Abstract: A core structure for an electromagnetic actuator includes an electrically conductive magnetic core component having a magnetic axis, an outer surface between axially opposite ends and at least one slit arranged between said axially opposite ends through the outer surface.

Abstract: An electric motor includes a rotor having a stack of laminations positioned axially relative to one another. The stack of laminations includes a first rotor lamination that is divided into a first portion and a second portion. The first rotor lamination is configured to have an asymmetric mass distribution such that the first portion has a first mass and the second portion has a second mass, with the first mass being different from the second mass. The electric motor is configured to selectively generate an unbalanced force during operation (i.e., when the rotor is spinning). The electric motor may include a stator configured to have an asymmetric magnetic field distribution. The electric motor may be employed in a haptic assembly and eliminates the need for a separate eccentric mass to generate a haptic signal.

Abstract: An electric starter system is used with an engine. The starter system may include a solenoid device coupled to a pinion gear, a brushless starter motor connectable to the engine via the pinion gear during a requested engine start event, and a controller. In response to the start event, when the engine speed is less than a threshold speed, the controller delivers a control current to the solenoid device at a peak current level sufficient for translating the pinion gear into contact with the flywheel. The control current is reduced to a holding current level less than the peak current level after the pinion gear is engaged with the flywheel. Motor torque is commanded from the starter motor, through the pinion gear, and to the flywheel while maintaining the holding current level, and held for a duration sufficient for starting the engine.

Abstract: A brushless electric motor includes a motor casing having a first bearing, a motor end-cap including a second bearing, a multi-phase stator assembly, and a rotor assembly having a rotor shaft. The shaft has a first end, a second end, and a knurled section therebetween. The shaft also has a first bearing surface proximate the first end and supported by the first bearing, a second bearing surface proximate the second end and supported by the second bearing, and a rotor position and speed sensor target. The shaft additionally has a sun gear integrated with the shaft proximate the first bearing surface for engaging a partial planetary gear set. The rotor assembly also includes a rotor lamination fixed to the shaft at the knurled section and having opposing first and second sides, and first and second end plates arranged on the respective first and second sides of the rotor lamination.

Abstract: A starter system includes a brushless electric starter motor and a battery power pack, the motor operatively connectable to an internal combustion engine of a powertrain. A power inverter converts direct current provided from the battery power pack to multi-phase alternating current to drive the motor. A pinion gear with one-way clutch is rotatably driven by the motor and movable between a disengaged position and an engaged position in which the pinion gear is meshingly engaged with a ring gear operatively connected to a crankshaft of the engine. A solenoid is operatively connected to the pinion gear. An electronic control system controls the motor to crank the engine using power provided from the battery power pack, and to separately command the solenoid to a disabled or an enabled state. A method of controlling the starter system controls the motor to crank the engine in a restart following an autostop.

Abstract: A starter assembly includes a partial planetary gear set connected to a pinion gear slidable along a first axis. The starter also includes a motor casing housing a brushless electric motor and having a first bearing. The motor includes multi-phase stator and rotor assemblies arranged inside the casing concentrically relative to the first axis. The rotor assembly has a rotor with a shaft supported by the first bearing and connected to a sun gear engaging the gear set, and a rotor position and speed sensor target. The starter additionally includes a motor end-cap for mating with and enclosing the motor casing and having a second bearing supporting the shaft. The starter also includes an electronics cover with a power connector for mating with the end-cap and housing an electronic commutator assembly. The commutator assembly includes power electronics, and control processor electronics arranged between the end-cap and the power electronics.

Abstract: A starter includes a three-phase switched reluctance electric motor including a rotor and a stator, a pinion gear, a power inverter that is connected to the stator, and a rotational position sensor. The rotor includes a quantity of rotor poles that is between 6 and 16, and the stator includes a quantity of stator poles that is between 8 and 24. An outer diameter of the electric motor is less than 85 mm. An active length of the motor is less than 50 mm. An airgap distance between the rotor and the stator is between 0.1 mm and 0.5 mm. A ratio between a rotor pole arc and a stator pole arc is at least 1.0:1. A ratio between a stator diameter and a rotor diameter is at least 2.0:1, and a ratio between a stator pole height and a rotor pole height is at least 2.5:1.

Abstract: A starter assembly includes a multi-phase brushless electric motor including a stator, a rotor disposed on a rotatable shaft, and a motor endcap disposed at a first end of the stator. An electronic commutator assembly includes a sensing circuit, a control electronics subassembly, a power electronics subassembly and a heat sink. The sensing circuit is disposed adjacent to the second end of the rotatable shaft. The control electronics subassembly, the power electronics subassembly and the heat sink are disposed on disk-shaped devices arranged in a stacked configuration orthogonal to the axis defined by the rotatable shaft. The control electronics subassembly is disposed adjacent to the sensing circuit, and the power electronics subassembly is disposed adjacent to the control electronics subassembly. The control electronics subassembly is interposed between the power electronics subassembly and the sensing circuit. The heat sink is disposed adjacent to the power electronics subassembly.

Abstract: A solenoid assembly includes a solenoid having a coil, a current sensor configured to measure the coil current, and a controller. The controller estimates the coil current using a solenoid model, with output of the solenoid model being an estimated coil current, and receives the measured coil current from the current sensor. The controller also calculates an error value having an error sign by subtracting the estimated coil current from the measured coil current. Responsive to the error value exceeding a calibrated error threshold while the control voltage deviates from a nominal value, the controller diagnoses a solenoid fault condition. Responsive to diagnosing the solenoid fault condition, the controller isolates or identifies a particular solenoid fault condition from among a plurality of possible fault conditions, and records a diagnostic code indicative of the particular solenoid fault condition.

Abstract: An electric powertrain includes an electric machine, an inverter connected to the electric machine, and an energy storage system for providing an electric current. The energy storage system includes a first energy storage device operable at a first device voltage, and a second energy storage device operable at a second device voltage. A plurality of low-loss switching devices interconnect the first energy storage device and the second energy storage device. The switching devices are selectively controllable between a first operating mode for providing the electric current at a first system voltage, and a second operating mode for providing the electric current at a second system voltage. The first system voltage is different from the second system voltage.

Abstract: A solenoid assembly is provided that includes male and female plungers and an electromagnetic coil configured to be energized to create a magnetic flux. Each plunger has a plunger face, where the female plunger face is configured to correspond with the male plunger face. The male plunger has a plurality of angled plunger steps that define the male plunger face, each angled plunger step including a corner having an angle in the range of 95 degrees to 115 degrees. The female plunger face has a similar, corresponding angled face. The solenoid assembly is suitable for use as a long stroke linear solenoid.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: A solenoid assembly is provided that includes male and female plungers and an electromagnetic coil configured to be energized to create a magnetic flux. Each plunger has a plunger face, where the female plunger face is configured to correspond with the male plunger face. The male plunger has a plurality of angled plunger steps that define the male plunger face, each angled plunger step including a corner having an angle in the range of 95 degrees to 115 degrees. The female plunger face has a similar, corresponding angled face. The solenoid assembly is suitable for use as a long stroke linear solenoid.

Abstract: An electric motor includes a rotor having a stack of laminations positioned axially relative to one another. The stack of laminations includes a first rotor lamination that is divided into a first portion and a second portion. The first rotor lamination is configured to have an asymmetric mass distribution such that the first portion has a first mass and the second portion has a second mass, with the first mass being different from the second mass. The electric motor is configured to selectively generate an unbalanced force during operation (i.e., when the rotor is spinning). The electric motor may include a stator configured to have an asymmetric magnetic field distribution. The electric motor may be employed in a haptic assembly and eliminates the need for a separate eccentric mass to generate a haptic signal.

Abstract: An apparatus for flexible DC fast charging of an electrified vehicle includes a charge receptacle and a vehicle charging controller programmed to establish a wireless communication with a charging station. The apparatus further includes a reconfigurable energy storage system selectively and electrically connected to the charge receptacle. The reconfigurable energy storage system includes a first rechargeable energy storage device selectively and electrically connected to the charge receptacle, a second rechargeable energy storage device selectively connected to the charge receptacle, and a plurality of low-loss switching devices selectively connected to the first rechargeable energy storage device and the second rechargeable energy storage device.

Abstract: An electric powertrain includes an electric machine, an inverter connected to the electric machine, and an energy storage system for providing an electric current. The energy storage system includes a first energy storage device operable at a first device voltage, and a second energy storage device operable at a second device voltage. A plurality of low-loss switching devices interconnect the first energy storage device and the second energy storage device. The switching devices are selectively controllable between a first operating mode for providing the electric current at a first system voltage, and a second operating mode for providing the electric current at a second system voltage. The first system voltage is different from the second system voltage.

Abstract: A vehicle propulsion system includes an engine and a first electric machine each configured to selectively provide torque to propel the vehicle. The propulsion system also includes a second electric machine coupled to the engine and configured to start the engine from an inactive state. A high-voltage battery powers both of the first electric machine and the second electric machine over a high-voltage bus. The vehicle further includes a controller programmed to issue a command to start the engine using the second electric machine in response to a threshold acceleration demand following a period of reduced acceleration demand.

Abstract: An electric machine is provided that has a rotor assembly having a rotor core configured to support permanent magnets spaced around the rotor core to define a number of rotor poles. The rotor core has multiple rotor slots arranged as multiple barrier layers at each of the rotor poles. The multiple barrier layers are positioned adjacent one another between an inner periphery of the rotor core and an outer periphery of the rotor core and include a first barrier layer nearest the inner periphery. Permanent magnets are disposed in at least the first barrier layer. A stator assembly surrounds the rotor assembly. The electric machine is configured to function as a motor in a motoring mode and as a generator in a generating mode. The electric machine is configured with predetermined operating parameters selected for optimizing operation in the motoring mode and/or the generating mode.

Abstract: A hybrid vehicle propulsion includes an engine and a first electric machine, where each is configured to selectively provide torque to propel the vehicle. The propulsion system also includes a second electric machine coupled to the engine to provide torque to start the engine from an inactive state. A high-voltage power source is configured to power both of the first electric machine and the second electric machine over a high-voltage bus. The propulsion system further includes a controller programmed to deactivate the engine and propel the vehicle using the first electric machine in response to the vehicle being driven at a steady-state speed for a predetermined duration of time. The controller is also programmed to restart the engine using the second electric machine powered by the high-voltage power source.

Abstract: A solenoid assembly includes a solenoid actuator having a core. A coil is configured to be wound at least partially around the core such that a magnetic flux (?) is generated when an electric current flows through the coil. An armature is configured to be movable based on the magnetic flux (?). A controller has a processor and tangible, non-transitory memory on which is recorded instructions for controlling the solenoid assembly. The controller is configured to obtain a plurality of model matrices, a coil current (i1) and an eddy current (i2). The magnetic flux (?) is obtained based at least partially on a third model matrix (C0), the coil current (i1) and the eddy current (i2). Operation of the solenoid actuator is controlled based at least partially on the magnetic flux (?). In one example, the solenoid actuator is an injector.