Fault-tolerant electric drive systems including a machine having a rotor and a stator having coils arranged in pairs. Each coil in each pair separated by 180 degrees, a first phase (ϕA) having one of the coil pairs and a phase drive circuit connected therewith, a second phase (ϕB) having a second one of the coil pairs and a second phase drive circuit connected therewith, a third phase (ϕC) having a third one of the coil pairs and a third phase drive circuit connected therewith, and a fourth phase having a fourth one of the coil pairs and a fourth phase drive circuit connected therewith. Further included is a controller connected with the first, second, third and fourth phase drive circuits to control operation thereof.

Fault-tolerant electric drive systems including a machine having a rotor and a stator having coils arranged in pairs. Each coil in each pair separated by 180 degrees, a first phase (ϕA) having one of the coil pairs and a phase drive circuit connected therewith, a second phase (ϕB) having a second one of the coil pairs and a second phase drive circuit connected therewith, a third phase (ϕC) having a third one of the coil pairs and a third phase drive circuit connected therewith, and a fourth phase having a fourth one of the coil pairs and a fourth phase drive circuit connected therewith. Further included is a controller connected with the first, second, third and fourth phase drive circuits to control operation thereof.

An electric motor includes a rotor mounted rotatably about an axis of rotation in a bearing accommodated in an end shield, and a stator including wound coils such that windings are defined by at least one winding wire with winding wire ends electrically connected to busbars of a busbar unit. The busbar unit is on an upper side of the stator and the end shield is seated on an upper side of the busbar unit. A magnetic shield is integrated into the end shield.

An electric motor includes a rotor mounted rotatably about an axis of rotation in a bearing accommodated in an end shield, and a stator including wound coils such that windings are defined by at least one winding wire with winding wire ends electrically connected to busbars of a busbar unit. The busbar unit is on an upper side of the stator and the end shield is seated on an upper side of the busbar unit. A magnetic shield is integrated into the end shield.

An example method of producing an electric machine is described herein. The method can include providing the electric machine. The electric machine can include a rotor and a stator, where the stator includes a magnetic core and a stator winding. Additionally, the magnetic core can include a plurality of teeth defining a plurality of slots between adjacent teeth. The stator winding can also include a first portion arranged inside a slot and a second portion arranged outside the slot. The method can further include optimizing, using a computing device, a geometry of the first portion of the stator winding, where the first portion of the stator winding in the provided electric machine has the optimized geometry.

An example method of producing an electric machine is described herein. The method can include providing the electric machine. The electric machine can include a rotor and a stator, where the stator includes a magnetic core and a stator winding. Additionally, the magnetic core can include a plurality of teeth defining a plurality of slots between adjacent teeth. The stator winding can also include a first portion arranged inside a slot and a second portion arranged outside the slot. The method can further include optimizing, using a computing device, a geometry of the first portion of the stator winding, where the first portion of the stator winding in the provided electric machine has the optimized geometry.

In one embodiment, a stator coil that includes a first turn with two or more strands is provided. The first turn includes first and second opposite sides, a coil termination at a first end of the first turn and an inversion region disposed at a second end, opposite the coil termination. The stator coil also includes at least one additional turn with two or more strands. The at least one additional turn includes first and second opposite sides, and an inversion region located adjacent to the inversion region of the first turn. The first and second sides of the first turn are inverted relative to the first and second sides of the at least one additional turn outside their respective inversion regions.

In one embodiment, a stator coil that includes a first turn with two or more strands is provided. The first turn includes first and second opposite sides, a coil termination at a first end of the first turn and an inversion region disposed at a second end, opposite the coil termination. The stator coil also includes at least one additional turn with two or more strands. The at least one additional turn includes first and second opposite sides, and an inversion region located adjacent to the inversion region of the first turn. The first and second sides of the first turn are inverted relative to the first and second sides of the at least one additional turn outside their respective inversion regions.

A tool includes a device including a housing and a rotor, the rotor to rotate about a longitudinal axis, and an axial gap generator including a stator assembly positioned adjacent to the rotor. The axial gap generator generates a voltage signal as a function of a gap spacing between the stator assembly and the rotor, the gap spacing being parallel to the longitudinal axis.

A tool includes a device including a housing and a rotor, the rotor to rotate about a longitudinal axis, and an axial gap generator including a stator assembly positioned adjacent to the rotor. The axial gap generator generates a voltage signal as a function of a gap spacing between the stator assembly and the rotor, the gap spacing being parallel to the longitudinal axis.