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:
Rotor for electric machines and methods for fabricating rotors for electric machines are provided. An exemplary method includes assembling a stack of laminations to form a rotor core having an external surface. The rotor core defines one to five layers of internal cavities and an interior permanent magnet is positioned in a selected internal cavity. The method also includes locating a non-magnetic structural element in the selected internal cavity. Further, the method includes applying a compressive force on the external surface of the rotor core with an annular sleeve.
Abstract:
An electric drive-unit encased in a housing includes an electric motor, a first output member, and a second output member. The drive-unit also includes first, second, and third planetary gear-sets, each having first, second, and third nodes. The first gear-set has one node connected to the electric motor. The second gear-set has one node connected to the first planetary gear-set, another node connected to the first output member, and the remaining node fixed to the housing. The third gear-set has one node connected to the first gear-set and another node connected to the second output member. The drive-unit additionally includes a first torque-transmitting device configured to selectively connect one third gear-set node to the housing to thereby affect a first speed-ratio. Furthermore, the drive-unit includes a second torque-transmitting device configured to selectively connect one first gear-set node to one of the third gear-set nodes to thereby affect a second speed-ratio.
Abstract:
A mechanical clutch such as a dog clutch includes a plurality of balls or rollers disposed in a carrier and positioned between opposed sets of straight cut teeth extending from opposed drive and driven elements. A ball or roller is positioned between each adjacent pair of teeth such that the torque load is transferred from the tooth on a first or drive element, through the ball or roller, to an adjacent projection or tooth on a second or driven element. The balls or rollers are maintained in position by the carrier having an inner ring and a concentric outer ring. Greatly reduced disengagement force, even under load, is exhibited by a clutch of this configuration.
Abstract:
An electric machine produces motor torque having continuously variable magnetic and reluctance torque components. The electric machine includes stator and rotor assemblies. Different ends of the rotor hub have different average magnetic field strengths, with the second field strength at one end being weaker than the other. The rotor hub translates along the rotor shaft to vary the magnetic and reluctance torque components at different speed and torque operating points of the electric machine. A vehicle includes the machine, a transmission, a load, and a controller executing a method for controlling the axial position of the rotor hub. The method may include determining the speed and a torque of the electric machine, determining a corresponding desired axial position of a rotor hub, and translating the rotor hub to the desired axial position.
Abstract:
A powertrain includes a drive unit that can be modular and is adaptable to be used as an all-electric drive unit, an input power-split drive unit, or an input and compound power-split drive unit. The drive unit includes a first planetary gear set that has a sun gear member, a ring gear member, and a carrier member all rotatable about a first axis of rotation. The drive unit includes a first electric machine operable as a motor and having a rotor connected to rotate in unison with the sun gear member about the first axis of rotation. A first brake is selectively engageable to ground the ring gear member, a first clutch is operatively connected to the ring gear member, and an output member is connected to rotate in unison with the carrier member about the first axis of rotation. Multiple drive units can be used on a vehicle.
Abstract:
An electrical system includes an engine, a motor-generator and a starter mechanism, and engine systems also include the engine. The electrical system includes a first energy storage device having a first voltage level and a second energy storage device having a second voltage level less than the first voltage level. The electrical system further includes a controller configured to control the motor-generator, the starter mechanism and first and second switching devices. Current from at least one of the first and second energy storage devices is delivered to the motor-generator when at least one of the first switching device is in a first closed state and the second switching device is in a second closed state such that the motor-generator transfers torque to the starter mechanism and the starter mechanism uses the torque to start the engine.
Abstract:
A transmission includes a single planetary gearset, a first torque machine, an output member and a two-speed gearset that is coupled to the drive member. The single planetary gearset includes a sun gear, a carrier gearset and a ring gear, wherein the carrier gearset is rotatably couplable to the input member and rotatably couplable to the output member, the sun gear is rotatably coupled to a rotor of the first torque machine, and the ring gear is rotatably couplable to the input member and rotatably couplable to the output member. The output member is rotatably couplable to the two-speed gearset, which is configured to operate in one of a first gear ratio and a second gear ratio.
Abstract:
A powertrain for a vehicle includes an engine and a method of assembling the powertrain includes providing the engine. A starter mechanism is selectively operable to start the engine. A motor-generator includes an adapter to dispose the motor-generator and the starter mechanism in alternative assembly configurations being a first assembly configuration and a second assembly configuration. The first assembly configuration is when the starter mechanism is coupleable to the adapter to selectively transfer torque from the motor-generator through the adapter and the starter mechanism to start the engine. The second assembly configuration is when the starter mechanism is spaced from the adapter to operate independently of the motor-generator such that the starter mechanism selectively transfers torque to start the engine.
Abstract:
A powertrain is provided that has an engine with a rotatable crankshaft. The powertrain has a transmission with a transmission input member and a transmission output member. A final drive is operatively connected to the transmission output member and includes a drive axle. An engine clutch has an engaged state that operatively connects the engine crankshaft with the transmission input member, and has a disengaged state that operatively disconnects the engine crankshaft from the transmission input member. A motor/generator is provided and a first torque-transmitting device has a selectively engaged state in which the first torque-transmitting device transmits torque between the motor/generator and the transmission output member independent of the engine, the crankshaft, and the engine clutch. A second torque-transmitting device has a selectively engaged state in which the second torque-transmitting device transmits torque between the motor/generator and the crankshaft independent of the first torque-transmitting device and the engine clutch.