Abstract: An axial flux electric motor includes a stator including a stator segment having a support frame formed with an opening defined by a continuous edge. A stator winding segment is arranged in the opening of the stator segment. The stator winding segment has an outer surface.

Abstract: A power control system includes a battery system and a DC-DC converter with first, second, third, and fourth power switches. A second terminal of the first power switch is connected to a first terminal of the second power switch. A second terminal of the third power switch is connected to a first terminal of the fourth power switch. A first inductor includes a first terminal connected to the second terminal of the first power switch and the first terminal of the second power switch and a second terminal connected to the second terminal of the third power switch and the first terminal of the fourth power switch. A first bypass switch is connected in parallel to the first power switch. A second bypass switch is connected in parallel to the third power switch.

Abstract: A method of manufacturing a permanent magnet for a rotor of an axial flux electric machine is described herein. The method includes forming multiple permanent magnet (PM) pieces to have the same shape. Each of the PM pieces has an inner radial surface, an outer radial surface, and a pair of side surfaces extending between the inner and outer radial surfaces. The method further includes attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor.

Abstract: An axial flux electric machine includes a casing, stator cores, windings, and fins. The casing has a hollow cylindrical shape with an inner radial surface and an outer radial surface. The stator cores are spaced circumferentially along the inner radial surface of the casing. The windings are wrapped around the stator cores. The fins project from the inner radial surface of the casing to spaces between the windings.

Abstract: A method of manufacturing a permanent magnet for a rotor of an axial flux electric machine is described herein. The method includes forming multiple permanent magnet (PM) pieces to have the same shape. Each of the PM pieces has an inner radial surface, an outer radial surface, and a pair of side surfaces extending between the inner and outer radial surfaces. The method further includes attaching at least one of the side surfaces of each of the PM pieces to one of the side surfaces of another one of the PM pieces to form partitions configured to extend in a radial direction of the rotor.

Abstract: An axial flux motor includes: a stator having a first side and a second side opposite the first side, the stator including: N stator core components on the first side, where N is an integer greater than two; N stator windings that are disposed around the N stator core components, respectively, where each of the N stator windings includes, from a point of view facing the first side: a first width at a first location; and a second width that is greater than the first width at a second location that is radially outward from the first location relative to an axis; slot openings disposed between adjacent ones of the stator windings; and a rotor including a third side and M permanent magnets on the third side, where the first side is parallel to the third side, and where M is an integer greater than or equal to two.

Abstract: An axial flux electric motor for an automobile includes a stator assembly, and a rotor assembly, the rotor assembly including a plurality of lamination blocks arranged in an annular pattern, a plurality of conductive wedges, one conductive wedge being positioned between each adjacent pair of lamination blocks, the plurality of lamination blocks and the plurality of conductive wedges defining a rotor core disk having an inner diameter and outer diameter and opposing axial faces, and a plurality of permanent magnets attached to one of the opposing axial faces of the rotor core disk.

Abstract: An axial flux motor includes: a stator having a first side and a second side opposite the first side, the stator including: N stator core components on the first side, where N is an integer greater than two; and pole shoes attached to radial sides of the N stator core components, N slot openings between adjacent ones of the pole shoes, where each of the N slot openings extends in at least one direction non-radially on the first side; and a rotor including a third side and M permanent magnets on the third side, where the first side is parallel to the third side, and where M is an integer greater than two.

Abstract: A power control system includes a battery system and a DC-DC converter with first, second, third, and fourth power switches. A second terminal of the first power switch is connected to a first terminal of the second power switch. A second terminal of the third power switch is connected to a first terminal of the fourth power switch. A first inductor includes a first terminal connected to the second terminal of the first power switch and the first terminal of the second power switch and a second terminal connected to the second terminal of the third power switch and the first terminal of the fourth power switch. A first bypass switch is connected in parallel to the first power switch. A second bypass switch is connected in parallel to the third power switch.

Abstract: An axial flux electric motor for an automobile includes a stator assembly, and a rotor assembly, the rotor assembly including a plurality of lamination blocks arranged in an annular pattern, a plurality of conductive wedges, one conductive wedge being positioned between each adjacent pair of lamination blocks, the plurality of lamination blocks and the plurality of conductive wedges defining a rotor core disk having an inner diameter and outer diameter and opposing axial faces, and a plurality of permanent magnets attached to one of the opposing axial faces of the rotor core disk.

Abstract: A stator core assembly for an axial flux electric motor for an automobile includes a cylindrical outer case that defines a central axis, and a plurality of segmented core sections spaced circumferentially around the central axis within the outer case, each of the segmented core sections including a lamination stack and a sleeve, the lamination stack being positioned within the sleeve and the sleeve being formed from a soft magnetic composite material, the sleeve of each of the plurality of segmented core sections including a first axial end having a pole shoe formed thereon and a second axial end having a pole shoe formed thereon, the pole shoes formed on the first and second axial ends of the sleeve of each of the plurality of segmented core sections including a radially outward surface having an arcuate shape that corresponds to and contacts the radially inward surface of the outer case.

Abstract: The present disclosure provides hybrid stator core components for an axial flux motor stator and methods for making the same. The hybrid stator core component includes a molded soft magnetic composite material and a laminated component. In one variation, a laminated insert comprising a plurality of insulated layers is non-releasably seated within a molded soft magnetic composite material. In another variation, a hybrid stator core component has a molded soft magnetic composite core and a laminated shell comprising a plurality of layers disposed around at least a portion of the molded soft magnetic composite core.

Abstract: The present disclosure relates generally to rotors for electric motor assemblies and methods of making the same, and more specifically, to variable thickness rotors for axial flux motors. More specifically, annular-shaped rotors having interiorly disposed magnets for axial flux motors are provided in certain aspects. The variable thickness rotors may each include an annular-shaped body having a first thickness at a first radial position and a second thickness at a second radial position. The first radial position may be spaced apart from the second radial position. The first thickness may be greater than or equal to about 200% of the second thickness.

Abstract: An axial flux motor includes: a stator having a first side and a second side opposite the first side, the stator including: N stator core components on the first side, where N is an integer greater than two; and pole shoes attached to radial sides of the N stator core components, N slot openings between adjacent ones of the pole shoes, where each of the N slot openings extends in at least one direction non-radially on the first side; and a rotor including a third side and M permanent magnets on the third side, where the first side is parallel to the third side, and where M is an integer greater than two.

Abstract: A fluid-cooled axial flux motor having a stator, a rotor disposed adjacent to the stator, and a rotor shaft rotationally fixed onto the rotor. The rotor shaft includes axial coolant passageway having an inlet and opposite outlet. The rotor includes coolant passageways extending radially from rotor shaft. The rotor coolant passageways include an inlet in fluid communication with the outlet of the axial coolant passageway and an outlet. The fluid-cooled axial flux motor further includes a coolant distribution header having an inlet in fluid communication with the outlet of the rotor coolant passageway, a coolant collection header having an inlet in fluid communication with the outlet of the coolant distribution header, and a collection header outlet. The outlet of the coolant distribution header is disposed above the stator and the inlet of the coolant collection header is disposed below the stator with respect to the direction of gravity.

Abstract: The present disclosure relates generally to rotors for electric motor assemblies and methods of making the same, and more specifically, to variable thickness rotors for axial flux motors. More specifically, annular-shaped rotors having interiorly disposed magnets for axial flux motors are provided in certain aspects. The variable thickness rotors may each include an annular-shaped body having a first thickness at a first radial position and a second thickness at a second radial position. The first radial position may be spaced apart from the second radial position. The first thickness may be greater than or equal to about 200% of the second thickness.

Abstract: The present disclosure provides hybrid stator core components for an axial flux motor stator and methods for making the same. The hybrid stator core component includes a molded soft magnetic composite material and a laminated component. In one variation, a laminated insert comprising a plurality of insulated layers is non-releasably seated within a molded soft magnetic composite material. In another variation, a hybrid stator core component has a molded soft magnetic composite core and a laminated shell comprising a plurality of layers disposed around at least a portion of the molded soft magnetic composite core.

Abstract: A distracted driving elimination system includes an image capture device within a passenger compartment of an automobile capturing images of a first hand and a second hand of a vehicle operator and a steering wheel. An analysis unit has a geometry and visual characteristics of multiple predetermined items saved in a memory. The analysis unit receives the images and compares the images to the predetermined items saved in the memory to identify if any one of the first hand or the second hand of the vehicle operator is not in direct contact with the steering and is in direct contact with one of the predetermined items thereby initiating a distracted driving event. A distracted driving signal is generated when the distracted driving event is initiated. An indication system generates an indication when the distracted driving signal is forwarded, the indication alerting the vehicle operator of the distracted driving event.

Abstract: A system for monitoring operation of a vehicle includes a processing device including an interface configured to receive measurement data from sensing devices configured to measure parameters of a vehicle system. The processing device is configured to receive measurement data from each of the plurality of sensing devices, and in response to detection of a malfunction in the vehicle, input at least a subset of the measurement data to a machine learning classifier associated with a vehicle subsystem, the classifier configured to define a class associated with normal operation of the vehicle subsystem. The processing device is also configured to determine whether the subset of the measurement data belongs to the class, and based on at least a selected amount of the subset of the measurement data being outside of the class, output a fault indication, the fault indication identifying the vehicle subsystem as having a contribution to the malfunction.

Abstract: A distracted driving elimination system includes an image capture device within a passenger compartment of an automobile capturing images of a first hand and a second hand of a vehicle operator and a steering wheel. An analysis unit has a geometry and visual characteristics of multiple predetermined items saved in a memory. The analysis unit receives the images and compares the images to the predetermined items saved in the memory to identify if any one of the first hand or the second hand of the vehicle operator is not in direct contact with the steering and is in direct contact with one of the predetermined items thereby initiating a distracted driving event. A distracted driving signal is generated when the distracted driving event is initiated. An indication system generates an indication when the distracted driving signal is forwarded, the indication alerting the vehicle operator of the distracted driving event.