A vehicle electric machine assembly including a stator core and a terminal block is provided. The stator core includes one or more three-phase terminals connected to end windings. The terminal block includes a connector for each of the three-phase terminals. A portion of the end windings extending from the stator core, the three-phase terminals, and the terminal block are overmolded as a single unit such that a portion of each of the connectors is exposed for connection to an inverter. The terminal block may further include one or more threaded apertures, each sized to receive a threaded stud to facilitate an electrical connection between one of the one or more three-phase terminals and the inverter. Each of the one or more three-phase terminals may extend axially along an axis substantially parallel to a central axis of a rotor disposed within a cavity defined by the stator core.

An electric machine assembly including a housing and a stator is provided. The housing may define a cavity and an inner surface having pockets spaced radially about a housing central axis. The stator may be disposed within the cavity and define an outer surface having tabs spaced from one another radially about a stator central axis and each tab including opposing circumferential sides. The housing and stator may be arranged with one another such that each of the opposing circumferential sides contacts a side of a respective pocket to create interference therebetween. Each tab may further include a tab outer surface and each of the pockets may be sized such that a space is defined between each tab outer surface and a respective pocket side.

A housing for cooling an electric motor in an electric vehicle includes a tubular frame with a first end and a second end, where the first end has first openings, the second end has second openings, and the tubular frame has first channels encased in the tubular frame running between the first openings and the second openings. The housing also includes a first cover that mates with the first end of the tubular frame and includes third openings positioned to mate with the first openings, and second channels that connect the first openings together. A second cover mates with the second end of the tubular frame and has fourth openings positioned to mate with the second openings of the tubular frame, and third channels that connect the second plurality of openings together. The first channels, the second channels, and the third channels form pathways through which coolant can flow.

A rotor includes a rotor core forming a cylindrical body and a plurality of equally-sized circular sectors, where each of the equally-sized circular sectors includes three slots. A first slot configured to house a first magnetic bar includes a first long axis that is oriented in a radial direction in the rotor core. A second slot configured to house a second magnetic bar includes a second long axis that is oriented in the radial direction in the rotor core, where the second slot is sized the same as the first slot. A third slot configured to house a third magnetic bar includes a third long axis that is oriented circumferentially along an out circumferential edge of the rotor core between the first slot and the second slot.

A vehicle includes a housing, an electric machine configured to propel the vehicle, and a clamp. The housing defines an internal cavity, and has first and second stepped surfaces extending radially inward and into the cavity. The electric machine is disposed within the cavity. The electric machine has a stator that includes third and fourth stepped surfaces that extend radially outward. The clamp engages the first and third stepped surfaces, and axially forces the fourth stepped surface into engagement with the second stepped surface.

The invention relates to a drive system, in particular for a vehicle, comprising a fuel cell unit for generating electric energy, a secondary battery for storing electric energy, an electric machine with windings, and an inverter for actuating the electric machine. The inverter is designed as a 3-level inverter and has multiple electronic switches, diodes, a plus pole, a minus pole, and a neutral pole. The fuel cell unit and the secondary battery are connected in series and are connected to the poles of the inverter. The invention also relates to a method for heating a drive system according to the invention, wherein the switches of the inverter are actuated such that a short-circuit current path is produced between the poles of the inverter to which the fuel cell unit is connected.

A hybrid vehicle includes a power bus electrically connected to an inverter and an electrical socket electrically connected to the power bus. A ground fault circuit interrupter (GFCI) is electrically connected between the power bus and the socket. The GFCI has a circuit breaker with a mechanical reset. An actuator arrangement is configured to actuate the mechanical reset to reset the circuit breaker.

A rotor for an electrical machine with one or a plurality of cooling ducts through which a cooling agent can flow. One end face of the rotor there is provided an annular space, bounded axially inwardly and radially outwardly and joined communicating with the cooling duct or ducts. A cover plate is provided, attached to the end face and bounding the annular space axially outwardly, having a central through-opening for introducing the cooling agent into the annular space.

According to some embodiments, a traction system is disclosed. The traction system includes a DC bus, an energy storage device coupled to the DC bus, and a voltage converter assembly coupled to the energy storage device. The voltage converter assembly includes a plurality of phase legs. The traction system further includes an electromechanical device including a plurality of windings coupled to the voltage converter assembly. The traction system also includes a switch coupled to the DC bus between the voltage converter assembly and the energy storage device. The traction system includes a controller configured to control the switch and the voltage converter assembly such that a phase leg and a winding of the electromechanical device form a DC/DC converter.

An electric powered vehicle having a battery pack capable of storing electric energy and a clean fuel engine operated with a clean fuel. A first D/C alternator communicating with the clean fuel engine, supplying electric energy to the electric driving motor. A timing gear belt driven starter/alternator that is connected directly to the clean fuel engine, activating the clean fuel engine when the battery pack reaches loss at a maximum of 30% capacity remaining. Thereafter, a second D/C alternator and yet thereafter a third D/C alternator communicating with the clean fuel engine during periods when no electrical communication exists between the electric driver motor and battery packs. The D/C alternators maintain an electrical output to the battery packs until recharged.