Abstract: A motor comprises a stator having open slots with a double layer formed coil lapped winding and the method to manufacture thereof.

Abstract: In a first aspect, the invention is directed to a wheel assembly for a vehicle, including a non-rotating support member, a wheel and an electric motor. Loads incurred during vehicle use can cause dynamic flexing of portions of the wheel. The wheel assembly in accordance with the first aspect of the invention has a load path for loads incurred by the wheel that passes from the wheel to the non-rotating support member without passing through the motor, thereby reducing a potential source of distortion of the gap in the motor (between the motor's rotor and stator) during the aforementioned flexing.

Abstract: A differential mechanism for transmitting power from an input to an output includes a case containing a side gear, a locking member rotatably secured to the case and axially displaceable relative to the case. The locking member alternately engages the side gear to limit rotation of the side gear relative to the case, and disengages the side gear to permit rotation of the side gear relative to the case. An electromagnetic coil assembly is supported on the case for movement toward and away from the locking member. A first actuator including an electromagnetic coil is supported on the case for moving the locking member toward engagement with the side gear in response to energizing the coil. A second actuator urges the locking member away from engagement with the side gear.

Abstract: A differential mechanism for transmitting power from an input to an output includes a case containing a side gear, a locking member rotatably secured to the case and axially displaceable relative to the case. The locking member alternately engages the side gear to limit rotation of the side gear relative to the case, and disengages the side gear to permit rotation of the side gear relative to the case. An electromagnetic coil assembly is supported on the case for movement toward and away from the locking member. A first actuator including an electromagnetic coil is supported on the case for moving the locking member toward engagement with the side gear in response to energizing the coil. A second actuator urges the locking member away from engagement with the side gear.

Abstract: The present invention provides regenerative passive and semi-active suspension systems. A regenerative suspension system generally includes at least one regenerative damper, a module, an electric switch, and a battery. The at least one regenerative damper converts mechanical vibration energy within a vehicle into a voltage, which the damper passes to the module. The module measures the voltage from the regenerative damper, and in response, changes electric switch settings for each regenerative damper between an open circuit, a closed circuit completed by a power resistance, and a closed circuit completed by circuitry for charging a battery. Additionally, the module sets electric switch levels to adjust the damping forces within each regenerative damper.

Abstract: A regenerative damper and method for regenerative damping are disclosed. The regenerative damper uses the kinetic energy of undesirable vehicle motion to generate electrical current in a circuit. The electricity is generated by a power screw that operates like an alternator. Vehicle energy efficiency is increased by using the electrical current to charge a battery. The regenerative damper can be semi-active or passive. The semi-active embodiment is able to adapt to operating conditions to improve vehicle ride and handling, whereas the passive embodiment has a fixed response, regardless of operating conditions.

Abstract: Electromagnetic retarder brake systems, and methods for their use, are provided utilizing specified thickness conductive layers. The specified thickness of the conductive layer in each system is determined to obtain a certain desired torque at a certain desired low rotational frequency. The specified thickness conductive layer is disposed between a winding and a rotor within each system. By utilizing a specified thickness conductive layer, torque on the rotor at low rotational frequencies is increased, thereby improving deceleration capabilities.

Abstract: A drive assembly including an electric motor and frequency variable generator for use with a multi-axle vehicle. The vehicle generally includes an engine driving a first axle and a drive assembly with an electric motor driving a second drive axle. The drive assembly includes a frequency variable generator with an input shaft driven by the engine and the electric motor electrically communicates with the generator to receive output power from the generator. Other details of selected embodiments of the invention include the frequency variable generator having a rotor coupled to rotate with the engine output shaft and a stator electrically connected to the electric motor. An inverter is electrically connected to an electrical power source, such as a battery or the frequency variable generator, as well as to the rotor. A controller communicates with the inverter and is configured to control the magnitude and frequency of the power communicated from the inverter to the rotor winding.

Abstract: An automotive eddy current retarder includes a stator mounted to a frame of the vehicle, a plurality of claw-type poles disposed along an outer perimeter of the stator, and a single coil through each pole. A rotor, mechanically coupled to a wheelend of the vehicle, includes an annular ferro-magnetic body that rotates about the stator. The rotor further includes an annular conductor disposed on the radially inner surface of the ferro-magnetic body. The annular conductor, which preferably includes end rings bridged by integrally-formed, axially-extending bars whose depth dimension exceeds their width dimension, lowers the surface resistivity of the ferro-magnetic body to thereby increase the skin effects achieved at higher rotational speeds of the rotor relative to the stator, while further increasing the maximum braking torque generated by the retarder.

Abstract: The present invention provides regenerative passive and semi-active suspension systems. A regenerative suspension system generally includes at least one regenerative damper, a module, an electric switch, and a battery. The at least one regenerative damper converts mechanical vibration energy within a vehicle into a voltage, which the damper passes to the module. The module measures the voltage from the regenerative damper, and in response, changes electric switch settings for each regenerative damper between an open circuit, a closed circuit completed by a power resistance, and a closed circuit completed by circuitry for charging a battery. Additionally, the module sets electric switch levels to adjust the damping forces within each regenerative damper.

Abstract: A regenerative damper and method for regenerative damping are disclosed. The regenerative damper uses the kinetic energy of undesirable vehicle motion to generate electrical current in a circuit. The electricity is generated by a power screw that operates like an alternator. Vehicle energy efficiency is increased by using the electrical current to charge a battery. The regenerative damper can be semi-active or passive. The semi-active embodiment is able to adapt to operating conditions to improve vehicle ride and handling, whereas the passive embodiment has a fixed response, regardless of operating conditions.

Abstract: The present invention includes a novel regenerative energy management system having a flywheel assembly with an integrated motor-generator which is coupled to a drivetrain motor-generator. The coupling between the flywheel assembly and the drivetrain motor-generator includes a system controller having integrated voltage control and inverters. The flywheel of the present invention avoids the use of expensive bearings, vacuum systems, cooling systems, and other such support subsystems found in other high technology flywheels. The integration of the flywheel-motor-generator system saves valuable space within the vehicle, reduces the number of bearings necessary for operation, and simplifies the coupling of the flywheel motor generator to the flywheel. The system controller has integrated inverters and voltage control that determine the direction and flow of current between the flywheel assembly and the driveline motor-generator.

Abstract: The invention provides a reluctance generator for an eddy current braking system in a vehicle. The reluctance generator has a field winding and a compensation winding, which induce magnetomotive forces. The magnetomotive force induced by the compensation winding balances the magnetomotive force generated by a rotor in the reluctance generator. The field winding has less inductance.

Abstract: A drive assembly including an electric motor and frequency variable generator for use with a multi-axle vehicle. The vehicle generally includes an engine driving a first axle and a drive assembly with an electric motor driving a second drive axle. The drive assembly includes a frequency variable generator with an input shaft driven by the engine and the electric motor electrically communicates with the generator to receive output power from the generator. Other details of selected embodiments of the invention include the frequency variable generator having a rotor coupled to rotate with the engine output shaft and a stator electrically connected to the electric motor. An inverter is electrically connected to an electrical power source, such as a battery or the frequency variable generator, as well as to the rotor. A controller communicates with the inverter and is configured to control the magnitude and frequency of the power communicated from the inverter to the rotor winding.

Abstract: Electromagnetic retarder brake systems, and methods for their use, are provided utilizing specified thickness conductive layers. The specified thickness of the conductive layer in each system is determined to obtain a certain desired torque at a certain desired low rotational frequency. The specified thickness conductive layer is disposed between a winding and a rotor within each system. By utilizing a specified thickness conductive layer, torque on the rotor at low rotational frequencies is increased, thereby improving deceleration capabilities.

Abstract: An eddy current brake or retarder device for bringing a vehicle to rest is disclosed. The device includes a stator mounted to a frame of the vehicle, a plurality of poles disposed along a perimeter of the stator, a plurality of coils each wound about each of the plurality of poles, wherein an adjacent pair of poles form an electromagnet when the coil is energized, and a rotor in communication with a transmission axle of the vehicle and located concentric with the stator. A relative rotation of the rotor with respect to the stator produces eddy currents between the poles of the stator and an outer surface of the rotor, causing the rotor to come to a rest.

Abstract: The present invention includes a novel regenerative energy management system having a flywheel assembly with an integrated motor-generator which is coupled to a drivetrain motor-generator. The coupling between the flywheel assembly and the drivetrain motor-generator includes a system controller having integrated voltage control and inverters. The flywheel of the present invention avoids the use of expensive bearings, vacuum systems, cooling systems, and other such support subsystems found in other high technology flywheels. The integration of the flywheel-motor-generator system saves valuable space within the vehicle, reduces the number of bearings necessary for operation, and simplifies the coupling of the flywheel motor generator to the flywheel. The system controller has integrated inverters and voltage control that determine the direction and flow of current between the flywheel assembly and the driveline motor-generator.

Abstract: The invention provides a reluctance generator for an eddy current braking system in a vehicle. The reluctance generator has a field winding and a compensation winding, which induce magnetomotive forces. The magnetomotive force induced by the compensation winding balances the magnetomotive force generated by a rotor in the reluctance generator. The field winding has less inductance.

Abstract: An eddy current brake or retarder device for bringing a vehicle to rest is disclosed. The device includes a stator mounted to a frame of the vehicle, a plurality of poles disposed along a perimeter of the stator, a plurality of coils each wound about each of the plurality of poles, wherein an adjacent pair of poles form an electromagnet when the coil is energized, and a rotor in communication with a transmission axle of the vehicle and located concentric with the stator. A relative rotation of the rotor with respect to the stator produces eddy currents between the poles of the stator and an outer surface of the rotor, causing the rotor to come to a rest.