公开(公告)号：US20220271583A1

公开(公告)日：2022-08-25

申请号：US17181193

申请日：2021-02-22

Applicant: GM Global Technology Operations LLC

Inventor： Derek F. Lahr ,  Alireza Fatemi ,  Farzad Samie ,  Thomas W. Nehl

IPC: H02K1/27

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.

公开(公告)号：US11316335B2

公开(公告)日：2022-04-26

申请号：US16863412

申请日：2020-04-30

Applicant: GM Global Technology Operations LLC

Inventor： Chandra S. Namuduri ,  Rashmi Prasad ,  Thomas W. Nehl ,  David J. Brooks

IPC: H02H3/08 ,  H05K1/18

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.

公开(公告)号：US20210237587A1

公开(公告)日：2021-08-05

申请号：US16782681

申请日：2020-02-05

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Thomas W. Nehl ,  Alireza Fatemi ,  Chandra S. Namuduri

IPC: B60L15/20 ,  H02K11/33

Abstract: A modular drive system includes a first motor and a second motor. The first motor generates a first torque over a first torque bandwidth, and has a first stator, a first rotor, and a first winding. The first winding has a first number of turns, a first conductor area and a first insulation suitable for a first peak voltage of the first motor. The second motor generates the first torque over a second torque bandwidth, and has a second stator matching the first stator, a second rotor matching the first rotor and a second winding. The second winding has the first number of turns, the first conductor area and a second insulation suitable for a second peak voltage of the second motor. The second peak voltage is greater than the first peak voltage. The second torque bandwidth is wider than the first torque bandwidth.

公开(公告)号：US11056991B2

公开(公告)日：2021-07-06

申请号：US16691925

申请日：2019-11-22

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Alireza Fatemi ,  Thomas W. Nehl

IPC: H02P21/00 ,  H02P23/00

Abstract: A method and system for controlling and regulating operation of a multi-phase rotary electric machine in a manner that minimizes power loss under partial load conditions is described. This includes an instruction set that is executable to determine a torque command and a rotational speed of the electric machine, determine a peak torque per loss parameter for the electric machine based upon the rotational speed, and determine a second torque parameter for the electric machine based upon the rotational speed. A modulated torque command for controlling the electric machine is determined based upon the peak torque per loss parameter and the second torque parameter, wherein the electric machine generates an average torque that is equivalent to the torque command when operating in response to the modulated torque command. The inverter is controlled to operate the electric machine based upon the modulated torque command.

公开(公告)号：US20210159826A1

公开(公告)日：2021-05-27

申请号：US16691925

申请日：2019-11-22

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Alireza Fatemi ,  Thomas W. Nehl

IPC: H02P21/00 ,  H02P23/00

Abstract: A method and system for controlling and regulating operation of a multi-phase rotary electric machine in a manner that minimizes power loss under partial load conditions is described. This includes an instruction set that is executable to determine a torque command and a rotational speed of the electric machine, determine a peak torque per loss parameter for the electric machine based upon the rotational speed, and determine a second torque parameter for the electric machine based upon the rotational speed. A modulated torque command for controlling the electric machine is determined based upon the peak torque per loss parameter and the second torque parameter, wherein the electric machine generates an average torque that is equivalent to the torque command when operating in response to the modulated torque command. The inverter is controlled to operate the electric machine based upon the modulated torque command.

公开(公告)号：US11015564B2

公开(公告)日：2021-05-25

申请号：US15961137

申请日：2018-04-24

Applicant: GM Global Technology Operations LLC

Inventor： Chandra S. Namuduri ,  Lei Hao ,  Alexandru Rajala ,  Thomas W. Nehl

IPC: F02N11/08 ,  H02K11/33 ,  H02K11/21

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.

公开(公告)号：US10923969B2

公开(公告)日：2021-02-16

申请号：US16247521

申请日：2019-01-14

Applicant: GM Global Technology Operations LLC

Inventor： Alireza Fatemi ,  Anthony M. Coppola ,  Thomas W. Nehl ,  David J. Brooks

IPC: H02K1/04 ,  H02K15/12 ,  H02K1/16 ,  H02K1/20 ,  H02K3/12 ,  H02K7/00 ,  H02K15/06 ,  B29C45/14 ,  B29K509/00 ,  B29L31/00 ,  B29K63/00

Abstract: Systems, methods and motor-generators with preform windings and a molded core are described. The preform windings include a first end, a second end, and a plurality of in-slot portions extending from the first end to the second end. The molded core includes a plurality of slots. Each of the plurality of slots including a respective in-slot portion disposed therein. Each of the plurality of slots includes a wall conforming to an outer profile of the respective in-slot portion.

公开(公告)号：US10923287B1

公开(公告)日：2021-02-16

申请号：US16533176

申请日：2019-08-06

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Anthony M. Coppola ,  Alireza Fatemi ,  Thomas W. Nehl

IPC: H01G9/00 ,  H01G9/08 ,  H01G9/012 ,  H01G9/26

Abstract: A vascular cooled capacitor assembly includes a plurality of capacitors having respective first and second leads, first and second busbars disposed in electrical contact with the first and second leads, an encapsulant enveloping the capacitors and a respective major portion of each of the first and second busbars, and a network of channels enveloped within the encapsulant and formed by deflagration of a sacrificial material. The network has at least one network inlet and at least one network outlet, each of which is configured for sealable engagement with a cooling fluid system. A branch of each channel is positioned inside a central axial passage of a capacitor, around an outer periphery of a capacitor, and/or between two capacitors. A housing may enclose the capacitors, the channels and major portions of the first and second busbars.

公开(公告)号：US20210043389A1

公开(公告)日：2021-02-11

申请号：US16533176

申请日：2019-08-06

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Anthony M. Coppola ,  Alireza Fatemi ,  Thomas W. Nehl

IPC: H01G9/00 ,  H01G9/26 ,  H01G9/012 ,  H01G9/08

Abstract: A vascular cooled capacitor assembly includes a plurality of capacitors having respective first and second leads, first and second busbars disposed in electrical contact with the first and second leads, an encapsulant enveloping the capacitors and a respective major portion of each of the first and second busbars, and a network of channels enveloped within the encapsulant and formed by deflagration of a sacrificial material. The network has at least one network inlet and at least one network outlet, each of which is configured for sealable engagement with a cooling fluid system. A branch of each channel is positioned inside a central axial passage of a capacitor, around an outer periphery of a capacitor, and/or between two capacitors. A housing may enclose the capacitors, the channels and major portions of the first and second busbars.

公开(公告)号：US10900458B2

公开(公告)日：2021-01-26

申请号：US16406658

申请日：2019-05-08

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Suresh Gopalakrishnan ,  Paul S. Lombardo ,  David W. Walters ,  Chunhao J. Lee ,  Chandra S. Namuduri ,  Neeraj S. Shidore ,  Thomas W. Nehl

IPC: F02N19/00 ,  F02N11/00

Abstract: A method of stopping an engine crankshaft includes selecting a target angular position at which the engine crankshaft is to be stopped and detecting an actual angular position of the engine crankshaft and a rotational speed of the engine crankshaft. A stopping torque in calculated based on the actual angular position of the engine crankshaft and the rotational speed of the engine crankshaft. The stopping torque is applied to the engine crankshaft via a motor/generator operably connected to the engine crankshaft. The engine crankshaft is stopped at the target angular position via the application of the stopping torque.