Electrical machine

Abstract

To provide an electrical machine.SOLUTION: An electrical machine includes a cooling jacket defining a plurality of recess cavities, and the cooling jacket is configured to maintain the temperature of the electrical machine below a predetermined threshold. The electrical machine also includes a plurality of segmented inverters, and each of the plurality of segmented inverters is received within one of the plurality of recess cavities of the cooling jacket. The electrical machine also includes a plurality of stator windings electrically coupling the plurality of segmented inverters to an alternating current (AC) terminal. The electrical machine also includes a direct current (DC) power connection ring. The power connection ring includes a positive DC power connection electrically coupling the segmented inverter with a positive DC power source and a negative DC power connection electrically coupling the segmented inverter with a negative DC power source.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of U.S. patent application Ser. No. 18 / 738,357, filed Jun. 10, 2024, the contents of which are incorporated herein by reference.

[0002] (Technical field) FIELD OF THE DISCLOSURE The present disclosure relates generally to electric machines, and more particularly to poly-phase electric machines. [Background technology]

[0003] (background) Electric machines, such as motors and generators, may include a rotor mounted on a shaft and arranged to rotate inside a stator. The rotor may include windings or permanent magnets. The rotor windings or permanent magnets generate a rotating magnetic field across an air gap between the rotor and the stator. The stator may include multiple coil windings wound around the stator teeth to form separate poles. The coil windings on a pole are synchronized to provide the same magnetic polarity, creating a rotating magnetic field that induces rotation in the rotor coupled to the stator. Each of the coil windings is electrically coupled to a power inverter, which converts DC power provided by a direct current (DC) energy source into alternating current (AC) power used to control the polarity of the poles. Summary of the Invention [Means for solving the problem]

[0004] (overview) In one embodiment, the electric machine includes a cooling jacket defining a plurality of recessed cavities, the cooling jacket configured to maintain a temperature of the electric machine below a predetermined threshold. The electric machine also includes a plurality of segmented inverters, each of the plurality of segmented inverters received within one of the plurality of recessed cavities of the cooling jacket. The electric machine also includes a plurality of stator windings electrically coupling the plurality of segmented inverters to alternating current (AC) terminals. The electric machine also includes a DC power connection ring. The power connection ring includes a positive DC power connection electrically coupling the segmented inverter with a positive DC power source and a negative DC power connection electrically coupling the segmented inverter with a negative DC power source.

[0005] In some embodiments, each of the multiple inverters operates independently from one another. In some embodiments, the DC power connection ring comprises laminations, the laminations isolating the positive DC power connection from the negative DC power connection in the DC power connection ring. In some embodiments, each of the multiple segmented inverters includes a control module configured to control the function of the segmented inverter, a power module electrically coupled to the control module, at least one positive DC bus bar to which the positive DC power connection is electrically coupled, and at least one negative DC bus bar to which the negative DC power connection is electrically coupled. In some embodiments, each of the multiple segmented inverters is a three-phase power inverter. In some embodiments, the DC power connection ring is coupled to a bottom side of the cooling jacket.

[0006] In some embodiments, the electric machine includes a back plate and a front plate, the back plate being on an opposite end of the electric machine from the front plate, the back plate and the front plate forming at least a portion of a housing for the electric machine. In some embodiments, the electric machine includes a stator with a plurality of teeth projecting radially inward, the plurality of teeth defining a plurality of slots that accommodate a plurality of stator windings. In some embodiments, the electric machine includes a rotor disposed within the stator and configured to rotate within the stator and generate electricity for the electric machine. In some embodiments, the plurality of stator windings are preformed coils positioned on the plurality of teeth. In some embodiments, the plurality of stator windings are at least one of flat wire windings or hairpin windings. In some embodiments, the plurality of stator windings are grouped into a plurality of subgroups of stator windings, and each of the plurality of subgroups of stator windings is coupled to a single segmented inverter of the plurality of segmented inverters.

[0007] In some embodiments, each of the plurality of subgroups of stator windings is a three-phase system of windings that creates three complete and independent layers without being connected to other subgroups of stator windings. In some embodiments, each of the plurality of subgroups of stator windings is coupled to the plurality of segmented inverters through a plurality of terminals that are configured as insulated separators. In some embodiments, the cooling jacket includes eight recessed cavities configured to receive the eight segmented inverters. In some embodiments, the plurality of segmented inverters includes a thin coating of thermal interface material configured to enhance thermal coupling between the plurality of segmented inverters and the plurality of recessed cavities.

[0008] The summary is illustrative only and is not intended to be in any way limiting. The present invention provides, for example, the following items. (Item 1) 1. An electric machine, comprising: a cooling jacket defining a plurality of recessed cavities, the cooling jacket configured to maintain a temperature of the electric machine below a predetermined threshold; a plurality of segmented inverters, each of the plurality of segmented inverters received within one of the plurality of recessed cavities of the cooling jacket; a plurality of stator windings electrically coupling the plurality of segmented inverters to alternating current (AC) terminals; A direct current (DC) power connection ring, said DC power connection ring comprising: a positive DC power connection electrically coupling the plurality of segmented inverters to a positive DC power source; a negative DC power connection electrically coupling the plurality of segmented inverters to a negative DC power source; DC power connection ring and An electric machine comprising: (Item 2) 10. The electric machine of claim 9, wherein each of the plurality of segmented inverters operates independently of the others. (Item 3) 10. The electric machine of claim 1, wherein the DC power connection ring comprises a lamination that insulates the positive DC power connection from the negative DC power connection at the DC power connection ring. (Item 4) Each of the plurality of segmented inverters comprises: a control module configured to control the function of the segmented inverter; a power module electrically coupled to the control module; at least one positive DC bus bar to which the positive DC power connection is electrically coupled; at least one negative DC bus bar to which the negative DC power connection is electrically coupled; and 10. An electric machine according to any of the preceding items, comprising: (Item 5) 10. The electric machine of claim 1, wherein each of the plurality of segmented inverters is a three-phase power inverter. (Item 6) 10. The electric machine of claim 1, wherein each of the plurality of segmented inverters is a six-phase power inverter. (Item 7) 10. The electric machine of claim 1, wherein the DC power connection ring is coupled to a bottom side of a cooling jacket. (Item 8) 10. The electric machine of claim 1, further comprising a back plate and a face plate, the back plate being on an opposite end of the electric machine from the face plate, the back plate and the face plate forming at least part of a housing for the electric machine. (Item 9) The electric machine comprises: a stator including a plurality of radially inwardly projecting teeth, the plurality of teeth defining a plurality of slots for receiving the plurality of stator windings; a rotor disposed within the stator and configured to rotate within the stator and generate electricity for the electric machine; 10. The electric machine of claim 9, further comprising: (Item 10) 10. The electric machine of claim 1, wherein the plurality of stator windings are preformed coils placed on the plurality of teeth. (Item 11) 10. The electric machine of claim 1, wherein the plurality of stator windings are at least one of flat wire windings or hairpin windings. (Item 12) 10. The electric machine of claim 1, wherein the plurality of stator windings are grouped into a plurality of subgroups of stator windings, each of the plurality of subgroups of stator windings being coupled to a single segmented inverter of the plurality of segmented inverters. (Item 13) 10. The electric machine of claim 9, wherein each of the plurality of subgroups of stator windings is a three-phase system of windings, creating three complete and independent layers without connection to other subgroups of stator windings. (Item 14) 10. The electric machine of claim 1, wherein each of the plurality of subgroups of stator windings is coupled to the plurality of segmented inverters through a plurality of terminals constructed as insulated separators. (Item 15) 10. The electric machine of claim 1, wherein the cooling jacket includes eight recessed cavities configured to receive eight segmented inverters. (Item 16) 10. The electric machine of claim 1, wherein the plurality of segmented inverters includes a thin coating of a thermal interface material configured to enhance thermal coupling between the plurality of segmented inverters and the plurality of recessed cavities. (Summary) The electric machine includes a cooling jacket defining a plurality of recessed cavities, the cooling jacket configured to maintain a temperature of the electric machine below a predetermined threshold. The electric machine also includes a plurality of segmented inverters, each of which is received within one of the plurality of recessed cavities of the cooling jacket. The electric machine also includes a plurality of stator windings electrically coupling the plurality of segmented inverters to alternating current (AC) terminals. The electric machine also includes a direct current (DC) power connection ring. The power connection ring includes a positive DC power connection electrically coupling the segmented inverters to a positive DC power source and a negative DC power connection electrically coupling the segmented inverters to a negative DC power source. [Brief explanation of the drawings]

[0009] The present disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like elements and in which:

[0010] [Figure 1] FIG. 1 illustrates a perspective view of an electric machine in accordance with an exemplary embodiment.

[0011] [Figure 2] FIG. 2 illustrates a perspective view of a DC power connection ring according to an exemplary embodiment.

[0012] [Figure 3A] FIG. 3A illustrates a perspective view of a cooling jacket in accordance with an exemplary embodiment.

[0013] [Figure 3B] FIG. 3B illustrates a perspective view of the cooling insert of the cooling jacket of FIG. 3A according to an exemplary embodiment.

[0014] [Figure 4] FIG. 4 illustrates a perspective view of a rotor and stator combination having multiple windings in accordance with an exemplary embodiment.

[0015] [Figure 5] FIG. 5 illustrates a front perspective view of a segmented inverter in accordance with an exemplary embodiment.

[0016] [Figure 6] FIG. 6 shows a rear perspective view of the segmented inverter of FIG.

[0017] [Figure 7] FIG. 7 illustrates an isometric view of an electric machine in accordance with an exemplary embodiment.

[0018] [Figure 8] FIG. 8 shows a front view of the electric machine of FIG.

[0019] [Figure 9] FIG. 9 shows a rear view of the electric machine of FIG.

[0020] [Figure 10] FIG. 10 shows a left side view of the electric machine of FIG.

[0021] [Figure 11] FIG. 11 shows a right side view of the electric machine of FIG.

[0022] [Figure 12] FIG. 12 shows a top view of the electric machine of FIG.

[0023] [Figure 13] FIG. 13 shows a bottom view of the electric machine of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0024] (Detailed explanation) Following below is a more detailed description of various concepts related to cooling systems for electric machines and implementations of the cooling systems. The systems introduced herein may be implemented in a variety of ways, such that the concepts described are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for purposes of illustration.

[0025] Before returning to the drawings, various embodiments of electric machines and their components have been described herein. While individual components have been described in detail, it should be understood that the details are to be considered by way of example only. Furthermore, the details may include variations as described herein. Thus, while individual components may be described with respect to an embodiment, it should be understood that any of the components may be used in any other embodiment described herein, unless otherwise specified.

[0026] The embodiments described herein generally relate to improved electric machines utilizing segmented inverters. According to various embodiments, the electric machine includes multiple segmented inverters distributed around a cooling jacket for the electric machine. In the embodiments described herein, the segmented inverters share a common cooling mechanism through the cooling jacket. In some embodiments, the electric machine includes stator windings that are directly connected to AC terminals for the segmented inverters on one side of the machine. The second side of the machine has DC terminals and a DC connection ring that distributes battery power to the inverters to operate the electric machine.

[0027] By utilizing segmented inverters that are each independently connected to the stator windings for the electric machine, the electric machine usefully incorporates redundancy in case one of the inverters is damaged and unable to function. The improved electric machine described herein includes segmented inverters that function independently so that the electric machine can continue to function even in the event of a failure of some of the segmented inverters distributed around the electric machine. Furthermore, the modularity of the segmented inverters allows for easier maintenance and replacement of any damaged segmented inverters.

[0028] FIG. 1 is a perspective view of an electric machine 100 according to an exemplary embodiment. In some embodiments, electric machine 100 is or can include a motor-generator configured to generate motion. In some embodiments, electric machine 100 is or can include a device configured to generate electricity. In some embodiments, electric machine 100 includes a cooling jacket 300 shown in FIGS. 3A-3B and described in more detail, a rotor-stator combination 400 shown in FIG. 4 and described in more detail, a power connection ring 106 shown in FIG. 2 and described in more detail, and a multiple-segmented inverter 108 shown in FIGS. 5-6 and described in more detail. In various embodiments described herein, electric machine 100 may include more or fewer components.

[0029] In some embodiments, the electric machine 100 includes a cooling jacket 300 defining a plurality of recessed cavities 302, the cooling jacket 300 configured to maintain a temperature of the electric machine 100 below a predetermined threshold. The electric machine 100 includes a plurality of segmented inverters 108, each of which is received within one of the plurality of recessed cavities 302 of the cooling jacket. The electric machine 100 includes a plurality of stator windings 110 electrically coupling the plurality of segmented inverters 108 to alternating current (AC) terminals. The electric machine 100 includes a direct current (DC) power connection ring 106. The DC power connection ring 106 includes a positive DC power connection 204 electrically coupling the segmented inverters 108 with a positive DC power source. The DC power connection ring 106 includes a negative DC power connection 202 electrically coupling the segmented inverters 108 with a negative DC power source.

[0030] In some embodiments, the electric machine 100 may include a back plate 102 and a front plate 104 on opposite ends of the electric machine 100. In some embodiments, the back plate 102 and the front plate 104 form at least a portion of a housing for the electric machine 100.

[0031] 3 and 4 , a rotor-stator combination 400 may be housed inside the cooling jacket 300. The rotor-stator combination 400 includes a rotor 402 and a stator 406 having stator windings 110 and a shaft 114. The rotor 402 is a rotating component of the electric machine 100. The rotor-stator combination 400 is disposed radially inward from the cooling jacket 300. The rotor-stator combination 400 defines a portion of an electromagnetic circuit. The magnetic field generated by the stator 406 interacts with the opposing magnetic field of the rotor 402, causing the rotor 402 to rotate. Induction of the rotor field by the stator field is a phenomenon used in induction motor technology. In particular, rotating the rotor 402 inside the stator 406 causes induction in the stator windings, which generates electricity for the electric machine 100.

[0032] Rotor 402 is coupled to shaft 114 such that rotation of rotor 402 causes rotation of shaft 114. Shaft 114 may be located on a central axis of electric machine 100. For example, the central axis extends through a center point of electric machine 100. As used herein, the term "axis" describes a theoretical line extending through the center of gravity (e.g., center of mass, geometric center, etc.) of an object. An object is centered on an axis. An object is not necessarily cylindrical (e.g., a non-cylindrical shape may be centered on an axis). Furthermore, an object is not necessarily on an axis (e.g., the center of gravity of a hollow object may be on an axis, but a portion of the object need not be on an axis).

[0033] The stator 406 can be a solid core or a laminated core. When the stator 406 is a laminated core, the stator 406 includes multiple thin metal sheets (e.g., laminations) that reduce energy loss in the electromagnetic circuit. The laminations are stacked together to form a hollow cylinder.

[0034] The stator 406 includes a plurality of teeth projecting radially inward and defining slots that accommodate the stator windings 110. In some embodiments, the stator windings 110 are in the form of coils that are positioned on the teeth and can be wound around the teeth. In other embodiments, the stator windings 110 can be preformed coils that can be slid onto the teeth. In some embodiments, the stator windings 110 can be flat wire windings or hairpin windings. In some embodiments, the stator windings 110 can be separated into multiple groups of stator windings 110, each connected to their associated terminals 404. In some embodiments, the terminals 404 can be insulated separators that facilitate connection of the stator windings 110 to the segmented inverter 108.

[0035] In some embodiments, the stator windings 110 may be a three-phase system of windings. In particular, each of the stator windings 110 includes coils A, B, and C (representing three phases), all of which are independently and completely connected to only one segmented inverter 108. For example, the entirety of coil A (e.g., from start to finish) is connected to a single segmented inverter 108, forming a complete layer without needing to be connected to any of the other groups of stator windings 110.

[0036] In some embodiments, each of the multiple segmented inverters 108 operates independently of one another. The electric machine 100 includes independent stator windings 110, each with three phases generally connected to each of the individual segmented inverters 108, so that the electric machine 100 can continue to operate even if one of the segmented inverters 108 malfunctions. In other embodiments, the stator windings 110 may be a six-phase system of windings or any other number of phases. However, regardless of the number of phases included in the stator windings 110, the independent functioning of the stator windings 110 and the segmented inverters 108 is maintained as described above. Because the stator windings 110 are directly connected to the segmented inverters 108 that are closely housed within the electric machine 100, as opposed to being connected to an inverter outside the electric machine through an extended AC cable, the independent functioning of the stator windings 110 and the segmented inverters 108 provides various benefits, including a reduced amount of AC cable loss.

[0037] In some embodiments, the motor 402 is rotated by a prime mover (not shown), and the rotating magnetic field produced by the permanent magnets causes current to flow in the stator windings 110 .

[0038] 3A , cooling jacket 300 is shown, in accordance with an exemplary embodiment. Cooling jacket 300 is a stationary or substantially stationary component of electric machine 100. Cooling jacket 300 defines a portion of the electromagnetic circuit of electric machine 100. Cooling jacket 300 is a shared cooling system distributed throughout electric machine 100, as opposed to having individual cooling systems for each of the inverters.

[0039] The cooling jacket 300 is disposed radially outward from the stator 406. In some embodiments, the cooling jacket 300 is coupled to the stator 406. The cooling jacket 300 is part of, or at least partially defines, a cooling system for the electric machine 100. The cooling jacket 300 facilitates the transfer of thermal energy from the electric machine 100 to a fluid, such as a coolant. In some embodiments, the cooling jacket 300 is configured to receive and distribute a cooling fluid around the electric machine. In this manner, the cooling jacket 300 can usefully reduce the temperature of the electric machine 100. In some embodiments, the cooling jacket 300 includes one or more flow paths within the jacket configured to circulate a fluid that cools the electric machine 100. In some embodiments, the flow paths are configured to receive the fluid via one or more paths that are fluidly coupled to a fluid source outside the electric machine 100.

[0040] The cooling jacket 300 may include a cooling insert 250. The insert 250 includes a plurality of ribs 252 extending between the interior surfaces of the stator jacket 300. The plurality of ribs 252 define a plurality of flow paths therebetween. The plurality of flow paths are fluidly coupled to pathways into the electric machine 100. The pathways extend into a cavity of the cooling jacket. The pathways allow fluid communication between a fluid source (e.g., a fluid reservoir, a fluid pump, a fluid heat exchanger, etc.) and the cavity of the cooling jacket.

[0041] In some embodiments, insert 250 includes an inlet portion 260 (shown in FIG. 3B ) disposed at a first end of plurality of ribs 252. In some embodiments, insert 250 includes an outlet portion 262 disposed at a second end of plurality of ribs 252 such that each of plurality of ribs 252 extends from inlet portion 260 to outlet portion 262. In some embodiments, insert 250 includes an insert wall 264 disposed between inlet portion 260 and outlet portion 262 such that insert wall 264 fluidly separates inlet portion 260 and outlet portion 262. Insert 250 includes a plurality of ribs 252. Each rib of plurality of ribs 252 extends between the interior surface of cooling jacket 300. As shown in FIG. 3B , each rib of plurality of ribs 252 extends circumferentially from a first rib end 258 to a second rib end 259. First rib end 258 is spaced circumferentially from second rib end 259. In some embodiments, the ribs 252 are spaced axially from one another. Each adjacent pair of the ribs 252 defines a flow path therebetween. More specifically, the flow path is defined by the axial space between the ribs 252 and the radial space between the interior surfaces of the cooling jacket 300.

[0042] In some embodiments, the ribs 252 form a pattern. In some embodiments shown in Figure 3B, the pattern is an angled wave pattern, in which adjacent segments of the ribs 252 are angled relative to one another. In other embodiments, the ribs 252 can have a different pattern, such as a smooth wave pattern, in which adjacent segments of the ribs 252 are curved relative to one another, or other suitable pattern.

[0043] In some embodiments, at least one rib 252 of the plurality of ribs 252 is an end rib. The end rib is disposed at an axial end of the insert 250. In some embodiments, the insert 250 includes two end ribs. For example, the insert includes a first end rib disposed at a first axial end of the insert 250 and a second end rib disposed at a second axial end of the insert 250 opposite the first axial end.

[0044] In some embodiments, the insert 250 includes a first end wall 255 and a second end wall 256. The first end wall 255 is disposed at a first axial end of the insert 250. The second end wall is disposed at a second axial end of the insert 250 opposite the first end. The first end wall 255 and the second end wall 256 extend around the circumference of the insert 250. The first end wall 255 and the second end wall 256 each extend radially between the interior surface of the cooling jacket 300. In this manner, the first end wall 255 and the second end wall 256 cooperate to at least partially define the interior volume of the insert 250.

[0045] In some embodiments, the axial spacing between the ribs 252 is uniform or substantially uniform. In other embodiments, the axial spacing between the ribs 252 is not uniform. In an exemplary embodiment, the ribs 252 may be spaced apart from one another such that the axial spacing between the ribs increases toward the center (e.g., axial center) of the insert 250. For example, the first three ribs of the insert 250 have a first axial distance from the second rib (e.g., an end rib), which is spaced apart from the third rib by a second axial distance that is greater than the first axial distance. Thus, the flow passages adjacent the axial ends of the insert 250 have a narrower axial width than the flow passages adjacent the axial center of the insert 250. The flow passages adjacent the axial ends of the insert 250 have a relatively narrower axial width. The flow passages adjacent the axial center of the insert 250 have a relatively wider axial width. The flow passages between the axial center and the axial ends of the insert 250 have an axial width between the relatively narrower axial width and the relatively wider axial width.

[0046] In some embodiments, the insert 250 includes one or more support members 257 (e.g., rods, rails, etc.). The support members 257 extend axially. The support members 257 intersect each of the ribs 252. The support members 257 extend axially through the flow passages but do not substantially impede the flow of fluid therethrough. In some embodiments, the support members 257 can be coupled to the ribs 252. In other embodiments, the support members 257 can be integrally formed with the ribs 252. In any embodiment, the support members 257 connect the ribs 252 to one another. In this manner, the support members 257 provide structural support for the insert 250. The insert 250 can include multiple support members 257. For example, the insert can include at least a first support member disposed proximate a first rib end 258 and a second support member disposed proximate a second rib end 259.

[0047] 3B , in some embodiments, insert 250 includes an inlet portion 260. Inlet portion 260 is disposed at first rib end 258. In some embodiments, insert 250 includes an outlet portion 262. Outlet portion 262 is disposed at second rib end 259. Each of the plurality of ribs 252 extends from inlet portion 260 to outlet portion 262. In some embodiments, insert 250 includes an insert wall 264 disposed between inlet portion 260 and outlet portion 262. Insert wall 264 extends between first interior surface 210 and second interior surface 212 such that insert wall 264 fluidly separates inlet portion 260 and outlet portion 262.

[0048] In the exemplary embodiment, inlet portion 260 is defined between insert wall 264, first end wall 255, second end wall 256, and first rib end 258. Inlet portion 260 may be fluidly coupled (e.g., in fluid communication) with at least one of them. More specifically, inlet portion 260 may receive fluid from a pathway. Inlet portion 260 may direct the fluid to flow into the flow channels in first rib end 258. In this manner, multiple flow channels are fluidly coupled to the pathway (e.g., via inlet portion 260).

[0049] In some embodiments, the cooling jacket 300 may include multiple recessed cavities 302 configured to receive multiple segmented inverters 108. Each segmented inverter 108 may be operably coupled to one electric machine controller (not shown), and the inverters 108 may be operated separately and independently from one another. In the exemplary embodiment shown in FIG. 3A, the cooling jacket 300 has a total of eight recessed cavities configured to receive a total of eight segmented inverters 108, as shown in FIG. 1. However, it will be understood that any suitable number of recessed cavities 302 / segmented inverters 108 may be included in the electric machine 100.

[0050] In some examples, the segmented inverters 108 may be formed as modules or segmented components that may be separately mounted. Each group of stator windings 110 is configured to be connected to a segmented inverter 108. For example, a first group of stator windings 110 may be connected to a first segmented inverter 108. In some embodiments, each of the plurality of segmented inverters 108 is a three-phase power inverter. Although a three-phase inverter is referenced herein, it should be understood that the segmented inverters 108 may alternatively be inverters of different phases, such as, for example, a six-phase inverter.

[0051] 5-6 , front and rear views of the segmented inverters 108 are shown in more detail, according to example embodiments. In some embodiments, each segmented inverter 108 includes an AC terminal 504 configured to electrically connect to a portion of the stator winding 110. In some embodiments, each of the segmented inverters 108 also includes a DC terminal 502 configured to electrically connect the segmented inverter 108 to the power connection ring 106. In some embodiments, each of the segmented inverters 108 is configured to receive DC power from the power connection ring 106 and convert the DC power to AC power for use by the electric machine.

[0052] In some embodiments, the segmented inverter 108 may include a thin coating of thermal interface material 506. In some embodiments, the thermal interface material 506 may be a non-coated material, such as a phase change material (PCM). The thermal interface material 506 may be configured to enhance thermal coupling between the segmented inverter 108 and the recessed cavity 302. Additionally, the thermal interface material 506 may improve the smoothness of the segmented inverter 108, which further improves coupling of the segmented inverter 108 with the recessed cavity 302.

[0053] In some embodiments, each of the plurality of segmented inverters 108 includes a printed circuit board that includes a controller or control module configured to control the function of the segmented inverters 108. In some embodiments, the printed circuit board includes a power stage or power module that is electrically connected to the controller or control module.

[0054] In some embodiments, the segmented inverter 108 includes a positive DC terminal or bus bar 510 to which the positive DC power connection is electrically connected and a negative DC terminal or bus bar 508 to which the negative DC power connection is electrically coupled.

[0055] As shown in FIG. 2 , the DC power connection ring 106 includes a positive conductor 204 and a negative conductor 202. In the exemplary embodiment described herein, each of the segmented inverters 108 is electrically coupled to the positive DC power connection (e.g., conductor) 204 and the negative DC power connection (e.g., conductor) 202. In some embodiments, the DC power connection ring 106 includes laminations that electrically insulate the positive DC power connection 204 and the negative DC power connection 202 from each other and from any other surrounding components (e.g., other conductors, such as a casing) to prevent unwanted short circuits. Using laminations to insulate the power connection ring 106 eliminates the need for an air gap, which provides several advantages, including a more compact design of the electric machine 100. Additionally, as shown in FIG. 2 , the DC power connection ring 106 is coupled to the bottom side of the cooling jacket 300. Locating the DC power connection ring 106 on the bottom side of the cooling jacket 300 facilitates easier connection of the electric machine 100 to an external DC power source and allows for a more compact design of the electric machine 100 .

[0056] 7-12 show various views of electric machine 200, according to example embodiments. In some embodiments, electric machine 200 is or can include a motor-generator configured to generate motion. In some embodiments, electric machine 200 is or can include a device configured to generate electricity. In some embodiments, electric machine 200 is similar to electric machine 100 and includes the same components described above with respect to electric machine 100. For example, electric machine 100 may include a stator, a rotor, a cooling jacket, and one or more segmented inverters, as described above.

[0057] It should be noted that the term "example" and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and that such terms are not intended to imply that such embodiments are necessarily particular or top-tier examples).

[0058] As used herein, the term "coupled" and variations thereof refer to the direct or indirect joining of two members to one another. Such joining can be fixed (e.g., permanent or fixed) or movable (e.g., removable or releasable). Such joining can be achieved when two members are coupled to one another, when two members are coupled to one another using separate intervening members and optional additional intermediate members coupled to one another, or when two members are coupled to one another as a single, unitary body using an intervening member integrally formed with one of the two members. When "coupled" or variations thereof are modified by additional terms (e.g., directly coupled), the general definition of "coupled" provided above is modified by the plain language meaning of the additional terms (e.g., "directly coupled" means the joining of two members without any separate intervening members), resulting in a narrower definition than the general definition of "coupled" provided above. Such coupling may be mechanical, electrical or fluidic.

[0059] The locations of elements herein (e.g., "top," "bottom," "above," "below") are used merely to describe the orientation of various elements in the figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be covered by the present disclosure.

[0060] The hardware and data processing components used to implement the various processes, operations, illustrative logic, logic blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed using general purpose single-chip or multi-chip processors, digital signal processors (DSPs), application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs) or other programmable logic devices, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein.

[0061] A general-purpose processor may be a microprocessor or conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry specialized for a given function.

[0062] Memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage) for storing data and / or code for completing or facilitating the various processes, layers, and modules described in this disclosure. Memory may be or may include volatile or non-volatile memory and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in this disclosure. According to an exemplary embodiment, the memory is communicatively coupled to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or processor) one or more processes described herein.

[0063] It is important to note that the construction and arrangement of the systems as shown in the various exemplary embodiments are merely illustrative. Additionally, any element disclosed in one embodiment may be incorporated into or utilized in any other embodiment disclosed herein. For example, the system of the exemplary embodiment described with reference to Figures 3 and 4 may be incorporated into the system of the exemplary embodiment described with reference to Figure 1. While only one example of an element from one embodiment that can be incorporated into or utilized in another embodiment is described above, it should be understood that other elements of the various embodiments may be incorporated into or utilized in any of the other embodiments disclosed herein.

Claims

1. 1. An electric machine, comprising: a cooling jacket defining a plurality of recessed cavities, the cooling jacket configured to maintain a temperature of the electric machine below a predetermined threshold; a plurality of segmented inverters, each of the plurality of segmented inverters received within one of the plurality of recessed cavities of the cooling jacket; a plurality of stator windings electrically coupling the plurality of segmented inverters to alternating current (AC) terminals; A direct current (DC) power connection ring, said DC power connection ring comprising: a positive DC power connection electrically coupling the plurality of segmented inverters to a positive DC power source; a negative DC power connection electrically coupling the plurality of segmented inverters to a negative DC power source; a DC power connection ring comprising: An electric machine comprising:

2. The electric machine of claim 1 , wherein each of the plurality of segmented inverters operates independently of each other.

3. The electric machine of claim 1 , wherein the DC power connection ring comprises laminations that insulate the positive and negative DC power connections at the DC power connection ring.

4. Each of the plurality of segmented inverters comprises: a control module configured to control the function of the segmented inverter; a power module electrically coupled to the control module; at least one positive DC bus bar to which the positive DC power connection is electrically coupled; at least one negative DC bus bar to which the negative DC power connection is electrically coupled; and The electric machine of claim 1 , comprising:

5. The electric machine of claim 1 , wherein each of the plurality of segmented inverters is a three-phase power inverter.

6. The electric machine of claim 1 , wherein each of the plurality of segmented inverters is a six-phase power inverter.

7. The electric machine of claim 1 , wherein the DC power connection ring is coupled to a bottom side of a cooling jacket.

8. 10. The electric machine of claim 1, further comprising a back plate and a face plate, the back plate on an opposite end of the electric machine from the face plate, the back plate and the face plate forming at least a portion of a housing for the electric machine.

9. The electric machine comprises: a stator including a plurality of radially inwardly projecting teeth defining a plurality of slots for receiving the plurality of stator windings; a rotor disposed within the stator and configured to rotate within the stator and generate electricity for the electric machine; The electric machine of claim 1 further comprising:

10. The electric machine of claim 9 , wherein the plurality of stator windings are preformed coils placed on the plurality of teeth.

11. The electric machine of claim 1 , wherein the plurality of stator windings are at least one of flatwire windings or hairpin windings.

12. 2. The electric machine of claim 1, wherein the plurality of stator windings are grouped into a plurality of subgroups of stator windings, each of the plurality of subgroups of stator windings being coupled to a single segmented inverter of the plurality of segmented inverters.

13. 13. The electric machine of claim 12, wherein each of the plurality of subgroups of stator windings is a three-phase system of windings creating three complete and independent layers without connection to other subgroups of stator windings.

14. The electric machine of claim 13 , wherein each of the plurality of subgroups of stator windings is coupled to the plurality of segmented inverters through a plurality of terminals constructed as insulated separators.

15. The electric machine of claim 1 , wherein the cooling jacket includes eight recessed cavities configured to receive eight segmented inverters.

16. The electric machine of claim 1 , wherein the plurality of segmented inverters includes a thin coating of a thermal interface material configured to enhance thermal coupling between the plurality of segmented inverters and the plurality of recessed cavities.

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