A turbo generator having a turbine configured to be driven by exhaust gas from an internal combustion engine, and an electric generator having a rotor coupled to the turbine and a stator having an ironless coil arranged with the rotor to generate electric power when the rotor is rotated by the turbi
A turbo generator having a turbine configured to be driven by exhaust gas from an internal combustion engine, and an electric generator having a rotor coupled to the turbine and a stator having an ironless coil arranged with the rotor to generate electric power when the rotor is rotated by the turbine.
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1. A turbo generator, comprising: a housing having a coolant passage having a first circumferentially extending portion in communication with a second circumferentially extending portion, wherein the first circumferentially extending portion has an axial length greater than an axial length of the se
1. A turbo generator, comprising: a housing having a coolant passage having a first circumferentially extending portion in communication with a second circumferentially extending portion, wherein the first circumferentially extending portion has an axial length greater than an axial length of the second circumferentially extending portion, wherein the housing further comprises a coolant port to the first circumferentially extending portion of the coolant passage;a lubricant passage and a lubricant port to the lubricant passage, the lubricant port being radially offset from the coolant port;a turbine configured to be driven by exhaust gas from an internal combustion engine; andan electric generator having a rotor coupled to the turbine and a stator having an ironless coil arranged with the rotor to generate electric power when the rotor is rotated by the turbine. 2. The turbo generator of claim 1 wherein the turbine is configured to directly power the rotor. 3. The turbo generator of claim 1 wherein the rotor further comprises a permanent magnet. 4. The turbo generator of claim 1 wherein the stator further comprises a slotless stack surrounding the rotor, the ironless coil being positioned between the rotor and the slotless stack. 5. The turbo generator of claim 1 wherein the ironless coil comprises concentric inner and outer winding portions coupled together to form three-phase windings, wherein the winding portions are separated by at least one continuous fiber strand wrapped a plurality of times around the inner winding portion and impregnated with an encapsulation material. 6. The turbo generator of claim 1 wherein the turbine comprises a turbine wheel and a turbine shaft extending from the turbine wheel, and wherein the rotor comprises a hollow rotor shaft directly coupled to the turbine shaft. 7. The turbo generator of claim 6 wherein the hollow rotor shaft is directly coupled to the turbine shaft with a threaded connection. 8. The turbo generator of claim 1 further comprising a housing configured to be coupled to an exhaust manifold of the internal combustion engine, and wherein the turbine comprises a turbine wheel arranged within the housing such that the exhaust gas from the exhaust manifold drives the turbine wheel. 9. The turbo generator of claim 8 wherein the housing section further comprises an exhaust port configured to output the exhaust gas used to drive the turbine wheel. 10. The turbo generator of claim 1 wherein the stator further comprises a slotless stack concentric with the ironless coil, wherein the ironless coil extends beyond the slotless stack in both axial directions. 11. The turbo generator of claim 10 further comprising a housing having a coolant passage having a portion that extends circumferentially around a portion of the ironless coil that extends beyond the slotless stack in one of the axial directions. 12. The turbo generator of claim 1 further comprises a housing having coolant and lubricant passages. 13. The turbo generator of claim 1 further comprising a turbine housing section, a generator housing section coupled to the turbine housing section, and a heat deflector between the turbine housing section and the generator housing section. 14. The turbo generator of claim 1 further comprising a housing having a cooling passage configured to be coupled to a vehicle's engine cooling system. 15. The turbo generator of claim 1 wherein the lubricant port is axially offset from the second circumferentially extending portion of the cooling passage. 16. The turbo generator of claim 1 further comprising a housing having a lubricant passage configured to be coupled to a vehicle's engine lubrication system. 17. The turbo generator of claim 1 further comprising a housing having a machined lubricant passage including one or more auxiliary holes that are closed after machining. 18. The turbo generator of claim 1 further comprising a housing having a lubricant passage that extends through the housing at an angle other than perpendicular to an axial axis of the housing. 19. The turbo generator of claim 1 further comprising a housing having a lubricant passage, a bearing in the lubricant passage, and a lubricant port in communication with the lubricant passage, wherein the turbine further comprises a turbine shaft configured to rotate in the bearing, and wherein the lubricant port is axially offset from the bearing. 20. The turbo generator of claim 19 wherein the bearing comprises a floating journal bearing. 21. The turbo generator of claim 1 further comprising a turbo housing section and a generator housing section having first and second housing sections fastened together. 22. The turbo generator of claim 1 further comprising a housing and at least one electrical connector assembly extending from the ironless coil through the housing, wherein each of said at least one electrical connector assembly comprises a stud and an insulator between the stud and the housing. 23. The turbo generator of claim 22 wherein each of said at least one electrical connector assembly is configured such that the stud is rotatable with respect to the insulator before the electrical connector assembly is coupled to the ironless coil. 24. A turbo generator, comprising: a housing having a coolant passage having a first circumferentially extending portion in communication with a second circumferentially extending portion, wherein the first circumferentially extending portion has an axial length greater than an axial length of the second circumferentially extending portion;a lubricant passage and a lubricant port to the lubricant passage, the lubricant port being radially offset from the coolant port;a coolant port to the first circumferentially extending portion of the coolant passage;a lubricant passage and a lubricant port to the lubricant passage, the lubricant port being radially offset from the coolant port;a turbine configured to be driven by exhaust gas from an internal combustion engine; andan electric generator having a rotor coupled to the turbine and a stator having an ironless coil surrounding the rotor. 25. The turbo generator of claim 24 wherein the turbine is configured to directly power the rotor. 26. The turbo generator of claim 24 wherein the rotor further comprises a permanent magnet. 27. The turbo generator of claim 24 wherein the stator further comprises a slotless stack surrounding the rotor, the ironless coil being positioned between the rotor and the slotless stack. 28. The turbo generator of claim 24 wherein the ironless coil comprises concentric inner and outer winding portions coupled together to form three-phase windings, wherein the winding portions are separated by at least one continuous fiber strand wrapped a plurality of times around the inner winding portion and impregnated with an encapsulation material. 29. The turbo generator of claim 24 wherein the turbine comprises a turbine wheel and a turbine shaft extending from the turbine wheel, and wherein the rotor comprises a hollow rotor shaft directly coupled to the turbine shaft. 30. The turbo generator of claim 29 wherein the hollow rotor shaft is directly coupled to the turbine shaft with a threaded connection. 31. The turbo generator of claim 24 further comprising a housing configured to be coupled to an exhaust manifold of the internal combustion engine, and wherein the turbine comprises a turbine wheel arranged within the housing such that the exhaust gas from the exhaust manifold drives the turbine wheel. 32. The turbo generator of claim 31 wherein the housing section further comprises an exhaust port configured to output the exhaust gas used to drive the turbine wheel. 33. The turbo generator of claim 24 wherein the stator further comprises a slotless stack concentric with the ironless coil, wherein the ironless coil extends beyond the slotless stack in both axial directions. 34. The turbo generator of claim 33 further comprising a housing having a coolant passage having a portion that extends circumferentially around a portion of the ironless coil that extends beyond the slotless stack in one of the axial directions. 35. The turbo generator of claim 24 further comprises a housing having coolant and lubricant passages. 36. The turbo generator of claim 24 further comprising a turbine housing section, a generator housing section coupled to the turbine housing section, and a heat deflector between the turbine housing section and the generator housing section. 37. The turbo generator of claim 24 further comprising a housing having a cooling passage configured to be coupled to a vehicle's engine cooling system. 38. The turbo generator of claim 24 wherein the lubricant port is axially offset from the second circumferentially extending portion of the cooling passage. 39. The turbo generator of claim 24 further comprising a housing having a lubricant passage configured to be coupled to a vehicle's engine lubrication system. 40. The turbo generator of claim 24 further comprising a housing having a machined lubricant passage including one or more auxiliary holes that are closed after machining. 41. The turbo generator of claim 24 further comprising a housing having a lubricant passage that extends through the housing at an angle other than perpendicular to an axial axis of the housing. 42. The turbo generator of claim 24 further comprising a housing having a lubricant passage, a bearing in the lubricant passage, and a lubricant port in communication with the lubricant passage, wherein the turbine further comprises a turbine shaft configured to rotate in the bearing, and wherein the lubricant port is axially offset from the bearing. 43. The turbo generator of claim 42 wherein the bearing comprises a floating journal bearing. 44. The turbo generator of claim 24 further comprising a turbo housing section and a generator housing section having first and second housing sections fastened together. 45. The turbo generator of claim 24 further comprising a housing and at least one electrical connector assembly extending from the ironless coil through the housing, wherein each of said at least one electrical connector assembly comprises a stud and an insulator between the stud and the housing. 46. The turbo generator of claim 45 wherein each of said at least one electrical connector assembly is configured such that the stud is rotatable with respect to the insulator before the electrical connector assembly is coupled to the ironless coil. 47. A turbo generator, comprising: a housing having a coolant passage having a first circumferentially extending portion in communication with a second circumferentially extending portion, wherein the first circumferentially extending portion has an axial length greater than an axial length of the second circumferentially extending portion;a coolant port to the first circumferentially extending portion of the coolant passage;a lubricant passage and a lubricant port to the lubricant passage, the lubricant port being radially offset from the coolant port;a turbine configured to be driven by exhaust gas from an internal combustion engine; andan electric generator having a rotor coupled to the turbine, and a stator having a slotless stack surrounding the rotor and a coil positioned between the rotor and the slotless stack. 48. The turbo generator of claim 47 wherein the coil comprises an ironless coil. 49. The turbo generator of claim 48 wherein the ironless coil comprises concentric inner and outer winding portions coupled together to form three-phase windings, wherein the winding portions are separated by at least one continuous fiber strand wrapped a plurality of times around the inner winding portion and impregnated with an encapsulation material. 50. The turbo generator of claim 47 wherein the turbine is configured to directly power the rotor. 51. The turbo generator of claim 47 wherein the rotor further comprises a permanent magnet. 52. The turbo generator of claim 47 wherein the turbine comprises a turbine wheel and a turbine shaft extending from the turbine wheel, and wherein the rotor comprises a hollow rotor shaft directly coupled to the turbine shaft. 53. The turbo generator of claim 52 wherein the hollow rotor shaft is directly coupled to the turbine shaft with a threaded connection. 54. The turbo generator of claim 47 further comprising a housing configured to be coupled to an exhaust manifold of the internal combustion engine, and wherein the turbine comprises a turbine wheel arranged within the housing such that the exhaust gas from the exhaust manifold drives the turbine wheel. 55. The turbo generator of claim 54 wherein the housing section further comprises an exhaust port configured to output the exhaust gas used to drive the turbine wheel. 56. The turbo generator of claim 47 wherein the slotless stack is concentric with the coil, and wherein the coil extends beyond the slotless stack in both axial directions. 57. The turbo generator of claim 56 further comprising a housing having a coolant passage having a portion that extends circumferentially around a portion of the coil that extends beyond the slotless stack in one of the axial directions. 58. The turbo generator of claim 47 further comprises a housing having coolant and lubricant passages. 59. The turbo generator of claim 47 further comprising a turbine housing section, a generator housing section coupled to the turbine housing section, and a heat deflector between the turbine housing section and the generator housing section. 60. The turbo generator of claim 47 further comprising a housing having a cooling passage configured to be coupled to a vehicle's engine cooling system. 61. The turbo generator of claim 47 wherein the lubricant port is axially offset from the second circumferentially extending portion of the cooling passage. 62. The turbo generator of claim 47 further comprising a housing having a lubricant passage configured to be coupled to a vehicle's engine lubrication system. 63. The turbo generator of claim 47 further comprising a housing having a machined lubricant passage including one or more auxiliary holes that are closed after machining. 64. The turbo generator of claim 47 further comprising a housing having a lubricant passage that extends through the housing at an angle other than perpendicular to an axial axis of the housing. 65. The turbo generator of claim 47 further comprising a housing having a lubricant passage, a bearing in the lubricant passage, and a lubricant port in communication with the lubricant passage, wherein the turbine further comprises a turbine shaft configured to rotate in the bearing, and wherein the lubricant port is axially offset from the bearing. 66. The turbo generator of claim 65 wherein the bearing comprises a floating journal bearing. 67. The turbo generator of claim 47 further comprising a turbo housing section and a generator housing section having first and second housing sections fastened together. 68. The turbo generator of claim 47 further comprising a housing and at least one electrical connector assembly extending from the coil through the housing, wherein each of said at least one electrical connector assembly comprises a stud and an insulator between the stud and the housing. 69. The turbo generator of claim 68 wherein each of said at least one electrical connector assembly is configured such that the stud is rotatable with respect to the insulator before the electrical connector assembly is coupled to the coil. 70. A turbo generator, comprising: means for converting exhaust gas energy from an internal combustion engine to rotary power, wherein the converting means comprises a housing having a coolant passage having a first circumferentially extending portion in communication with a second circumferentially extending portion, wherein the first circumferentially extending portion has an axial length greater than an axial length of the second circumferentially extending portiona coolant port to the first circumferentially extending portion of the coolant passagea lubricant passage and a lubricant port to the lubricant passage, the lubricant port being radially offset from the coolant port; andmeans for converting the rotary power to electric power using an ironless coil. 71. The turbo generator of claim 70 wherein the means for converting exhaust gas energy from an internal combustion engine to rotary power comprises a turbine, and the means for converting the rotary power to electric power comprises an electric generator. 72. A vehicle, comprising: an internal combustion engine; anda turbo generator having a turbine configured to be driven by exhaust gas from the internal combustion engine wherein the turbine generator comprises:a cooling system comprising;a housing having a coolant passage having a first circumferentially extending portion in communication with a second circumferentially extending portion, wherein the first circumferentially extending portion has an axial length greater than an axial length of the second circumferentially extending portion;a coolant port to the first circumferentially extending portion of the coolant passage;a lubricant passage and a lubricant port to the lubricant passage, the lubricant port being radially offset from the coolant port; andan electric generator having a rotor coupled to the turbine and a stator having an ironless coil arranged with the rotor to generate electric power when the rotor is rotated by the turbine. 73. The vehicle of claim 72 wherein the turbine is configured to provide power to the rotor. 74. The vehicle of claim 72 wherein the rotor further comprises a permanent magnet. 75. The vehicle of claim 72 wherein the stator further comprises a slotless stack surrounding the rotor, the ironless coil being positioned between the rotor and the slotless stack. 76. The vehicle of claim 72 wherein the turbine comprises a turbine wheel and a turbine shaft extending from the turbine wheel, and wherein the rotor comprises a hollow rotor shaft directly coupled to the turbine shaft. 77. The vehicle of claim 76 wherein the hollow rotor shaft is directly coupled to the turbine shaft with a threaded connection. 78. The vehicle of claim 72 wherein the cooling system is configured to provide coolant to the internal combustion engine and the turbo generator. 79. The vehicle of claim 72 further comprising a lubrication system configured to provide lubricant to the internal combustion engine and the turbo generator.
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