Abstract: Methods and apparatus are provided for an axial electric motor. The apparatus comprises, a stator having coils thereon for producing a magnetic field, a rotor rotated by the magnetic field, an output shaft coupled to the rotor, and a ring incorporating a coolant channel circumferentially engaging the stator for absorbing heat and reaction torque from the stator. It is preferable that that the ring have inwardly extending teeth that mesh with the coils on the stator. The space between the teeth and the coils is preferably filled with a substantially solid thermally conductive material to transmit stator reaction torque to the teeth and cool the stator. The coils are preferably formed from a flat ribbon a portion of whose principal surface is perpendicular to the teeth. A supporting frame is desirably fixedly coupled to the ring and rotatably coupled to the output shaft.

Abstract: Alternating current motors used to drive wheels of hybrid or fuel cell vehicles have capacitors which are mounted diametrically on the motors, i.e., mounted around the diameter of the motors. The capacitors may be annular or arcuate in shape. By so configuring the power capacitors, axial space adjacent to the motors is reduced, providing enhanced design flexibility for automotive vehicles.

Abstract: Methods and apparatus are provided for an electric vehicle embodying an axial flux traction motor directly coupled to a wheel thereof. The fraction motor includes a stator having coils for producing a magnetic field, an annular rotor magnetically coupled to the stator and mechanically to an output shaft Permanent magnets of alternating polarity are mounted on the annular rotor. Magnetic shunts bridge a portion of the stator slots above the coils. The magnets are arranged in groups with group-to-group spacing exceeding magnet-to-magnet spacing. Adjacent edges of the magnets diverge. The method comprises, looking up d- and q-axis currents to provide the requested torque and motor speed for the available DC voltage, combining at least one of the d- and q-axis currents with a field weakening correction term, converting the result from synchronous to stationary frame and operating an inverter therewith to provide current to the coils of the motor.

Abstract: In order to provide a modular arrangement, an inverter for an electric traction motor used to drive an automotive vehicle is positioned in proximity with the traction motor. The inverter is located within a compartment adjacent to one end of the electric traction motor and is cooled in a closed system by spraying a liquid coolant directly onto the inverter. The liquid coolant absorbs heat from the inverter and is cooled by a heat exchange arrangement comprising a reservoir with pipes carrying a second coolant from the radiator of the automotive vehicle. In a preferred embodiment, the coolant is collected from the inverter in an annular reservoir that is integral with the compartment containing the inverter. In accordance with one embodiment of the cooling arrangement, heat from the inverter vaporizes the liquid coolant by absorbing heat from the inverter during a phase change from a liquid to a vapor.

Abstract: A method of controlling an IPM machine having a salient rotor. Stator terminal signals are measured and rotated to obtain synchronous reference frame current signals. A rotor position is estimated based on an impedance generated using the rotor and included in the current signals. The estimated rotor position is used to control the machine. An alternator-starter system in which this method is used can provide high cranking torque and generation power over a wide speed range while providing operational efficiency.

Abstract: A power module with heat sources wherein the heat is dissipated by a heat sink. The heat sink includes a manifold with coolant flowing therein. An opening on the manifold enables the coolant to come in direct contact with a base plate of the power module. The power module being retained on the heat sink by a plurality of spring clips.

Abstract: A wheel motor traction assembly configured for use on a light duty vehicle adaptable for electric traction. The wheel motor traction assembly includes a wheel, a brake disc operatively connected to the wheel, a motor operatively connected to the wheel and a motor housing operatively connected to the motor. The motor housing has structural connectors for steering and suspension systems on a vehicle chassis and has a brake caliper operatively connected thereto. A parking brake caliper may also be connected to the motor housing for connection to a parking brake cable on the chassis. The motor housing is configured to bear vehicle chassis loads as the motor housing structurally interconnects the wheel to the chassis through the structural connectors.

Abstract: A wheel motor traction assembly configured for use on a light duty vehicle adaptable for electric traction. The wheel motor traction assembly includes a wheel, a brake disc operatively connected to the wheel, a motor operatively connected to the wheel and a motor housing operatively connected to the motor. The motor housing has structural connectors for steering and suspension systems on a vehicle chassis and has a brake caliper operatively connected thereto. A parking brake caliper may also be connected to the motor housing for connection to a parking brake cable on the chassis. The motor housing is configured to bear vehicle chassis loads as the motor housing structurally interconnects the wheel to the chassis through the structural connectors.

Abstract: A power electronics cooling housing for use in a power electronics system. The power electronics cooling housing has a body with a coolant cavity formed in one surface and a capacitor bus assembly potting cavity formed in an opposite surface. A bus bar passthrough opening is formed through the body. The bus bar passthrough opening provides an opening from the coolant cavity and the capacitor bus assembly potting cavity. A coolant inlet manifold having a coolant cavity inlet and a coolant outlet manifold having a coolant cavity outlet are formed in the body that are coupled to respective ends of the coolant cavity. An environmental sealing gasket surrounds the coolant cavity.

Abstract: A power electronics chassis (10) for electric vehicles and other applications that use liquid coolant to cool power electronic devices (20) contained within the chassis. The chassis (10) includes an electrically conductive housing (12) and an electrically non-conductive manifold (16) that permits coolant flow into and out of the housing. The housing (12) has at least one wall (34) that includes an outer surface (42) and a pair of recessed apertures (36,72), each of which provide access to an interior region (38) of the housing (12) via a passageway (40,74). The manifold (16) has an inlet (26) and an outlet (28), each of which has a connecting tube (54,80) that extends through one of the passageways (40,74). Each passageway (40,74) is defined by an axial wall (44,78) of the housing (12) that extends towards the interior region (38) from the outer surface (42) to its respective aperture.

Abstract: A thermally cooled power electronics system. A cooling housing has a body with a coolant cavity formed in one surface and a capacitor bus assembly potting cavity formed in an opposite surface. A bus bar passthrough opening is formed through the body, along with a coolant inlet and outlet manifolds having a coolant cavity inlet outlet that are coupled to respective ends of the coolant cavity. An environmental sealing gasket surrounds the coolant cavity. A plurality of laminated copper bus bars are disposed through the bus bar passthrough opening. A laminated horizontal bus bar assembly extends along the length of the housing above the coolant cavity and has horizontal bus bars that are coupled to the laminated copper bus bars. A battery input connector is coupled by way of a vertical bus bar assembly to the horizontal bus bar assembly. A plurality of power switching devices are coupled to the laminated horizontal bus bar assembly.

Abstract: A chassis cast power connector with coaxial shielding is presented according to the present invention. In an exemplary embodiment, the chassis cast power connector comprises a connector receptacle which is integrally cast with a chassis and extends away from one surface of the chassis. The connector receptacle includes an opening which receives male and female connector members, wherein the male connector member is capable of being slidably received in the female connector receptacle to form an electrical connection therebetween. The integral connector receptacle provides coaxial shielding of the electrical connection.

Abstract: A power electronics chassis (10) and liquid-cooled heat sink mounting assembly for electric vehicles and other applications that use liquid coolant to cool power electronic devices (20) contained within an electrically conductive housing (12). The power electronics chassis (10) includes an inverter (18) containing power switching devices (20) that are heat sunk using the liquid-cooled mounting assembly. The mounting assembly includes a heat exchanger (22) and a plastic, electrically non-conductive coolant manifold (16) that has an inlet (26) and outlet (28) for passage of liquid coolant into and out of the electronics housing (12). The power switching devices (20) are attached to a mounting surface (40) of the heat exchanger (22) and are thermally coupled to the coolant within the heat exchanger (22) via the mounting surface (40).

Abstract: A pin fin heat sink having mixed geometry pin fin configurations is presented. The mixed geometry pin fin configuration are designed to optimize the positive attributes of each individual pin fin geometry to provide a low cost overall system and provide better system performance in high flow rate systems. In an exemplary embodiment, the pin fin heat sink comprises a base surface having a plurality of pin fins perpendicular to and protruding therefrom. The plurality of pin fins actually comprises a plurality of pin fins having a first configuration and a plurality of pin fins having a second configuration. The second configuration pin fins are intended to streamline any turbulence created by the first configuration pin fins which are located upstream of the second configuration pin fins. Preferably, the first configuration comprises substantially circular shaped pin fins and the second configuration comprises substantially elliptical shaped pin fins.