US 12,149,131 B2
Motor position sensing system for rotating electric machines
Mojtaba Bahrami Kouhshahi, Ann Arbor, MI (US); Mohammed (Rakib) Islam, Saginaw, MI (US); Jeffrey T. Klass, Kawkawlin, MI (US); Steven J. Collier-Hallman, Frankenmuth, MI (US); and Md. Zakirul Islam, San Jose, CA (US)
Assigned to Steering Solutions IP Holding Corporation, Saginaw, MI (US)
Filed by Steering Solutions IP Holding Corporation, Saginaw, MI (US)
Filed on May 23, 2022, as Appl. No. 17/750,597.
Prior Publication US 2023/0378851 A1, Nov. 23, 2023
Int. Cl. H02K 11/215 (2016.01); H02K 7/00 (2006.01); H02K 29/08 (2006.01)
CPC H02K 11/215 (2016.01) [H02K 7/003 (2013.01); H02K 29/08 (2013.01)] 20 Claims
OG exemplary drawing
 
1. An electric machine comprising:
a rotor structure disposed within a stator and a motor housing, the rotor structure extending from a first rotor end to a second rotor end, wherein the second rotor end has a plurality of axially stacked laminations;
a motor output shaft operatively coupled to or integrally formed with the first rotor end; and
a motor position sensor system comprising:
a first plurality of cutouts defined in the plurality of axially stacked laminations at the second rotor end, wherein the first plurality of cutouts have a progressively smaller cross-sectional area at each lamination of the plurality of axially stacked laminations, wherein the plurality of axially stacked laminations comprises a first end lamination of the entire plurality of axially stacked laminations and a second end lamination of the entire plurality of axially stacked laminations, wherein the progressively smaller cross-sectional area of each of the first plurality of cutouts at each lamination occurs along an entirety of the axially stacked laminations from the first end lamination to the second end lamination;
a second plurality of cutouts defined in the plurality of axially stacked laminations at the second rotor end, wherein the second plurality of cutouts have a progressively smaller cross-sectional area at each lamination of the plurality of axially stacked laminations, wherein the second plurality of cutouts are arranged radially outward of the first plurality of cutouts on the rotor structure, wherein the progressively smaller cross-sectional area of each of the second plurality of cutouts at each lamination occurs along an entirety of the axially stacked laminations from the first end lamination to the second end lamination;
a plurality of motor sensors axially spaced from the second rotor end; and
a plurality of sensor magnets axially spaced from the second rotor end and the plurality of motor sensors, wherein the plurality of motor sensors and the plurality of sensor magnets are operatively coupled to a printed circuit board operatively coupled to the motor housing.