Abstract: A modular stator-inverter assembly for an electric machine includes a stator and a traction power inverter module (“TPIM”). The stator includes a stator core having a center axis, an inner diameter (“ID”), an outer diameter (“OD”), and electrical conductors forming stator windings. Stator teeth extending radially toward the center axis from the ID collectively define stator slots occupied by the stator windings. Each adjacent pair of stator teeth defines a respective stator slot. The TPIM delivers a polyphase voltage to the stator windings to generate a predetermined number of stator poles, such that the stator has either two, three, or four of the stator slots per electric phase per stator pole. The stator defines a center cavity and is configured to receive a selected rotor from an inventory of preconfigured machine rotors. The inventory includes multiple synchronous reluctance machine rotors and an induction machine rotor.

Abstract: An electric machine includes a housing, a rotor rotatably mounted to the housing, and a stator mounted to the housing about the rotor. The stator includes a stator body formed from a plurality of laminations. The plurality of laminations include an outer annular surface defining a radius, an inner annular surface spaced from the rotor, and a plurality of radially inwardly extending stator teeth spaced one from another by plurality of gaps. Each of the plurality of gaps extend along the radius and include an opening exposed at the inner annular surface. The opening has a first side portion and a second side portion each extending at an angle relative to the radius.

Abstract: Presented are segmented hairpin bar conductors for electric machines, methods for making/using such segmented bar conductors, electromagnetic motors using such segmented bar conductors, and vehicles equipped with an induction motor generator unit using segmented hairpin bar conductors. An electric machine includes a stator that defines multiple circumferentially spaced, radially elongated stator slots. A rotor is located adjacent and movable with respect to the stator. One or more permanent magnets are mounted to the rotor, and one or more U-shaped hairpin windings are mounted to the stator in juxtaposed spaced relation to the magnet(s). Each hairpin winding is formed from an array of collimated, electrically conductive wires that are bundled together into a unitary bar conductor. The segmented hairpin winding has a pair of hairpin legs, each of which adjoins and projects from a respective end of a hairpin crown. Each hairpin leg inserts into a respective one the stator slots.

Abstract: A rotor core for an electric motor includes a core stack including a plurality of lamination plates, each lamination plate including a plurality of apertures formed therein, the plurality of apertures of each of the lamination plates axially aligned and defining a plurality of axial magnet slots extending through the core stack and adapted to support a plurality of permanent magnets therein, and at least one insert extending axially through the core stack and adapted to provide radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the electric motor.

Abstract: A charging system includes a scalable power source for powering a motor of a vehicle and telematics and battery management modules. The scalable power source includes: N battery packs, where N is an integer greater than or equal to 3; and multiple switches connected to the N battery packs including N?1 switches for serially connecting the N battery packs between supply and return lines and a multiple of N switches for parallel connecting the N battery packs to the supply and return lines. The telematics module requests capability of a charging station and receives a response signal from a device indicating the capability of the charging station. The battery management module: based on the capability of the charging station, selects one of the available arrangements in which to connect the N battery packs, sets states of the multiple switches; and then charges the N battery packs based on the states.

Abstract: The present disclosure discloses a vehicle propulsion system. The vehicle propulsion system includes a first electric machine including a first set of machine windings that are configured to cause a rotor to rotate about an axis to selectively drive a transmission during a first vehicle operating state and a second electric machine including a second set of machine windings that are configured to cause a rotor to rotate about an axis selectively drive the transmission during at least one of the first vehicle operating state or a second vehicle operating state. The second vehicle operating state different from the first operating state, and a number of series turns per phase for the first set of machine windings is different from a number of series turns per phase for the second set of machine windings.

Abstract: An electric propulsion system includes a rotary electric machine having an output member, a rechargeable energy storage system (“RESS”) connected to the electric machine, a user interface device, and a controller. The RESS includes multiple battery modules and a switching circuit, the latter being configured, in response to electronic switching control signals, to connect the battery modules in a parallel-connected (“P-connected”) configuration or a series-connected (“S-connected”) configuration, as a selected battery configuration. The user interface device receives an operator-requested drive mode signal indicative of a desired drive mode of the electric propulsion system.

Abstract: An electric machine includes a stator and a rotor positioned in operational engagement with one another and defining a radial gap extending circumferentially between the stator and the rotor, the rotor including a plurality of rotor segments defining a plurality of segment gaps between adjacent pairs of the plurality of rotor segments, the rotor segments radially moveable relative to the stator, wherein movement of the plurality of rotor segments radially outward increases the radial gap between the stator and the rotor and the segment gaps between adjacent pairs of the plurality of rotor segments.

Abstract: A rotor core for an electric motor includes a core stack including a plurality of identical lamination plates, each lamination plate including a plurality of magnet slots formed therein, the magnet slots of each of the lamination plates axially aligned and adapted to support a plurality of permanent magnets therein, and a plurality of heat conductive inserts extending axially through the core stack and adapted to conduct heat from inner portions of the core stack outward toward distal ends of the core stack.

Abstract: A mobile power source apparatus includes a mobile unit having a platform structure, a frame connected to the platform structure and multiple wheels rotatably connected to the platform structure to promote moving the mobile unit. An electronics power module is connected to a DC power source defining a high voltage DC battery. The electronics power module converts DC energy of the DC battery to at least one of an alternating current (AC) power and a direct current (DC) power. A wireless communication device promotes wireless communication of a battery state-of-charge (SOC) of the high voltage DC battery. A liquid cooling thermal system provides positive cooling of the electronics power module.

Abstract: A mobile power source apparatus includes a mobile unit having a platform structure, a frame connected to the platform structure and multiple wheels rotatably connected to the platform structure to promote moving the mobile unit. An electronics power module is connected to a DC power source defining a high voltage DC battery. The electronics power module converts DC energy of the DC battery to at least one of an alternating current (AC) power and a direct current (DC) power. A wireless communication device promotes wireless communication of a battery state-of-charge (SOC) of the high voltage DC battery. A liquid cooling thermal system provides positive cooling of the electronics power module.

Abstract: A rotor core for an electric motor includes a core stack including a plurality of lamination plates, each lamination plate including a plurality of apertures formed therein, the plurality of apertures of each of the lamination plates axially aligned and defining a plurality of axial magnet slots extending through the core stack and adapted to support a plurality of permanent magnets therein, and at least one insert extending axially through the core stack and adapted to provide radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the electric motor.

Abstract: A method of controlling fast charging of at least one battery pack within a high voltage electrical propulsion system includes identifying an operating condition, wherein the operating condition is one of charging mode and propulsion mode, and, when the electrical system is in charging mode, initiating charging of the at least one battery pack, terminating charging of the at least one battery pack and connecting the at least one battery pack to power components of the electrical propulsion system when there is a request to terminate charging of the at least one battery pack, and terminating charging of the at least one battery pack and connecting the at least one battery pack to power components of the electrical propulsion system when there is no request to terminate charging of the at least one battery pack and the charging of the at least one battery pack is complete.

Abstract: A current command module is configured to, based on a direct current (DC) bus voltage for an electric motor of the vehicle, generate a d-axis current command for the electric motor and a q-axis current command for the electric motor. A voltage command module configured to generate voltage commands based on the d-axis current command and the q-axis current command. A battery switching control module is configured to: determine a voltage operating state of a battery based on the voltage commands; compare a battery parameter to at least one of a predetermined voltage parameter and a predetermined current parameter during a dwell time when a plurality of switches of the battery are open; and generate a switch control signal to transition at least one switch of the plurality of switches to cause the battery to operate in the voltage operating state based on the comparison.

Abstract: Presented are segmented hairpin bar conductors for electric machines, methods for making/using such segmented bar conductors, electromagnetic motors using such segmented bar conductors, and vehicles equipped with an induction motor generator unit using segmented hairpin bar conductors. An electric machine includes a stator that defines multiple circumferentially spaced, radially elongated stator slots. A rotor is located adjacent and movable with respect to the stator. One or more permanent magnets are mounted to the rotor, and one or more U-shaped hairpin windings are mounted to the stator in juxtaposed spaced relation to the magnet(s). Each hairpin winding is formed from an array of collimated, electrically conductive wires that are bundled together into a unitary bar conductor. The segmented hairpin winding has a pair of hairpin legs, each of which adjoins and projects from a respective end of a hairpin crown. Each hairpin leg inserts into a respective one the stator slots.

Abstract: An electric machine includes a machine rotor circumscribed by a machine stator, and having a rotor shaft, rotor stack, and end cap which rotate about an axis. The end cap includes lobes equal in number to a number of pole pairs of the machine rotor. A position sensor assembly has a predetermined alignment with the machine rotor and stator. The sensor assembly includes a sensor rotor formed by the lobes and a sensor stator having a printed circuit board with conductive sine and cosine traces. Machine rotor rotation causes the sensor assembly to output an unmodulated sine and cosine signals to a controller, which then calculates a calibrated reference angle. A magnetic axis of an electrical phase of the machine is aligned with and bisects a peak of the sine trace. A direct axis of the machine rotor aligns with an edge of a lobe.

Abstract: A bi-material permanent magnet for an electric machine includes a core including a first magnetic material and a shell portion located on the core and made of a second magnetic material. The first magnetic material comprises a magnet material with an energy less than 20 Mega Gauss Oersteds (MGOe). The second magnetic material comprises a magnet material with an energy greater than 30 MGOe.

Abstract: An electric machine includes a stator and a rotor positioned in operational engagement with one another and defining a radial gap extending circumferentially between the stator and the rotor, the rotor including a plurality of rotor segments defining a plurality of segment gaps between adjacent pairs of the plurality of rotor segments, the rotor segments radially moveable relative to the stator, wherein movement of the plurality of rotor segments radially outward increases the radial gap between the stator and the rotor and the segment gaps between adjacent pairs of the plurality of rotor segments.

Abstract: Presented are segmented hairpin bar conductors for electric machines, methods for making/using such segmented bar conductors, electromagnetic motors using such segmented bar conductors, and vehicles equipped with an induction motor generator unit using segmented hairpin bar conductors. An electric machine includes a stator that defines multiple circumferentially spaced, radially elongated stator slots. A rotor is located adjacent and movable with respect to the stator. One or more permanent magnets are mounted to the rotor, and one or more U-shaped hairpin windings are mounted to the stator in juxtaposed spaced relation to the magnet(s). Each hairpin winding is formed from an array of collimated, electrically conductive wires that are bundled together into a unitary bar conductor. The segmented hairpin winding has a pair of hairpin legs, each of which adjoins and projects from a respective end of a hairpin crown. Each hairpin leg inserts into a respective one the stator slots.

Abstract: A disconnect device includes a mounting plate having a thermally conductive substrate applied onto the mounting plate. A first layer of an electrically conductive material is applied onto the substrate. A semiconductor switch supported on the first layer connects or disconnects an input power source to or from a load. A second layer of an electrically conductive material applied onto the substrate is electrically isolated from the first layer. An electronic sensing, control and protection circuit is supported on the second layer and is connected to the semiconductor switch to control operation of the semiconductor switch. A control unit in communication with the electronic sensing, control and protection circuit via an electrically isolated control path provides control and communication between the electronic sensing, control and protection circuit and the semiconductor switch.