The carrier plate defines features that engage mating features of the insulating housings while allowing each of the rods to rotate about its respective center axis within the carrier plate. A vehicle includes a direct current (DC) battery pack, a DC bus, an AC bus, a PIM that is electrically connected on a first side to the DC bus and on a second side to the AC bus, the AC connector rod assembly, a traction motor, and a transmission.

Abstract: Automotive propulsion systems and methods of operation are provided. The automotive propulsion system includes a first voltage source, a power electronics device comprising a plurality of power switching devices coupled to the first voltage source, an electric motor having a plurality of windings coupled to the plurality of power switching devices and a neutral node interconnecting the plurality of windings, and a second voltage source coupled to the neutral node of the electric motor and the first voltage source.

Abstract: An electrical system includes an alternating current (AC) connector rod assembly and a polyphase electric machine. The electric machine has a plurality of phase leads each electrically connected to the AC connector rod assembly. The assembly includes spaced AC connector rods each having a center axis. The assembly also includes insulating housings and a carrier plate defining through holes that receive and space the AC connector rods. The carrier plate defines features that engage mating features of the insulating housings while allowing each of the rods to rotate about its respective center axis within the carrier plate. A vehicle includes a direct current (DC) battery pack, a DC bus, an AC bus, a PIM that is electrically connected on a first side to the DC bus and on a second side to the AC bus, the AC connector rod assembly, a traction motor, and a transmission.

Abstract: A high frequency rotary transformer for an electrical machine includes a primary transformer component having a primary transformer winding, and a secondary transformer component having a secondary transformer winding. The primary transformer winding is configured to be coupled to a DC power source via a DC to AC converter. The secondary transformer winding is configured to be coupled to a winding of the rotor. Each of the primary and secondary transformer components are mechanically coupled to either the stator or the rotor. The secondary transformer component is configured to rotate with respect to the primary transformer component to produce a magnetic flux via the primary transformer winding and the secondary transformer winding.

Abstract: Systems and methods are provided for an automotive drive system using an absolute position sensor for field-oriented control of an induction motor. An automotive drive system comprises an induction motor having a rotor, and a position sensor coupled to the induction motor. The position sensor is configured to sense an absolute angular position of the rotor. A processor may be coupled to the position sensor and configured to determine a relative angular position of the rotor based on a difference between the absolute angular position and an initial angular position obtained when the induction motor is started. A controller may be coupled to the induction motor and the processor and configured to provide field-oriented control of the induction motor based on the relative angular position of the rotor.

Abstract: A high frequency rotary transformer for an electrical machine includes a primary transformer component having a primary transformer winding, and a secondary transformer component having a secondary transformer winding. The primary transformer winding is configured to be coupled to a DC power source via a DC to AC converter. The secondary transformer winding is configured to be coupled to a winding of the rotor. Each of the primary and secondary transformer components are mechanically coupled to either the stator or the rotor. The secondary transformer component is configured to rotate with respect to the primary transformer component to produce a magnetic flux via the primary transformer winding and the secondary transformer winding.

Abstract: Automotive propulsion systems and methods of operation are provided. The automotive propulsion system includes a first voltage source, a power electronics device comprising a plurality of power switching devices coupled to the first voltage source, an electric motor having a plurality of windings coupled to the plurality of power switching devices and a neutral node interconnecting the plurality of windings, and a second voltage source coupled to the neutral node of the electric motor and the first voltage source.

Abstract: An embodiment of a system for multiple source power conversion is implemented in a vehicle that includes an alternating current (AC) power source and first and second direct current (DC) power sources. The system includes an inverter, a DC-to-DC converter, and a controller. The controller receives external commands, inverter feedback signals, and DC-to-DC converter feedback signals, and executes and inverter control algorithm and DC-to-DC converter control algorithm. An embodiment of a method for multiple source power conversion between an AC power source, and first and second DC power sources includes receiving external commands from a remote source, inverter feedback signals from an inverter, and DC-to-DC converter feedback signals from a DC-to-DC converter. The method also includes executing an inverter control algorithm and a DC-to-DC converter control algorithm to generate drive signals for the inverter and DC-to-DC converter, respectively, based on the received commands and feedback signals.

Abstract: Methods and systems are provided for modeling temperature characteristics of components in a system such as a power module for a hybrid or electric vehicle. A power dissipation value is calculated for each of the components in the system. A first filter is applied to the power dissipation value associated with a selected component to determine its estimated temperature. For each of the neighboring components located adjacent to the selected component, a cross-coupling temperature is estimated by applying other filters to each of the power dissipation values for the neighboring components. The estimated temperature of the selected component and the estimated cross-coupling temperatures for each of the neighboring components can then be added to thereby estimate the operating temperature for the selected component. Further, the operation of the system may be adjusted if the operating temperature determined for the selected component exceeds a threshold value.

Abstract: Methods and systems are provided for modeling temperature characteristics of components in a system such as a power module for a hybrid or electric vehicle. A power dissipation value is calculated for each of the components in the system. A first filter is applied to the power dissipation value associated with a selected component to determine its estimated temperature. For each of the neighboring components located adjacent to the selected component, a cross-coupling temperature is estimated by applying other filters to each of the power dissipation values for the neighboring components. The estimated temperature of the selected component and the estimated cross-coupling temperatures for each of the neighboring components can then be added to thereby estimate the operating temperature for the selected component. Further, the operation of the system may be adjusted if the operating temperature determined for the selected component exceeds a threshold value.

Abstract: A coaxial stack of laminations for a stator of an electrical machine uses laminations that are substantially identical and in direct abutment with one another. Each of the laminations has an outer periphery and an inner periphery with the outer periphery being defined by an array of outwardly projecting pins and the inner periphery being defined by an array of inwardly projecting teeth. The outwardly projecting pins cooperate with a jacket surrounding the stack to provide a cooling space through which cooling liquid flows while the teeth provide spaces therebetween for receiving for receiving stator windings. The number of pins (npin) is proportional to the number of teeth (nth) according to the relationship (2K+1)/(2Kth) times the number of teeth (nth), where K is a selected integer number and Kth is the number of teeth past which each lamination is rotated with respect to adjacent laminations so that spaces between the teeth of adjacent laminations are aligned.