Abstract: A rotor assembly configured to be used by an electric motor includes an output shaft; one or more permanent magnets coupled with the output shaft to prevent angular displacement of the permanent magnet(s) relative to the output shaft; one or more composite sleeves positioned concentrically and radially outwardly relative to the permanent magnets; and a barrier coating applied to the composite sleeve that prevents contact with a surface of the sleeve(s) exposed to an ambient environment.

Abstract: A turbocharger includes a bearing housing containing a motor within an interior portion of the bearing housing. A liquid-cooled power module is secured to an exterior portion of a bearing housing. The power module contains electrical components that power and control speed of the motor, and has an enclosure that includes sealed first and second volumes separated by a common wall. The first volume is a liquid-cooled compartment for removing heat generated from the electrical components, and the second volume is a liquid-free compartment containing the electrical power components. The electrical power components are fixed to the common wall, which is formed of a heat conductive material, and which may include fins extending into the first volume to optimize heat transfer from the common wall into the liquid-cooled compartment. Finally, the liquid-cooled power module communicates with the motor directly through the bearing housing.

Abstract: A system and method is provided for controlling an electric machine rotatably coupled to a rotatable shaft of an electronically-controlled one of a turbocharger and an exhaust-driven turbo supercharger fluidly coupled to an exhaust duct of an internal combustion engine. An operating temperature of a component of the engine is determined or estimated an operating temperature of a component of the engine or coupled to the engine, which is compared to a threshold temperature. The electric machine is controlled to operate as a motor in response to the determined or estimated temperature of the component being below a threshold temperature.

Abstract: A turbocharger includes a bearing housing containing a motor within an interior portion of the bearing housing. A liquid-cooled power module is secured to an exterior portion of a bearing housing. The power module contains electrical components that power and control speed of the motor, and has an enclosure that includes sealed first and second volumes separated by a common wall. The first volume is a liquid-cooled compartment for removing heat generated from the electrical components, and the second volume is a liquid-free compartment containing the electrical power components. The electrical power components are fixed to the common wall, which is formed of a heat conductive material, and which may include fins extending into the first volume to optimize heat transfer from the common wall into the liquid-cooled compartment. Finally, the liquid-cooled power module communicates with the motor directly through the bearing housing.

Abstract: A number of variations may include a product comprising an engine having an intake manifold and an exhaust manifold; a turbocharger having a compressor operatively attached to a turbine, wherein the compressor is in fluid communication with the intake manifold through a first conduit and the turbine is in fluid communication with the exhaust manifold through a second conduit; an actuator in operative communication with one of a vane pack or a wastegate; a charge air cooler disposed within the first conduit; a first air filter in fluid communication with the compressor through a third conduit; a mass air flow sensor disposed within the third conduit; and an actuator cooling system operatively attached to an interior of the actuator to deliver an air flow to the interior of the actuator to cool the actuator.

Abstract: A system and method is provided for controlling an electric machine rotatably coupled to a rotatable shaft of an electronically-controlled one of a turbocharger and an exhaust-driven turbo supercharger fluidly coupled to an exhaust duct of an internal combustion engine. An operating temperature of a component of the engine is determined or estimated an operating temperature of a component of the engine or coupled to the engine, which is compared to a threshold temperature. The electric machine is controlled to operate as a motor in response to the determined or estimated temperature of the component being below a threshold temperature.

Abstract: An internal-combustion engine has an electronically-controlled one of a turbocharger and an exhaust-driven turbo supercharger coupled to an exhaust duct of the engine, and the engine is controlled during a shift event of a transmission coupled to an output shaft of the engine by determining a target engine speed at the end of the shift event, and controlling electrical energy supplied to an electric machine, rotatably coupled to a rotatable shaft that is rotatably coupled to the electronically-controlled turbocharger or exhaust-driven turbo supercharger, to control rotation of the rotatable shaft coupled to the turbocharger or exhaust-driven turbo supercharger to attain the target engine speed.

Abstract: A turbocharger includes a housing, a shaft received therein, a turbine wheel affixed to the shaft at or adjacent to a first end thereof, a compressor wheel affixed to the shaft at or adjacent to a second, opposite end thereof, a first bearing received on the shaft between the turbine wheel and the compressor wheel, and a second bearing received on the shaft between the first bearing and the compressor wheel. One of the first and second bearings is floating relative to the shaft and affixed to the housing, and the other is floating relative to the shaft and also floating relative to the housing.

Abstract: A rotor of an electric machine is disclosed that resists expansion of the rotor components even at high rotational speed. The rotor includes first and second pluralities of laminations having slots to accept rotor bars. A support disk, also having slots, is placed between the laminations. The support disk, into which the rotor bars are slid, restrains the rotor bars from bending outwardly at high rotational speeds of the rotor. The rotor bars are further restrained at the ends by end rings, which have apertures into which ends of the rotor bars are placed. In some embodiments, containment rings are placed over axial extension of the end rings to prevent outward bowing at high speeds. In some embodiments, the rotor includes a stiffener sleeve to provide additional resistance to expansion during high rotational speeds.

Abstract: An internal-combustion engine has an electronically-controlled one of a turbocharger and an exhaust-driven turbo supercharger coupled to an exhaust duct of the engine, and the engine is controlled during a shift event of a transmission coupled to an output shaft of the engine by determining a target engine speed at the end of the shift event, and controlling electrical energy supplied to an electric machine, rotatably coupled to a rotatable shaft that is rotatably coupled to the electronically-controlled turbocharger or exhaust-driven turbo supercharger, to control rotation of the rotatable shaft coupled to the turbocharger or exhaust-driven turbo supercharger to attain the target engine speed.

Abstract: A rotor of an electric machine is disclosed that resists expansion of the rotor components even at high rotational speed. The rotor includes first and second pluralities of laminations having slots to accept rotor bars. A support disk, also having slots, is placed between the laminations. The support disk, into which the rotor bars are slid, restrains the rotor bars from bending outwardly at high rotational speeds of the rotor. The rotor bars are further restrained at the ends by end rings, which have apertures into which ends of the rotor bars are placed. In some embodiments, containment rings are placed over axial extension of the end rings to prevent outward bowing at high speeds. In some embodiments, the rotor includes a stiffener sleeve to provide additional resistance to expansion during high rotational speeds.

Abstract: An electrical generator utilizing two internal combustion engine having an expanded range of power output is disclosed. A primary internal combustion engine is coupled to the magnet rotor assembly. The primary engine is operated solely in a lower power range. A secondary engine, coupled to a coil assembly is locked in place in such lower power range to make the coil assembly stationary. In a higher power range, that overlaps the lower power range, the secondary engine is unlocked and operated to rotate in a counter-rotating direction with respect to the first engine. The secondary engine can be started by operating the generator (consisting of the magnet rotor assembly and the coil assembly) as a motor by appropriate application of current.

Abstract: A rotor of an electric machine is disclosed that resists expansion of the rotor components even at high rotational speed. The rotor includes first and second pluralities of laminations having slots to accept rotor bars. A support disk, also having slots, is placed between the laminations. The support disk, into which the rotor bars are slid, restrains the rotor bars from bending outwardly at high rotational speeds of the rotor. The rotor bars are further restrained at the ends by end rings, which have apertures into which ends of the rotor bars are placed. In some embodiments, containment rings are placed over axial extension of the end rings to prevent outward bowing at high speeds. In some embodiments, the rotor includes a stiffener sleeve to provide additional resistance to expansion during high rotational speeds.