A position sensor includes a plurality of E-shaped ferromagnetic cores arranged to define a circular opening therethrough to receive a shaft. Each E-shaped ferromagnetic core has a plurality of teeth, wherein adjacent E-shaped ferromagnetic cores of the arranged plurality of E-shaped ferromagnetic cores have an overlapping tooth. The position sensor further includes a frame surrounding the arranged plurality of E-shaped ferromagnetic cores, with the E-shaped ferromagnetic cores coupled to the frame.

A motor assembly is described and includes a housing; a plurality of motors disposed within the housing; and a drive shaft comprising a plurality of interconnected drive shaft segments, wherein each one of the drive shaft segments is driven by a different one of the motors connected to the drive shaft segment via an integrated overrunning clutch.

A modular hybrid transmission that provides for an improved support of the rotor as well as an improved cooling layout for the stator. The modular hybrid transmission has a rotating assembly and a housing assembly. The rotating assembly includes a rotor assembly, a rotor carrier hub that supports the rotor, and an input shaft. The rotor carrier is rotationally fixed on the input shaft. The housing assembly houses the rotating assembly, and includes a housing having an outer wall, a stator assembly connected to the outer wall, and a radially extending stationary wall that extends from the outer wall toward the output shaft. The stationary wall includes an axially extending wall portion that extends parallel to an outer surface of the input shaft, and a radial ball bearing supports the input shaft on this axially extending wall portion. Two stator cooling paths are channeled in the housing.

A method of fabricating a coil for mounting on a tooth of a stator or a rotor of an electric machine includes winding a wire about a mandrel to form a coil having a first shape corresponding to the shape of the mandrel. The method may also include removing the coil having the first shape from the mandrel, and applying a mechanical force on the coil to change the shape of the coil from the first shape to a second shape. The second shape may correspond to the shape of the tooth. The method may also include mounting the coil of the second shape on the tooth.

A motor assembly is described and includes a housing; a plurality of motors disposed within the housing; and a drive shaft comprising a plurality of interconnected drive shaft segments, wherein each one of the drive shaft segments is driven by a different one of the motors connected to the drive shaft segment via an integrated overrunning clutch.

A system includes a motor, a frame, and connecting bolts. The motor includes a shaft. The frame is configured to house the motor. The frame includes connection holes and a base. Two or more of the connection holes are selected corresponding to a selected height of the shaft. The base is configured to mount the motor onto a foundation. Each of the connecting bolts is configured to pass through a respective connection hole and bolt to the motor to secure the motor to the frame.

An outer-rotor brushless direct-current (BLDC) motor is provided including a stator core having an aperture extending therethrough, a stator mount including an elongated cylindrical member projecting into the aperture of the stator core, an outer rotor, and a rotor mount including an outer rim arranged to couple to the outer rotor and an inner body supporting an outer race of a motor bearing. A piloting pin is provided including a rear portion received within the hollow portion of the elongated cylindrical member of the stator mount and a front portion received within the inner race of the motor bearing.

An electric power system for a vehicle includes at least one electric machine, one or more power rectifiers, and a plurality of DC channels. The at least one electric machine includes a plurality of tooth-wound multi-phase windings that are substantially magnetically decoupled, and the at least one electric machine is mechanically balanced even if one of the plurality of windings is de-energized. The one or more power rectifiers are configured to produce rectified power from the power generated by the at least one electric machine. The plurality of DC channels are formed after the at least one power rectifier and are configured to provide DC power to one or more loads within a vehicle.

A segmented stator has a plurality of individual teeth (12) connected to one another in the direction of rotation. Each individual tooth (12) has a connecting portion (17) to produce a nonpositive mechanical connection with at least one directly adjacent individual tooth (12). The respective connecting portion (17) has a groove-shaped fastening contour (18, 18a, 19, 19a), at least on one connecting side (17a, 17b), facing toward the directly adjacent individual tooth (12). The fastening contour (18, 18a, 19, 19a) of an adjacent individual tooth (12) can be connected to its connecting portion (17), such that a nonpositive connection is produced which ensures a magnetic flux.

A radial flux electric machine includes an inner stator and an outer rotor configured to rotate about the stator. The outer rotor may include a rotor base and a plurality of annularly arranged permanent magnets axially extending from the rotor base parallel to an axis of rotation of the rotor. A cylindrical core may extend from the rotor base encircling the plurality of permanent magnets. The core may be formed of a Soft Magnetic Composite (SMC). A sleeve may encircle the rotor. The sleeve may support the cylindrical core and the cylindrical core may support the plurality of permanent magnets. The cylindrical core may be positioned radially between the sleeve and the plurality of permanent magnets.